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Logistics

At
SESA Goa Ltd.
Amona Beneficiation Plant
Presented by:-
Ritesh Kumar
About Sesa Goa ltd.
Sesa Goa is India's largest producer and exporter of Iron Ore in
the private sector, with mining and processing facilities located
in Goa, Karnataka and Orissa, India.
They are on course to be one of the top four Iron Ore producing
companies in the world.
There Goa operation consist of two major iron ore mining areas
one in Codli village in South Goa district
One in Sonshi village in North Goa district
Apart from this their iron ore production is derived from VS
Dempo mines and other satellite mines in south and north Goa
districts.
Codli Mines
Tinaighat/ Karnataka
Codli Pr. Plants
Dharbandora
Usgoan
Capxem Jetty

Sanvordem Jetty

Satellite mines Sonshi mines
Surla Jetty
Amona Jetty
Cudnem Pr. Plant
South Goa mines

Transit store Yard
Transit store Yard
Amona Pr. Plant
North Goa Mines

GOA Logistics (Sesa)
Mooring Dolphin
TV / FC
Port Berth No.9
Vessel
Suktalim/RR Plot
Transit store Yard
Tixem Jetty
Kothambi Jetty
Sesa Goa operates through
Mormugao Port in Goa

Mangalore in Karnataka
Karwar in Karnataka
Belekeri in Karnataka

Kolkata in West Bengal
Haldia in West Bengal

Paradip in Orissa

Krishnapatnam in Andhra Pradesh
Vizag in Andhra Pradesh
Codli mines
Codli mine first commenced production in 1973.
Codli is situated in South Goa, approximately 50 kilometres east of Panaji.
Codli mines are open-pit operation, multi-pit, multi-lease fully mechanised
mining units.
The nearest railway stations, Sanvordem and Margao, are approximately 13
kilometres and 40 kilometres, respectively, from the mine.
The river loading points at Sanvordem and Capxem are approximately 12
kilometres and 14 kilometres, respectively.
From the Codli mines the port is approximately 40 nautical miles.
They have extensive ore processing facilities for upgrading the ore, which
include crushing, dry screening, scrubbing, log washing, classifying,
hydrocycloning, and magnetic separation with ultra fines recovery.
codli has 4 processing plants one for processing high grade ore and rest all
for low grade ore.
Codli Mines
Sanvordem stn.
13
km.
Sanvordem jetty
Capxem jetty
12
km.
14 km.
Sonshi mines
Mining at Sonshi commenced in 1958.
Sonshi is one of the oldest operating mine by Sesa Goa.
It is situated in North Goa, approximately 34 kilometres from Panaji.
Sonshi mine comprises of an open-pit mine and it is fully mechanised mining unit.
Over 2.0 million tonnes of iron ore was produced from Sonshi in FY2010.
Current production capacity is more than 3.0 mtpa.
Near Sonshi Mine they also operate Mareto Sodo Mine with a production capacity of 0.5
mtpa.
The nearest railway station, Thivim is approximately 25 kilometres, from the mine.
The river loading point Amona is 9 Kilometres from the mine.
The port is approximately 35 nautical miles from the river loading point.
At Sonshi they don't have any processing plant onsite.
The extracted ore is transported by road to the processing plants at Amona approximately
nine kilometres away and at Cudnem approximately six kilometres away.
The processed and unprocessed ore is transported by road to a riverhead jetty by 10 tonne
tipper trucks at Amona Jetty and then further transported by barges to the Goa port or
transhipper for onward shipment.

Sonshi Mines
Cudnem Pr. Plant
06 km.
Amona Pr. Plant
Amona jetty
09
km.
Jetty stack
Mooring Dolphin
TV / FC
Port Berth No.9
Vessel
North Goa Mines South Goa Mines Transit Points
Sonshi Codli Usgaon
Sanquelim RR plot
Mareta sodo Dharbandora
Botvadecho Dongor
Orasso Dongor
Surla (VS Dempo)
Bicholim(VS Dempo)
Sesa Goa Mines
Amona Processing Plant
Amona Plant is a strategically situated processing plant in North Goa at the banks of
river Mandovi.
It is approximately 09 km from Sonshi mines and approximately 40-50 km from Codli
mines.
It has facility of barge loading also where the iron ore is finally loaded for
transshipment or transported to the port for final loading at designated vessel.
It has compliment of two processing plants currently operating namely- plant 1-A
and plant 1-C. one more upcoming plant 1-B is under construction which will be
commencing its operation soon.
It has compliment of around 9-10 mobile iron ore processing plants which can be
mobilize to any point.
It comprises of 7 functional weighbridges and two upcoming weighbridges almost
ready for commencement for operations.


Process map of iron ore transportation

Mines sonshi,
codli, OD
Dumper 40-
50 tonnes
Mine stack


600-700 TPH
Wheel Loader


10-30 tons
Tippers


Dry Screening
Wet Processing
Tailing disposal
Beneficiation Plant

Stock Piling
Drying
Plant Stacks


10 tons
Tippers
Weigh-
Bridge


750-2500 Tons
Own/TC/ Spot hired
Barges


500-1600 TPH
Transhipper


55000-60000
Bulk carrier
Time study of weighbridges
weighbridge no.02
Date
Truck
Side no From To Time In
(A)
Security
time(in
seconds)
(B)
W/B
processing
time(in
mm:ss)
(C)
Security
time(in
seconds)
(D)
W/B OUT
time(in
mm:ss) Time Out
(A+B+C+
D)
Total
Time(in
mm:ss)
01-02-2011
PVG-
3093 USGAON AMONA 14:33 00:20 00:49 00:09 00:09 14:34 01:27
01-02-2011
PVG-
4559 USGAON AMONA 14:36 00:24 00:53 00:15 00:15 14:37 01:37
01-02-2011
PVG-
5032 USGAON AMONA 14:38 00:18 00:49 00:23 00:17 14:39 01:47
01-02-2011
PVG-
6347 DHARBANDORA AMONA 14:39 00:17 01:05 00:16 00:17 14:41 01:55
01-02-2011
PVG-
4911 USGAON AMONA 14:41 00:19 00:47 00:17 00:12 14:42 01:35
AVERAGE 00:19 00:52 00:16 00:14 01:40

weighbridge no.03
Date
Truck Side
no From To Time In
(A)
Security
time(in
seconds)
(B)
W/B
processin
g time(in
mm:ss)
(C)
Security
time(in
seconds)
(D)
W/B OUT
time(in
mm:ss) Time Out
(A+B+C+
D)
Total
Time(in
mm:ss)
01-02-
2011 PVG-4005 DHARBANDORA AMONA 10:57 00:16 00:45 00:15 00:15 10:58 01:31
01-02-
2011 PVG-5145 USGAON AMONA 14:28 00:17 00:56 00:08 00:08 14:29 01:29
01-02-
2011 PVG-3647 CODLI AMONA 14:52 00:25 01:15 00:15 00:15 14:54 02:10
01-02-
2011 PVG-4363 USGAON AMONA 14:56 00:15 01:00 00:13 00:14 14:57 01:42
01-02-
2011 PVG-5570 USGAON AMONA 15:09 00:14 00:56 00:17 00:13 15:10 01:40
AVERAGE 00:17 00:58 00:13 00:13 01:42
Date
Truck Side
no From To Time In
(A)
Security
time(in
seconds)
(B)
W/B
processing
time(in
mm:ss)
(C)
Security
time(in
seconds)
(D)
W/B OUT
time(in
mm:ss)
Time
Out
(A+B+C+
D)
Total
Time(in
mm:ss)
07-02-2011 PVG-4132 USGAON AMONA 10:37 00:14 00:53 00:12 00:11 10:38 01:30
07-02-2011 PVG-3473 RRPLOT AMONA 10:38 00:13 00:52 00:13 00:20 10:40 01:38
07-02-2011 PVG-2394 USGAON AMONA 10:40 00:17 00:47 00:11 00:10 10:41 01:25
07-02-2011 AMIT-144 SONSHI AMONA 10:41 00:16 01:30 00:10 00:10 10:43 02:06
07-02-2011 PVG-5768 USGAON AMONA 10:43 00:19 01:19 00:15 00:11 10:45 02:04
AVERAGE 00:15 01:04 00:12 00:12 01:44
Weighbridge no. 04
Weighbridge no.05
Date
Truck Side
no From To Time In
(A)
Security
time(in
seconds)
(B)
W/B
processing
time(in
mm:ss)
(C)
Security
time(in
seconds)
(D)
W/B OUT
time(in
mm:ss)
Time
Out
(A+B+C+
D)
Total
Time(in
mm:ss)
07-02-2011 PVG-5012 USGAON AMONA 10:12 00:20 00:45 00:15 00:18 10:13 01:38
07-02-2011 PVG-4445 USGAON AMONA 10:14 00:23 00:47 00:12 00:13 10:15 01:25
07-02-2011 PVG-5054 USGAON AMONA 10:15 00:18 00:49 00:10 00:18 10:17 01:35
07-02-2011 PVG-5853 USGAON AMONA 10:19 00:34 01:00 00:18 00:13 10:22 02:05
AVERAGE 00:23 00:50 00:13 00:15 01:40
Average of average times
Weighbridge no.
Average
Security
time(in
seconds)
Average
W/B
processing
time(in
mm:ss)
Average
Security
time(in
seconds)
Average
W/B OUT
time(in
mm:ss)
Average
Total
Time
W/b 02
00:19 00:52 00:16 00:14 01:40
W/b 03
00:17 00:58 00:13 00:13 01:42
W/b 04
00:15 01:04 00:12 00:12 01:44
W/b 05
00:23 00:50 00:13 00:15 01:40



Average time
00:18 00:56 00:13 00:13



01:41
Chart showing average time taken in each activity at weighbridge
Time(in ss) 10 20 30 40 50 60 70 80 90 100 110 120 130 140

Security 18 sec

Security processing 13 sec
Weighbridge out 13 sec
Overall average time taken in weighbridge activities is 01:40 sec
Weighbridge processing 56 sec
Date
Truck
Side no From To Time In
Security
time(in
seconds)
W/B
processing
time(in
mm:ss)
Security
time(in
seconds)
W/B OUT
time(in
mm:ss)
Time
Out
Total
Time(in
mm:ss)
28-03-2011 PVG5900 RRPLOT AMONA 10:25 00:10 00:15 00:10 00:09 10:25 00:44
28-03-2011 PVG4332 USGAON AMONA 10:28 00:13 00:18 00:12 00:10 10:29 00:53
28-03-2011 PVG4307 DHARBANDORA AMONA 11:06 00:11 00:14 00:10 00:10 11:07 00:47
28-03-2011 PVG6838 RRPLOT AMONA 11:36 00:10 00:12 00:12 00:09 11:37 00:31
28-03-2011 PVG3827 DHARBANDORA AMONA 11:54 00:11 00:16 00:11 00:10 11:55 00:48
AVERAGE 00:11 00:15 00:11 00:09 00:44
Time study of weighbridges
weighbridge no.03 On 28-03-2011
Total time taken by a truck inside Amona plant
DATE AND TIME SIDE NO.
(A)
QUE
TIME(MM:SS)
(B)
W/B
PROCESSING
TIME
(C)
TIME TO
REACH
STACK
(D)
UNLOADING
TIME
(E)
TIME TO
REACH
OUTGATE
(A+B+C+D+E)
OVERALL
TIME
07-02-2011 14:33
PVG-2787 05:14 02:21 03:04 02:45 04:32 17:57
07-02-2011 14:52
PVG-5797 03:06 01:36 03:18 01:17 04:12 13:30
07-02-2011 15:13
PVG-5813 06:48 02:03 01:18 04:35 03:30 18:14
08-02-2011 10:28
PVG-5133 02:17 01:32 04:06 03:12 03:43 14:50
09-02-2011 10:14
PVG-6220 00:37 02:17 03:16 05:13 04:46 17:55
Average time 03:36 01:57 03:00 03:24 04:08 16:29
Note: due to safety and security reasons further study was stopped as security personnel
didnt allowed to go with trucks inside the plant.
Chart showing average time taken by trucks inside Amona
Time(in min) 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

03:36

Approach to w/b
01:57
w/b processing
03:00
03:24
Time to reach stack
Unloading at stack
04:08
Time to reach out gate
Overall time taken to complete one trip is 16:29 sec
No of trips No. of trucks
1 72
2 29
3 21
4 26
5 23
6 16
7 8
8 7
9 2
10 3
11 3
12 3
13 1
Trip details from RRPLOT to Amona from 12 feb 2011 to 28 mar 2011
0
10
20
30
40
50
60
70
80
1 2 3 4 5 6 7 8 9 10 11 12 13
N
o
.

o
f

t
r
u
c
k
s

Trips
Trip details from RRPLOT to Amona from 12-02-2011 to 28-03-
2011
Truck no.

Tonnage carried from
USTP(net weight in kg.)
Tonnage received at
Amona(net weight in kg.) Difference
PVG1448 14160 14190
30
PVG1448 13480 13410 -70
PVG1448 15970 15950 -20
PVG1448 11640 11600 -40
PVG1448 15190 15200 10
PVG1448 14040 14060 20
PVG1448 12280 12350 70
PVG1448 13010 13050 40
PVG1448 13580 13520 -60
PVG1448 12330 12230 -100
PVG1448 15350 15400 50
PVG1448 14570 14580 10
PVG1448 14950 14960 10
PVG1448 14900 14920 20
PVG1448 12370 12420 50
PVG1448 14990 14990 0
Total tonnage
222810 222830
Tripwise tonnage details from 06-03-2011 to 12-03-2011 from
Usgaon to Amona
Total tonnage(IN TONNES)
Date RRPLOT USTP DHARBANDORA
07/03/2011
2560.84 5898.14 2259.68
08/03/2011
2153.55 6750.13 2375.03
09/03/2011
2192.88 7111.27 2526.65
10/03/2011
1126.77 8811.41 1688.97
11/03/2011
1964.57 6326.73 1959.36
12/03/2011
1725.30 4976.07 1451.55
Average tonnage
1953.99 6645.63 2043.54
Locationwise tonnage report
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
7,000,000
8,000,000
9,000,000
10,000,000
RRPLOT
USTP
DHTP
Date








Tonnage
Locationwise tonnage from 06-03-2011 to 12-03-2011
Observations
The traffic system inside plant is very vulnerable as trucks come at high speed and try to over
take each other which sometimes results in accident. Speed breakers should be constructed to
reduce truck speed and avoid any accidents and speed restrictions should be imposed like it is
prevailing in Sonshi.
There is no proper maintenance of the weighbridges and there condition check is not done
from last few months.
The load cells of the weighbridge number 2 needs to be replaced as it has analog cell and
others have digital load cell. This also leads to difference in the weight of the trucks tonnage.
There is overloading of the ore on the trucks which results in reduction of the truck speed
and in turn their turn around time is increased and they feel difficulty in unloading.
Installation of new tarpaulin shed has increased the number of incoming trucks and reduced
the traffic blocks which was there at old tarpaulin untying shed.
Under the guidance of the logistics in-charge the weighbridge operators are learning quickly
and adapting to new software such as SAP and RFID.
After time study of weighbridges the down time of the weighbridges has been reduced
instead of going in two shifts for lunch now they are going in three shifts.
Proper eating facility should be provided to security personnels for their lunch etc.
There should be provision of proper sanitary facility as operators have to go down to office for
emergency which results in the loss the productive time.









Electrical fittings should be inspected at regular interval of time by the electricians to ensure
its safe working.
Drinking water facility should be provided for security personnel so that their time to go to the
gate to bring water is reduced and they concentrate more on the work.
The OTS software which is used to save the data requires some changes which has been a
problem for most of the wrong entries. The save option in the software should be moved to
extreme right side as when operator tries to shift from destination point window to loading
point window sometimes due to system problem the save button is clicked and the wrong
truck data is entered.
The efficiency of the weighbridge operator depends upon the type of hardware they are
working. The keyboards are required to be replaced by soft key keyboards which helps them in
fast typing and data entry.