MINE PLANNING & DESIGN AND ITS COMPONENTS

by
Prof. Phalguni Sen

WHAT IS MINE PLANNING AND DESIGN?

Planning is basically the process of taking decisions, on the basis of available
information, to fulfill an objective while satisfying the constraints present. It
involves in identifying (or developing) the possible alternatives and selecting the
optimum one through proper evaluation, and the process is generally a reiterative
one. Design is the process of translating the planning decisions into tangible
form.
In mine planning stage, the decisions, mostly financial, are taken to optimize an
objective function (e.g, net present value, total profit, internal rate of return, total
conservation, etc.) depending on the requirement on the basis of available
exploration data and other information while satisfying the various constraints
(e.g, available capital, legal considerations, market conditions, physical and
biological environment, techno-economic environment, climatic conditions,
geographic location, site characteristics, deposit characteristics, etc.) which are
likely to affect the venture.
In mine design stage, the planning decisions are translated in the form of maps,
drawings, figures, charts, tables, etc.
MINE PLANNING AND DESIGN COMPONENTS/TASKS
At the end of exploration phase the ore body modeling is done, and once this is
completed the next step is mine planning. The planning job involves a number of
tasks. These include broadly:
Selection of break-even cut-off grade – Net value-grade curve and stripping
ratio-grade curve are first constructed considering the cost (production,
amortization and depreciation, processing, overhead, etc.), percentage recovery
and the gross value of the ore, and then the break-even cut-off grade is
determined.
Development of the 3-D economic block model – This is done from the ore
body model with the help of the net value-grade curve.
Choice of mining method – Once the 3-D economic block model of the deposit
is constructed, decision regarding the mode of extraction (surface mining or
underground mining) is made based on the limiting stripping ratio.
Identification of geometrical extents of mine – The geometrical extents of the
mine are determined based on the economic block model through application of
some optimization technique.
In case of surface mines this means the identification of ultimate pit configuration
(UPC) and in case of underground mines this refers to identification of extents of
the mine in stike and dip-rise directions.
The ultimate pit configuration (UPC) in case of a surface mine is determined
based on the economic block model following the principal of total profit
maximization while satisfying the slope stability requirements. A number of
methods (hand methods, computer methods – floating cone, Lerchs –
Grossmann 2-D algorithm, 2½ -D algorithm, Lerchs-Grossmann 3-D algorithm,
etc., and computer assisted hand methods) are used to determine the UPC.
The extents of the mine in stike and dip-rise directions in case of an underground
mine is determined based on the economic block model following the principal of
total profit maximization while satisfying the requirements regarding stability of
excavations.
Estimation of total and mineable ore reserve vis-à-vis grade – Once the
geometrical extents of the mine are determined, the total tonnage of available
mineable ore reserves and the corresponding grade are determined. In case of
surface mines the associated quantity of waste within the pit are also determined.
Selection of optimum mine and mill cut-off grades in case of surface mines
– after the determination of UPC, knowing the reserve and the grade distribution,
the mine and mill cut-off grades are so selected that the total net present value
(NPV) of the venture is maximized. These cut-off grades may or may not remain
constant over the whole life of the mine depending on the mine specifics and
other factors.
Estimation of targeted production and mine life – Proper estimation of
targeted production vis-à-vis mine life for a given deposit is of paramount
importance. Too low production rate sacrifices possible economics of scale and
defers possible profits too far into the future. Conversely, too high a production
rate may drive up the project’s capital cost beyond any ability to repay within the
shortened mine life.
Taylor (1977), after studying many actual projects involving a wide range of ore
body sizes and shapes for which the total ore reserves were reasonably well
known, put forward an empirical relationship (Taylor’s mine life rule) between the
total ore tonnage and the mine life. The rule, a simple and useful guide, states:
Life (years) = 0.2 x (Expected ore tonnage)1/4
However, it is more convenient to use quantities expressed in millions, and
generally the practical range of variation of mine life seems to lie within  20%.
So the rule may be restated as:
Life (years) = (1  0.2) x 6.5 x (Tonnage in millions)1/4
Planning ore and waste excavation schedule vis-à-vis intermediate pit
layout in case of surface mines– These activities basically relates to
identification of the optimum sequence of ore and waste excavation and the
corresponding intermediate pit layouts so that the NPV (or IRR / total cash flow/
any other objective function) of the venture is optimized. A number of techniques
(such as, sequencing by nested pits, phase scheduling, block sequencing, push
back design, etc.) may be used for the purpose.
Planning mine development and ore excavation schedule in case of
underground mines– These activities basically relates to identification of the
optimum sequence of development of stopes (in metal mines) / panels (in coal
mines) and ore / coal excavation so that the NPV (or IRR / total cash flow/ any
other objective function) of the venture is optimized.
Planning the equipment system – This task involves the selection of right type,
size and number of units to accomplish the various unit operations, and their
phasing/scheduling in relation to the mine life.
The surface mining being a machine intensive one, the economic success of a
surface mining project depends to a great extent on the selection of the right
equipment system in relation to the chosen mining system and the method of
work.
Factors that affect the choice of equipment in a mine are: (i) required production,
(ii) haul /transport distance, (iii) operating room within the mine design,
(iv) availability and costs of power, fuel, etc., (v) weather / environment
conditions, (vi) material type (rock, alluvium, etc.), (vii) mine life vs. capital
required for a specific mining system, and (viii) operating characteristics of
equipment.
The size of equipment is influenced by a variety of factors, such as, mine design,
production rates, comparative operating costs, and capital costs. The total
number of units needed is determined from the required production rate and the
productivity of individual unit. The outcome of equipment selection may dictate
changes in mine design and rates of mining if the benefits of one type of mining
system place it far ahead of other systems.
Calendar planning – This is the planning of various activities related to calendar
schedule.
In a surface mining project, the calendar plans generally required are:
Instantaneous excavation indicating the production of mineral, removal of waste,
and stripping ratio per year (or some other time interval) basis
(a) Cumulative excavation showing the cumulative mineral production,
cumulative handling of waste, and stripping ratio upto that year or instant
(b) Instantaneous and cumulative machinery deployment
(c) Instantaneous and cumulative variation in ore quality
(d) Development and dismantling of haul roads
(e) Manpower requirement.
Slope stability planning (in case of surface mines) – This relates to planning
and design of slopes (highwall and dump slopes) based on the site specific geo-
mining conditions and prevailing techno-economic environment. The selection of
optimum slope angle is a critical decision that can have far reaching effects on
the accumulated cash flow and the overall economics of a mining project.
For the highwall slopes, the optimum slope angle/angles is/are determined based
on the depth of the coal seam(s), dip and physico-mechanical characteristics of
coal seam(s), physico-mechanical characteristics of host rocks and groundwater
conditions. For waste dumps the optimum slope angle and height are determined
considering the dump foundation conditions, physico-mechanical properties of
spoil materials, dump formation method, planned final dump profile, effects of
surface water and groundwater, dump drainage system design, likely effects of
short term stress fields (earthquakes, heavy blast vibrations, etc.) and the
stabilizing and reclamation measures.
Waste dump planning (in case of surface mines) – This involves the planning
and design of dumps (external, internal) in terms of their location/site, optimum
height vis-à-vis slope angle, profile, formation method, drainage system,
stabilizing and reclamation measures.
Tailings dump planning (in case of metal mines) – In case of metal mines the
ore is sent to concentrator/plant. The plant produces concentrate and mill tailings.
The concentrate produced is sent to the smelter & refinery for extraction of the
metal (or in some cases sold). The mill tailings are stored in tailings dumps (the
coarser portion) and in tailings pond (finer particles). The tailing dumps need to
be designed in terms of their location/site, optimum height vis-à-vis slope angle,
profile, formation method, drainage system, stabilizing and reclamation
measures.
Washery rejects dump planning (in case of coal mines) – In case of coal
mines the coal may be required to be washed in coal washery. The washery
produces clean coal and rejects. The washery rejects are stored in dumps. These
dumps need to be designed in terms of their location/site, optimum height vis-à-
vis slope angle, profile, formation method, drainage system, stabilizing and
reclamation measures.
Mine illumination system planning – This is required for both surface and
underground mines.
In surface mines, the illumination is generally required only after sundown and
this is done primarily through permanent (in permanent location like haul roads)
and/or movable (in semi-permanent or moving location like working faces, dump
yards, etc.) tower lighting system.
In underground mines, illumination is required round the clock. The system is
designed depending on the type of mines (coal or non-coal) complying the
necessary safety standards. In addition to the general mine illumination system,
the persons working in the mine are provided with individual cap lamps.
Mine ventilation system planning (in case of underground mines) – The
ventilation system in case of an underground mine is required to be properly
planned considering the total quantity of air required, their required distribution at
the different parts/locations of the mine, etc.. This requires of planning and
design of the main mine fan; ventilation ducts, split air ways, ventilation
crossings, ventilation stoppings, ventilation doors and regulators; auxiliary and
booster fans; etc.
Mine transportation system planning – Proper planning and design of
transportation system in case of both surface mines and underground mines is of
paramount importance. In surface mines it is generally the costliest or second-
costliest unit operation depending on the mine specifics. It involves in selecting
the right type, size and number of transportation equipment in accordance with
the mine system to be adopted and the targeted production.
Mine drainage planning – This is an area that is often neglected. This involves
the planning and design of mine drainage system, mine sump (location and
capacity), pumps (type, size and number) and pumping system based on the
estimates of accumulation of water in the mine through surface water (generally
in case of surface mines only) and groundwater flow and their seasonal variation.
In mine drainage planning, the problem of acid mine drainage should also be
given due importance.
Environmental management planning – This involves in planning the
necessary mitigating measures to be taken so that the adverse impacts on
environment due to mining are kept under control and the pollution level of
different components of physical environment (air, water, land, flora and fauna)
are maintained within the permissible maximum.
Environmental disaster management planning – This is the planning
regarding the measures to be taken in the eventuality of an environmental
disaster so that the hazard level due to such disaster is kept to a minimum.
Mine reclamation/mine closure planning – This relates to the planning of
measures to be taken for mechanical and biological reclamation (simultaneous
and/or at the end of mine life) and closure (ongoing and final) of a surface mine.