Professional Documents
Culture Documents
4
Mine Layout
H A R D
R O C K
M I N E R S
H A N D B O O K
4 Mine Layout
4.1 Introduction
The classic procedure for designing a mine starts by determining the mining method(s) and probable optimum mining rate (discussed in other chapters). This chapter is principally devoted to the next step determining initial mine layout or conceptual mine design. The procedure is also considered initial mine planning. If the mining method is open pit, the layout starts with the basic design of the open pit itself. This includes pit layouts in intervals up to the final design (ultimate pit). With the pit established, the infrastructure is planned, including surface haul roads, stockpiles, dumps, tailings impoundment, utility corridors, and surface plant layout. The mine layout for an open pit mine might have to be modified if underground mining is contemplated when the pit is exhausted. If the plan includes underground mining, planning starts with locating and sizing pre-production and on-going development requirements. The initial planning includes determining level intervals, haulage ways, primary access (shaft, ramp or adit), and other major entries. The design of major entries requires considering the requirements for ore handling, waste rock handling, primary ventilation circuit, backfill, transfer, materials handling, access for personnel, refuge stations, and escape route(s). Once the underground mine concept is established, the surface infrastructure is designed, including access roads, dumps, tailings impoundment, utility corridors, maintenance facilities, explosives storage, and surface plant layout. While the procedures outlined above may appear to be sequential, they are actually iterative to the extent that the process can become tedious. The practical solution for this dilemma is to conduct the exercise employing short-cut methods based on the following activities. Comparisons Intuitive reasoning Rules of thumb Tricks of the trade
Comparisons Comparisons refer to the study of comparable well-engineered projects. In some cases, the layout of another mine may be accepted as a starting model. Intuitive Reasoning Intuitive reasoning by the team participants is knowledge-based and relies on rational perception, first-hand mining experience, and good judgment. Rules of Thumb Rules of thumb may be applied to break circular references by providing benchmarks and starting points. Rules are also useful in identifying significant planning problems at an early stage. Tricks of the Trade Tricks of the trade are particular concepts and efficient procedures employed to save time and effort.
McIntosh Redpath Engineering 50
C H A P T E R 4 M I N E L A Y O U T
Crown Pillar
Mine Entries
51
H A R D
R O C K
M I N E R S
H A N D B O O K
Mine Entries (continued) In good ground, at production rates less than one million tons per year, truck haulage on a decline (ramp) is a viable alternative to shaft hoisting to depths of at least 300m. Source: G.G. Northcote Shallow ore bodies mined at over 5,000 tpd are more economically served by belt conveyor transport in a decline entry than haul trucks in a ramp entry. Source: Al Fernie As a rule, a belt conveyor operation is more economical than rail or truck transport when the conveying distance exceeds one kilometer (3,281 feet). Source: Heinz Altoff The normal location of the production shaft is near the center of gravity of the shape (in plan view) of the ore body, but offset by 200 feet or more. Source: Alan OHara The first lift for a near vertical ore body should be approximately 2,000 feet. If the ore body outcrops, the shaft will then be approximately 2,500 feet deep to allow for gravity feed and crown pillar. If the outcrop has been or is planned to be open cut, the measurement should be made from the top of the crown pillar. If the ore body does not outcrop, the measurement is taken from its apex. Source: Ron Haflidson The depth of shaft should allow access to 1,800 days mining of ore reserves. Source: Alan OHara For a deep ore body, the production and ventilation shafts are sunk simultaneously and positioned within 100m or so of each other. Source: D.F.H. Graves Footwall drifts for blasthole mining should be offset from the ore by at least 15m (50 feet) in good ground. Deeper in the mine, the offset should be increased to 23m (75 feet) and for mining at great depth it should be not less than 30m (100 feet). Source: Jack de la Vergne Ore passes should be spaced at intervals not exceeding 500 feet (and waste passes not more than 750 feet) along the footwall drift, when using LHD extraction. Source: Jack de la Vergne The maximum economical tramming distance for a 5 cubic yard capacity LHD is 500 feet, for an 8 cubic yard LHD it is 800 feet. Source: Len Kitchener The amount of pre-production stope development required to bring a mine into production is equal to that required for 125 days of mining. Source: Alan OHara
Shafts
Underground Layout
52
C H A P T E R 4 M I N E L A Y O U T
Outcrop ore bodies are traditionally open cut to the economic limit, after which mining may take place underground. For a steeply dipping ore body of uniform width, the optimal depth of the open cut is a function of the stripping ratio, which in turn approximates the ratio of underground to surface mining costs. It may be economical to increase the stripping ratio where waste rock is to be later employed underground as fill. Various Sources For an outcrop ore body (ore extends from surface of the bedrock), it is said to be best to mine by open pit down to the point where the cost of mining the last ton is equal to the cost of mining that ton from underground. This concept is not simple to apply. The last cut in the pit is highly profitable and while the first production from underground is the most costly because it will take months to develop the sequence of stoping required to meet full production capacity. Moreover, the economical depth of an open pit is likely deeper if no underground mining is contemplated. Source: Tim Koniaris Haulage costs for open pit are at least 40% of the total mining costs; therefore, proximity of the waste dumps to the rim of the pit is of great importance. Source: Frank Kaeschager As a pit deepens, grade control and blending may become more difficult. This is one reason that proposed underground operations should be phased in at an early date. Source: Unknown The old rule that says a vertical shaft should be located 200 feet from the crest of an open pit has been proven invalid by sorry experience. The set back distance should be determined by rock mechanics. Source: Jack de la Vergne To design the optimum layout for a new underground mine, it is important to first determine the planned mining methods and stoping sequence. Conceptual engineering should be referenced first to the ore body. Mine layout serves the miners; it is not the other way around. Source: Jack de la Vergne Bad ground is traversed at less risk with a vertical shaft than a lateral or inclined heading. Where a choice must be made, a shaft should be located in the bad ground and the lateral access to the ore body in the good ground not the other way around. Source: Jack de la Vergne In the case of a deep ore body, it has already been well proven that a twin shaft layout can be used to bring a new mine into a high rate of production at an early stage, which must be the aim of every new mining venture. Sinking two shafts simultaneously also provides desirable insurance against the possibility of one shaft encountering serious sinking difficulties. Source: L.D. Browne For deep mines with a natural rock temperature exceeding 1000 F (380 C), the size and location of shafts should be determined mainly by ventilation considerations. Source: Dr. J.T. McIntyre A twin shaft layout (shafts close together) for a deep mine will require twin cross cuts to the ore body for an efficient ventilation circuit. It may be better to set the shafts far apart. Source: Jozef Stachulak Normally, the concentrator (mill) should be located close to the mine head. Pumping tailings from the mill is less expensive than truck hauling ore over a similar distance. When pumping water to the mill, hauling concentrate from the mill and use of a portion of the tailings for paste fill is also considered, the argument is even stronger. Source: Edgar Kster
53
H A R D
R O C K
M I N E R S
H A N D B O O K
The mine administration offices should be located as near as possible to the mine head to reduce the area of disturbance, improve communications, and reduce transit time. Source: Brian Calver When a mine has a camp incorporated into its infrastructure, the campsite should be as close as practical to the mine to minimize the cost of service and utility lines, as well as to expedite emergency call-outs. Source: George Greer It is normally false logic to consider particular items of used plant and equipment at the conceptual design stage. The conceptual engineering should consider all new plant and equipment sized and built to provide optimum extraction and recovery. In this manner, a benchmark reference is provided against which opportunities to provide particular items of used plant and equipment may be later evaluated. Source: Jack de la Vergne
54
C H A P T E R 4 M I N E L A Y O U T
Conventional Methods of Ore Transport At the conceptual stage, it is normally better to consider only conventional methods for the transport of ore and resort to the unusual methods only under unusual circumstances. A good example of unusual is the aerial tramway installed across a fjord at the Black Angel Mine in Greenland to access an ore body located high on a cliff face. Table 4-1 lists methods employed at underground mines for ore transport. Table 4-1 Ore Transport Methods Employed at Underground Mines
Transport Vertical Inclined Horizontal Conventional Shaft Conveyor, Truck Conveyor, Truck, Rail Unusual Vertical Conveyor Shaft, Tramway Road Train, Slusher Prototype Pipeline, Airlift Pipeline
The following flow chart (Figure 4-1) summarizes rules of thumb for bringing ore to surface from an underground mine. The flow chart is only a guideline. For example, one underground mine employed truck haulage (for a very small rich ore body) to a vertical depth of 700m before the operation was abandoned.
55
H A R D
R O C K
M I N E R S
H A N D B O O K
Main Entry The foregoing strategy determines a main entry to the underground on the basis of ore transport. In many cases, this entry also serves for personnel and materials transfer, particularly at small operations. Consideration should be given to a separate entry for man and materials handling when it can be afforded. For example, some mines use the production shaft for ore/waste hoisting, main exhaust, and alternate escape while a second shaft provides cage service in the main fresh air entry. If a shaft system is employed at an operation of substantial capacity, it is not uncommon to find a ramp access from surface as a third entry. This is a logical progression when an internal ramp system is required by the mining method to be employed. The access ramp has advantages described in previous text of this chapter.
56