Mine planning

mine planning consist of
1.introduction
2.projectimlementation and monitoring
3. open cast mining
4 underground mining
5.equipment planning

1. MINE PLANNING
1. INTRODUCTION

2. PROJECT IMPLEMENTATION
ANDMONITORING

3. OPENCAST MINING


4. UNDERGROUND MINING

5. EQUIPMENT PLANNING

2. INTRODUCTION

PLAN: “Premeditated course of action.”

Life of the mine:
1) Taylor’s formula..
T (years) = 0.20 R 0.25
where,
R= Mineable Reserves in tonnes.

3. So obviously annual production is Q=R/T=5R0.75
2)Modified Taylor’s rule:
T=0.165R0.25


IMPORTANCE OF PLANNINGTECHNICAL FACTORS IN

TECHNICAL FACTORS IN MINE PLANNING
Geological and mineralogy information
Size of the area to be mined(length ,width ,thickness)
Dip/plunge ,depth
Discontinuities
Variation of thickness and width within the mineralised zone.
Boundaries between cut off and waste.

Structural information(physical & chemical)
Depth
Structure features-both OB and mineral
Type of rock
Approximate strength
Porosity and permeability, swelling nature.
RQD
SILICEOUS CONTENT OF THE ORE

4. Economic information
Tons of mineral reserve of various grades in all of the mining zones,
seams.(proven,probable,inferred)
Details of ownership, Royalties to be paid
Availability of water and its ownership on or near the property.
The details of the surface ownership and surface structure that be effected by subsidence.
The location of mining area in relation to ;any existing roads railroads ,rivers; power ,
infrastructure and available commercial supplies.
The local ,regional and national political situations.

LIFE OF THE MINE
Life of the mine:
1) Taylor’s formula..
T (years) = 0.20 R 0.25
where,
R= Mineable Reserves in tonnes.

So obviously annual production is Q=R/T=5R0.75
2)Modified Taylor’s rule:
T=0.165R0.25

METHODOLOGY OF MINE PLANNING

PRELIMINARY SENSITIVITY ASSESSMENT OF MINE AREA

PRELIMINARY MINE PLANNING ASSESSMENT

DETAILED SENSITIVITY ASSESSMENT

5. DETAILED MINE PLANING

MINING APPOROVAL APPLICATION

6. MINE PLANNING –SHORT RANGE AND LONG RANGE

7. LONG RANGE PLAN:
Looks at providing mineral for a finite number of years and a specific size of power (coal) or
mineral beneficiation plant.

4 objectives of long range plans:
1) the plan must be feasible.
2) potential mining problems must be resolved
3)the plan must identify the major capital expenditures, equipment acquisition,
lead times required for implementation.
4)all reclamation and other mining related environmental questions must be
identified and answered.

In general this plan is prepared for one or two the following reasons
1) consideration is being given to increase the number of units (size of power
plant/smelters).
2)the previous plan is outdated due to technological or economical changes.

INFLUENCES OF DIFFERENT GROUPS ON THE PLANNING PROCESS

8. MINE MODELLING-SIMULATION AND SYSTEM APPROACH.
ELEMENTS OF MINE MODEL
Mine Modeling involves spatial location and interconnection of the basic elements.
Graphical modeling is designing by drawing like sketches, technical diagrams etc.
Physical modeling is illustration of shape and structure either 2D or 3D on a suitable scale.
Physical models are used for conducting tests and measurements, Visual illustration like seam
depth, location and disturbances etc,
Mathematical modeling involves simulation and optimization using mathematical techniques.
Analytical modeling is basically subset of mathematical modeling.
Systems approach in mine planning conception, planning, design and engineering of any
interrelated elements so that objective is automatically optimized.

10. PRODUCTIVE AND NON-PRODUCTIVE SUBSYSTEM IN THE DESIGNED SYSTEM “THE MINE”

13. UNIT-2

FEASIBILITY REPORT
“Feasibility Report is studying a situation and a plan to do something about it, and then determines
whether the plan is "feasible" and whether it is practical.”

Feasibility Report answers the question of whether a plan should be implemented by stating "yes",
"no", and sometimes "maybe". Not only recommendation, Feasibility Report should also provide the
data and the reasoning behind that recommendation.
FEASIBILITY REPORT CONSISTS OF ….
 Information on deposit
 Information on general project economics
 Mining method selection
 Processing method
 Capital and operating cost estimates

Information on deposit:
 Geology

14.  Geometry
 Geography
 Exploration
Information on general project Economics:
Markets
Transportation
Utilities
Land and mineral rights
Water
Labor
Governmental consideration
Financing

Mining method selection:

 Physical control
 Selectivity
 Preproduction requirement
 Production requirement

Processing method:
 Mineralogy
 Alternative process
 Recoveries
 Plant layout

Capital and operating costs:
Capital cost:
Exploration
Mining
Mill
Operating cost:
Mining

15. Labor
Development
Maintenance
Mill
Administration
Overhead charges
Irrecoverable social cost

The FR prepared for getting finance for the project has to be submitted to the bankers/financers ,that
is called BANK FR.

DETAILED PROJECT REPORT
Detailed project report gives all the break ups of the feasibility report parameters…like cost of mining
will be given in FR ,but in DPR in the cost of mining category all the break ups like cost for
equipment,maintenance,wages…etc everything will be there.

At the end of the DPR , no reader should have doubts about the project, everything should be
explained.
SOURCES OF FUNDS
Major source of funding is Government- state and central.
Planning commission of Government of India allocates the funds for mining projects.
About 2/3 or 60% of mine funding is by government.
Sources:
1)by government(CIL,NLC,NMDC,TAMIN,TANMAG..)
2)by private (ADANI,RELIENCE,GRANITE COMPANIES..
3)by government and private ( VEDANTA..)
4)FDI (Foreign Direct Investment)-up to 51%.
5) International funding ( world bank..)
6)Soft loans
- interest is very low(<1%)
- period of repayment of the money is higher.
7)Venture capital
funding by a sole entrepreneur.
8)Contract funding

16. mine the mineral and give the mineral to that country and return the money.
example:NMDC- kudremukh is funded by IRAN.
9)SAP(Special assistance program)
IMPORT OF TECHNOLOGY
developing countries: resource rich but capital and technology poor
globalization of industry.

Methods of import technology:
Non commercial
1. Technical literature
2. Exchange of information
3. Education and training
Commercial
1)Employment of experts & consultancy arrangement
2)Import of machinery & equipment
3) foreign Direct investment (FDI) in the royalty, dividend

ASPECTS OF IMPORT OF TECHNOLOGY:
Process technology
Manufacturing technology ( path are easy to transplant and operate)
Sophisticated technology complete import of scientific base essential for absorption
Practice technology (mining) – difficult – technology developed and then adopted to scientific studies
/ requirement. Practice oriented – calls for a very dedicated and trained workforce. Existing base is
not wide enough for transportation – difficult to replace existing practice (time and conditioning of
the mind) .


CRUPP CONSULTANCY,GERMANY-----
SIEMENS,GERMANY--- ING,OCP-2,SCCL.
BRITISH MINING COUNCIL(BMC)-
CVN:COAL VIDHASH NIGAM
MECON: METAL & ENERGY CONSULTANTS.

SELECTION OF CONTRACTS AND CONTRACT MANAGEMENT :

17. Contract :
“a contract is an agreement between two parties with certain objectives.”
Contract may be between,
1) Management and Employees – ( Example: NCWA-National Coal Wage
Agreement)
2) Management and Government
3) Management and Financers- Asian Development Bank
4) Management and Equipment Suppliers- in terms of guarantee and warranty.
5) Management and service provider - railways and telecommunication
providers.

OBJECTIVES OF GOOD CONTRACT:
Clear in ToR (Terms of Reference).
Clear objectives and responsibilities
Promote harmonious relationship.
Clearly spell out the obligations of each party.
Build good working relationship.
Mutual benefits
Should tell the validity of agreement.

Factors in Selecting Contract Types
- Capability of seller’s accounting system

- Uncertainty in the cost estimate

- Type and complexity of requirements

- Urgency

- Marketplace and competition

- Seller’s technical capability

18. Administrative costs to both parties

Selection and Managing:
Selection is through.....
NAMINATION
TENDOR – global / local.
consider both technical and economic elements to select.
Managing contracts......
The other party should provide facilities like communication ,housing, roads , water...to
contract people.
Penalty : if the agreed operations are not satisfied by other party then penalty should be there.




TIME MANAGEMENT AND COST CONTROL
EFFECTIVE TIME MANAGEMENT

Time is valuable resource, democratically shared – all have 24 hrs, you cannot buy time; you
cannot board time – it flows. All you can do is make the best use of the time available. PLAN TO
USE TIME Think and organize things in their order of importance. Earmark a unit of time for day
dreaming – plans that are up in the air. This may be at any time of the day that suits you and you
are undisturbed.

19. Set apart blocks of time for work; not little bits and pieces of time interspersed with other activities.
Never handle a paper more than once – do not put it away for later reading. Effective decisions are
taken right away. The percentage of errors / mistakes is no greater than if delay is made in decision
making. Act at once unless more information is called for and the available is inadequate


For saving time in paperwork / communication restrict it to the minimum. Prefer verbal
communication which is direct & immediate. Written orders / notes should be clear,
unambiguous, short, straight forward. Purpose & objective should be clear in your mind before
you write. Tone and tenor should be positive and persuasive – avoid a torrid tirade or temper.

Meetings are phenomenal waste of most time if not conducted properly. They should be well
planned, purpose oriented, agenda driven and to the point. They should be useful and essential;
start on time and not drag on. The meeting should be kept in control by the executive who
convenes it and he should avoid becoming a protagonist in the debate.

An essential task an executive has to perform is decision making. Quick decisions yield two
benefits:
You gain time
You will have spare time available to correct an occasional incorrect decision.

If you do not control time , it will begin to control you.

20. The best decision is of no use unless it works. Involve all concerned right from the beginning;
acquaint all with the rationale & benefits flowing. Insist on subordinates giving recommendations
/ solutions to problems – not passing all the buck to all the time. They receive paining in the art
of decision making.
Goals give a dimension to time and provide a framework for the choices we must make and also
help time management / accountability. Focus on task and priorities. It does not mean working
longer or harder – it means working more systematically. In the ultimate analysis it is what we
get and gain as results that is the bottom line in the balance sheet.

Costs – their identification, measurement and control – most worked business area .
An enormous amount of work goes into cost control, an enormous amount of time goes to cost
analysis – there is no lack of tools & technique. Focus on results is the best and most effective cost
control. Cost does not exist by itself, it is always incurred.

Several prerequisite in effective cost control:
Concentration must centre on controlling costs where they are incurred.
Different costs must be treated differently
One truly effective way to cut costs is to cut out an activity altogether.
“costs” is a term of economics. The cost system that need to be analyzed is therefore the entire
economic activity which produces economic value.


To be able to control costs a business therefore needs cost analysis which:
Identifies cost centers – areas where significant costs incurred needs effective cost reduction
Finds what the important cost points are in each major cost centre.
Looks at the entire business as one cost – stream.

21. Define “cost” as what the customer pays rather than a what the legal or two unit of accounting incurs.
Classifies costs according to their basic characteristics and thus produces a cost diagnosis
Cost centers in the business and its economic process are where it is really worth while to work on the
control of costs.
Cost points are simply the few activities within a cost centre that are responsible for the bulk of its
costs. Assumption is that a few activities will account for the bulk of the costs.
Cost categories:
Major cost points fall into four main categories:
 Productive costs
 Support costs
 policing costs
 waste

What to tackle, where to go to work, what to aim at – should become part of all overall understanding
of the business and the comprehension program for making it fully effective.

MATERIAL MANAGEMENT SYSTEM


“Material management system involves identification , procurement , storage(inventory control)
and distribution of materials.”

Key points:
- timely availability of materials/equipments
- spares control/inventory control
- capital locked in spares

22. STAGES OF MMS
 Design stage
 Determination of requirements
 Procurement
 Receiving, storage and distribution
 Inventory control
 Disposal

Design stage:
Variety reduction, interchangeability, value engineering, splitting standardization.
Identify the ‘A’ item spares for reducing the numbers of same type of item required. A,B,C
analysis A:B:C 10/15 : 20/25 : 70/30 can be done by members, value, cost of consumption,
etc…
Determination of requirements:
Engineering assessments, data bank, insurance spares, all time buy.
Procurement:
Catalogues & illustrated spare parts list, quality, warranty, price increase,
indigenization, manufacturing plans, make or buy, contract protection for future supply
Receiving , storage and distribution:
Inspection, testing, identification, handling preservation

Inventory control:
Safety stocks, spare bunk, forecasts, all time buy, distribution, dynamics,
consumption, control of items.

Disposal:
Modification, substitution, reclamation.

23. QUALITY ASSURANCE:

activities include a planned system of review procedures conducted by personnel not directly
involved in the inventory compilation/development process.

Reviews, preferably by independent third parties, should be performed upon a finalised inventory
following the implementation of QC(quality control) procedures.

24. “a program for the systematic monitoring and evaluation of the various aspects of a project, service,
or facility to ensure that standards of quality are being met.”

emphasizes the prevention of defects and the addition of quality.

quality is determined by the intended users, clients or customers, not by society in general.
ASSURANCE OF QUALITY IN MINING
Avoiding the dilution ore in the site .
Blending : Mixing of different grades of ore to achieve required grade.
While transporting through conveyor employ people to identify the waste visually and to remove
using pickers.
At the transfer points : Belt to belt , belt to hopper ,hopper to dumper.
At the dispatch point-at bunkers
Do sampling to ensure the grade- Auto samplers/Laboratory
With electromagnets system the iron rods or pieces coming with ore is removed while conveying . (in
belt conveyors.)
Adopt Selective Mining.

SOCIAL RESPONSIBILITY

25. Environmental Impact Assessment

26. Environment may be defined differently depending upon the perspective of the definer.
In the case of EIA, environment is usually considered to constitute
three main subsystems:
1. Physical Environment (geology, topology, climate, water, air).
2. Biological Environment (terrestrial and aquatic communities, rare and endangered species,
sensitive habitats, significant natural sites).
3. Socio-cultural Environment (population, land use, development activities, goods and services,
public health, recreation, cultural properties, customs, aspirations).


Impact may be defined as the consequences of changes in the environment but it should not be
confused with effect.
For example, increase in river pollution due to the initiation of a new project is an effect while
consequences of river pollution on human health, flora, fauna, etc. is the impact.

Assessment normally does not mean doing new science, but rather assembling, summarizing,
organizing and interpreting pieces of existing knowledge, and communicating them so that an
intelligent but inexpert policymaker will find them relevant and helpful in their deliberations


"the systematic process of identifying future consequences of a current or proposed action (IAIA).”

EIA is both an art and a science. Management aspect in EIA is an art, whereas the technical analysis is
based on the scientific principles.
AIMS AND OBJECTIVES OF EIA
CAN BE DIVIDED INTO TWO CATEGORIES.

The immediate aim of EIA is to inform the process of decision-making by identifying the potentially
significant environmental effects and risks of development proposals.

• The ultimate (long term) aim of EIA is to promote sustainable development by ensuring that
development proposals do not undermine critical resource and ecological functions or the well being,
lifestyle and livelihood of the communities and peoples who depend on them.

27. THE EIGHT STEPS OF THE EIA PROCESS

1) Screening: First stage of EIA, which determines whether the proposed project, requires an EIA and
if it requires EIA, then the level of assessment required.
2) Scoping: This stage identifies the key issues and impact that should be further investigated. This
stage also defines the boundary and time limit of the study.
3) Impact analysis: This stage of EIA identifies and predicts likely
environmental and social impact of the proposed project and evaluates the significance.

4) Mitigation: This step in EIA recommends the actions to reduce and avoid the potential adverse
environmental consequences of development activities.
5) Reporting: This stage presents the result of EIA in a form of a report to
the decision-making body and other interested parties.

6) Review of EIA: It examines the adequacy and effectiveness of the EIA
report and provides information necessary for the decision-making.

7) Decision-making: It decides whether the project is rejected, approved or needs further change.

8) Post monitoring: This stage comes into play once the project is commissioned. It checks whether
the impacts of the project do not exceed

28. the legal standards and implementation of the mitigation measures are in
the manner as described in the EIA report.












UNIT-3

SELECTION OF OC MINE CUTS & SURFACE STRUCTURES
FACTORS IN INFRASTRUCTURE PLANNING:
 Topography
 Existing infrastructure
 Future operations
 Ownership of the land
 Geology
 Surface ground water
 Communication available- roads,rail,telecommunication
 Power
 Location fir fighting station
 Dumping yard location

TYPES OF INFRASTRUCTURES
DISPERSE TYPE:
-Scattered infra-structure

29. - Mostly not preferred due its disadvantages like
# land
# transportation difficulties
# communication
BLOCK TYPE:
structure are kept as close as possible.
( see figure 5.1 of the principles of mine planning , Jayant Bhattacharya)

LOCATION OF SURFACE STRUCTURES
The starting point for design of the main mine surface area is the siting of the mining plant,
preliminary selection of the region or locality being followed by the final decision on the
exact location.

In general, the siting of the mining plant is dictated by the position of the deposit in the mine
concession area.

The ultimate location of both the main and auxiliary surface areas depends on:
Deposit mining and geological condition
Ownership of the land
Ground and surface condition
Existing infrastructure

Before the detailed development plan for the main mine surface is prepared, it is necessary
to:

Fix the siting and duties of the main shafts in relation to the model of underground section

Electric power, configuration of the land

Fix the size of the particular facilities and installation and site the individual facilities and
installation in relation to the assumed main production streams

30. For this development plan the following principles must be observed:
Mutual siting of building, facilities and installations
Streams of coal, rock, materials, personnel, etc. should follow the routes established
Distances between buildings should be big enough to comply with fire fighting regulations
Formation of barren rock dumps and spoil tips should be avoided
Protection zones and green belts should be established.
Regulations concerning protection of natural environment should be rigorously observed.
EXAMINATION OF GEOLOGICAL AND DETERMINATION OF ORE BODY,SELECTION
OF SITE FOR BLOCKING,MINE DELINEATIONThe following points should be
considered:

Geology of the mineralized zone;

Physical size and shape of the deposit;

Quantitative data on grade and tons of material within pertinent cut-off limits;

Mineralogical and metallurgical characteristics of the ore;

Physical characteristics of the ore and waste; and

Data on ground conditions, groundwater and other factors that affect mine design
and operation.
BLOCKING OF OREBODY/DELINEATION
BLOCKING: “Delineating the ore body.”

For the convenience of mining operation ,sometimes the
ore body is divided into blocks.

OTHER REASONS FOR BLOCKING:

31. 1) Lease restrictions
2)Geological formations/faults
3) Grade variation
4) Operational Reasons – Very large block may not be mined as a single block. So
in a single mine the block may be divided into South block , North block .
Example : NLC has Mine 1,1A,2.
5) Depth
6) Safety Aspects
7)Natural/Environmental Restrictions
MINE DESIGN AND PLANNING OF LAYOUT
PRINCIPLES OF MINE DESIGN
Mine design techniques focus on three groups of problems
Indicating most appropriate investment schemes and program of exploitation.
Optimization of basic parameters for new mine for map profit on given investment outlay.
Execution of technical design for implementation mine design involves:
Analyse feasibility of new design methods and justify choice of suitable ones and their
applications.
Practical use of modeling techniques

PRACTICAL USE OF MODELING TECHNIQUES..
Graphical modeling – design by drawing –sketches, technical drawings, diagrams(flow sheet)
automated computer data processing system.

Physical design models- provide a clean objective of proposed design – illustrate shape /
structure: two dimentional or three dimentional (block shapes – scaled down).

Mathematical modeling – currently more frequently applied. Simulation and optimization
models are particularly important. These models tend to elimination of the abstract and
hence can stimulate the true situation with considerable accuracy and also the number of
parameters to be optimized can be increases more accurately for natural deposit conditions
and provide for more objective design decisions

DESIGNING OF OPEN PIT MINE

32. Determination of pit outline in planning involves finding of pit slope angles, pit bottom width,
etc.

Designing of open cast mine involves:

1. Height of benches with reference to its stability, strength and its
capability to withstand the forces, cleavages

2. Specific gravity, cohesive strength, internal frictional angle

3. Width of the benches

4. Slope of the benches, berm, face angle and bank width, final pit slope

5. Design of the haul roads

6. Planning for production, length of face, etc.


LAYOUT SHOULD GIVE PROVISIONS FOR.

Vehicle movement and vehicle parks.
Contractor’s compounds - temporary canteens ,offices ,site huts.
Stores and workshops
Site services – boiler house, electrical substation, sewage disposal
Pit side facilities – lamp room, report centre , pit offices , rescue room ..etc
Clean side facilities – pithead baths, medical centre , canteen ,mine offices , time and wages
offices.

CLASSIFICATION OF SURFACE LAYOUTS:
1) Dispersed Type

33. The dispersed type contains a large number of facilities located over a relatively
large area.
This is olden approach ,in those days space was not a constraint and
environmental, public reactions were minimum.
2) Block Type –TYPES: BELT FORM,ZONE FORM.
Requires smaller site
Better space utilization
Easy transport
REFER : BHATTACHRYA PAGE:133.

LAYOUTS

Spiral layouts:
-for hilly deposits.
-Iron ore mines in hilly areas and steeply dipping deposits.
- gradient > 60*

FACTORS INFLUENCING THE LAYOUT OF MINE
Stripping ratio

34. Type of the machinery

Local geology of the area – Gradient ,thickness ,depth

Terrain – Hilly terrain / Flat terrain.

Capital available- Example : NLC in Gujarat they have shovel dumper system due to the shortage of
capital available.

35. BENCH AND HAUL ROAD DESIGN
BENCH DESIGN
Bench height is depend upon
i. Rock type
ii. Reach of the machine.

Bench width should not be less than
the bench height &
also thrice the width of the dumper or
twice the width of largest machine ply over the bench
and 2m clearance.
Bench slope should not be more than the angle of the repose of the material.
HAUL ROAD DESIGN
Should transfer travelling load to base
Should seal off the water penetration
Should have least friction
Should produce least dust
Layers of Haul Road:

36. Wearing Surface: To resist abrasion (made up of asphalt or concrete or crushed rock).
Base: To resist shrinkage and swelling and should have high stability and density to
spread the load acting and distribute the stresses.
Sub base (optional): It is required for weak soils. Granular material can be used for both
base and sub base layers.
Sub grade: Foundation layer which support all the load acting. If the rock is strong, then
the ground itself can be used as sub grade layer.

Load acting on the Dumper tyres:
33 % on front tyres & 67 % on rear tyres

Gradient:
1 in 14 for haul roads & 1 in 10 for ramps

Super Elevation Rate:
E = (V2/(10 * R)) - F

Where, E – Super elevation rate (ft/ft) or (m/m)
V – Vehicle speed in (mph) or (kmph)
R – Curve radius in m
F – Friction factor (0.3 to 0.001)
Haul Road Signs
Lighting
Runaway Precautions
Curve Design
Drains and Culverts
Road Edge Barriers
Sumps & Pumping

37. SLOPE STABILITY
Safety Factor:
F = S/Sm
where S = shear strength and Sm = mobilized shear resistance.

F < 1: failure can take place, F > 1: safer slope, F=1: under equilibrium.

Types of Failures:
Planar Failure
Wedge Failure
Circular Failure
Toppling Failure

40. ROCK SLOPE STABILIZATION MEASURES

41. CALENDAR PLANNING
Calendar Plan is the Plan of various activities related to calendar schedule.

a. Instantaneous excavation which indicates the following at any instant:
Production of Mineral per year
Removal of Waste per year
Stripping ratio per year

b. Cumulative excavation which indicates the following:
Cumulative production of mineral upto that year
Cumulative handling of waste upto that year
Overall stripping ratio upto that year
Stages upto which will be taken, upto that year

OBJECTIVES & NEED OF CALENDAR PLANS
Objectives of a Calendar Plan:
To frame/set a definite Production Goals in space, with quantity of material to be moved,
To allow better economic evaluation than the phase average period.

42. Need of a Calendar Plan:
In a calendar plan, a pictorial representation of stripping ratio with respect to time is made
with a view to optimizing the extraction of mineral.
In calculation of stripping work, the whole life span of the mine is taken into consideration.


c. Instantaneous and Cumulative Machinery Utilization – indicate Instantaneous and cumulative
utilization of machinery at various stages of mining.

d. Quality – indicates the quality of mineral acquired at various stages of mining work.

e. Development and dismantling of haul roads and ramps

43. f. Manpower Requirements.
The total life of the mine can broadly be divided into following four stages:
1. Construction Stage
2. Development Stage
3. Remunerative Stage
4. Slack Period.

Overall planning of a mine is correlated to all phases of mining operations, which will facilitate and
ensure maximum utilization of heavy earth moving machinery(HEMM) and other complementary
equipment which will be a function of the total work load of waste rock handling and mineral output
within a particular time frame.

The yearly productivity of the deployed equipment will indicate the complementary and
supplementary manpower required.

PRODUCTION SCHEDULING AND PLANNING

Production planning:
Optimum levels of production is to keep cost of production as low as possible
Operational Viability
Sufficient exposure of minerals
Keep the gap as little as possible between the ore and waste
Minimize the pit slope
Alternative production rate
Proper equipment selection






MINE SCHEDULING:
‘Mine Scheduling is a process of simulating the
extraction of deposit over time’

44. This process comprises of,
Defining the deposit as a group of mining blocks and establishing attributes for these blocks.
Establishing rates of removal for the minerals in the mining blocks and the sequence in
which the blocks are to be removed.
Simulating this extraction sequence.

Reporting the results of the schedule.

Because of the spatial relationships between
mining blocks usually play an important role in
the feasibility of an extraction sequence, the
mining engineer can benefit from a graphical
representation of the schedule.
ECONOMIC PRODUCTIVITY INDICES
TECHNO – ECONOMIC ANALYSIS
Performance monitoring / analysis
Technical analysis includes:
Production – achieving target – precession plant efficiency
Productivity – OMS
Machinery – machine utilization – machine availability – machine efficiency
Manpower – skilled, semi-skilled, unskilled

45. Safey – accidents per million hours or for thousand tonnes of production or man lakh hours
Energy –conservation, utilization
Environment – green house gas emission – any bank loans – 10% of amount should be
availed for environment
ECONOMIC ANALYSIS
Economic analysis includes all of the above + capital and operating costs
Ex: Energy – cost/ tonne produced
Safety – compensation and damage
Production – cost / tonne ; NPV – techno economic indices
Productivity – cost per labor of manpower
National Productivity Council : For measuring the performance of different organizations
Capital cost
Ex: for a shovel – dumper : 50 crores for million tonnes per year
For a BWE: 90 – 100 crores per million tonne production per year
(Neyveli in Gujarat is not using BWE because of lack of capital funds)
Operating cost

47. UNIT-4
LOCATION OF UG ENTRIES
Type of/ mode of entry - Shaft, Decline, Adit
Comparison of calculated construction costs, unit and total costs
Unit cost – cost / ton
Total cost - construction, maintenance, cost of haulage
Objective: to meet the production requirement
SITE CONSTRAINTS
Shaft Location – presence of water bodies, forest area etc.
Geological Disturbances, Hydrological Disturbances, Topography etc.,
HFL
Loss of Mineral in Shaft Pillar
Infrastructure ( in remote areas) – power and materials
Purpose of Shaft – production / ventilation / waste pumping
Haulage/ Transport – dispatch
Energy availability
Sand stowing – location of same
Algorithms to select shaft / decline: Zian’s method, Vez’s method – Analytical method

Optimization of mine parameters (Size of panel, length of face, location of levels, level
intervals)
Optimization is a mathematical operation involving the parameters that influence the
objective which can be minimization or maximization.
Production - In terms of Economics, Safety and Environment – graph
Panel Size –
For coal mines – Production * Incubation Period
For metal mines – No Incubation Period but production is a problem
Level Interval – Graph
Dimensions of galleries –
Larger galleries can give lots of advantages but safety problems are also high.

48. Regulations /rules .
Face- Length of Longwall Face
Let the production / day / shift for 6 hour shift be 330 tonnes
Length of Longwall Face = 330/(γ*Area of panel)
Where
γ =
Area of Panel = Panel length * thickness
Panel length is dictated by the Incubation Period
LONGWALL FACE LENGTH

The chosen length determines:
Rate at which advances/ repeats
Tonnage recoverable from panel
AFC length
Number of supports required.
Capital cost of face equipment


ADVANTAGES OF LONG FACE
Output/ shearer greater.
Greater cutting time as less time loss at face end measurement.
Reduced devi seqts fewer faces per panel
Reduced mix of gate side packs.
Fewer face moves, reduced interruptions to production
Reduced construction work are crossings in, doors, conveyor installation.
Important vent effects, lesser leakage points.
ADVANTAGES OF SHORTER FACES
Lower capital requirements/ face
Higher speed of face, better strata control, consistent production
Light loading on AFC promote reliability, avoids unplanned stoppages
Less equipments involved in face transfers.

49. More development work.
COAL INDIA has standardized on 150m length faces.



DESIGN OF PROTECTIVE AND SHAFT PILLAR
SHAFT PILLAR
Consider, D=depth of the shaft in m,
T=Thickness of seam in m,
R=Radius of shaft pillar in m.
(1) DRON’S rule:
Area of shaft pillar = area to be supported + D/6 on all sides
(2) FOSTER’S rule:
R=3√Dt
(3) WADIN’S rule:
For shaft upto 100m depth, size should not be less than 36.5m×36.5m.
There after for every 36.5m depth, increase size by9m.
(4) MINING ENGINEERS rule:
For shallow shafts the minimum radius for shaft pillar is 18m.
For deeper shaft, √Dt
R=18.3+ 32.8

50. (5) DONAHUE’s formula for inclined seams:
If D= Depth of shaft, X= angle of dip of coal seam,
Then y = D Sinx Cosx
S= Margin of safety, usually equal to 5% to10% of the depth,
Then width of the pillar on rise side = S+ D/7+ 2y/3
Then width of the pillar on Dip side = S+ D/7 – v/3
Then width of the pillar along strike = S+ D/7
SHAFT PILLAR PROTECTION
 Rapid Mining
 Stowing
 Harmonic Extraction
 Partial Extraction

SELECTION OF METHOD OF EXTRACTION



FACTORS IN SELECTION
 Spatial characteristics of deposit
Size(dimensions, especially height or thickness)
Shape (tabular, lenticular, massive, irregular)
Altitude(inclination or dip)
Depth (mean and extreme values, stripping ration)

51.  Geologic and hydrologic conditions
Mineralogy and petrography (sulfides vs. oxides)
Chemical composition (primary, by-product minerals)
Deposit structure (folds, faults, discontinuities, intrusions)
Planes of weakness (joints, fractures, cleavage in mineral, cleats in coal)
Uniformity, alteration weathering (zones, boundaries)
Groundwater and hydrology (occurrence, flow rate, water table)
 Geotechnical(soil and rock mechanics ) properties
Elastic properties (strength, modulus of elasticity, Poisson’s ratio. Etc.)
Plastic or viscoelastic behavior (flow, creep
State of stress (original, modified by mining)
Consolidation, companion, and competence (ability of opening to stand unsupported)
Other physical properties (specific gravity, voids, porosity, permeability, moisture content)
 Economic considerations
Reserves (tonnages and grades_
Production rate( output per unit time)
Mine life ( operating period for development and exploitation)
Productivity (output per unit of labor and time)
Comparative mining costs of suitable methods.
 Technological factors
Mine recovery
Dilution( amount of waster produced with ore
Flexibility of method with changing conditions
Selectivity of method to distinguish ore and waster.
Concentration or dispersion of workings
Capital, labor and mechanization intensities
 Environmental concerns
Ground control to maintain integrity of openings
Subsidence, or caving effects on the surface.
Atmospheric control (ventilation, quality control, heat and humidity control)
Work force(recruitment, training, health and safety, living, community conditions)

52. Man Power Management
 List of life Time certificates
 List of statutory certificates
 List of statutory and life time certificates
 Details of employees – Due date prior 3 months
 License and PME information details

53.  List of employees for selected period whose license, statutory certificates are for renewal
 List of employees for selected period who did not attend PME
 List of employees who did not attend PME in their service.

 Strikes

 All strike details

 For selected month

 For selected period

 Cause wise analysis of strike

 Legal/Illegal wise Strike Details

 Partial/Total wise Strike Details
 Designation

 Total number of lockouts

 Month wise/Year wise

 Charge Sheet

 Standing Order number wise Charge Sheet

 Standing Order number wise Status Report

 All charge Sheet details

 Enquiry

54.  Submitted /not submitted wise enquiry report

 Enquiry details based on Duration

 All enquiries Details

 Warning Letters/Charge Sheet Information Details

Planning on Water Management
1. Expected inflow assessment
Open cast relates to exposed area to rain (catchment area vis-a vis mine area),
Underground excess inflow due to rain on S/F, underground water generation, water from
water bearing strata/aquifer.
2.Plan to prevent ingress to mine
Open cast S/F drains, channels, guide run off –underground mine subsidence areas to
be protected, S/F drains, consolidation where feasible – such as cracks/ fissures – prevent
run off access to mine workings outlets above HFL away from water bodies.

3. Plan for sump capacity
Open cast –heaviest showers in the past- required pumping capacity and sump volume
without affecting operations. Underground maximum inflow in the monsoon seasons- all
sources.
Number / location of sumps- special sumps- in particular if water is to be stored for future
use by mine in dry season – like spraying/ quenching / colony requirements.
Pump capacity – dead / live – type of pumping operation – concentrated spread out all sifts/
night shift.


4.Pumping Plans
Pit bottom main sump – open cast sump – single /supplicate drainages in stone may be
required – storage capacity 24 hours /2 days/ as required.
Cardinal Principle – collect water where it is generated, do not allow or take to lower levels-
use maximum of gravity flows to reduce pumping cost.
Ample size of delivery lines reduce open cost all points at crucial points to be duplicated with
separate (duplicate) delivery to meet any emergency.

55. Layout of pump room and foundations, pump fitting and switch gear- pump and pipe joints –
ventilation/ lighting / communication to pump room.
Choice of face / intermediate pumps – centrifugal (various types) turbine / MONO /
submersible types/piston type, etc










TECHNO ECONOMIC INDICES
BASIC TECHNO ECONOMIC INDICES


VENTILATION PLANNING
AIR QUANTITY & VELOCITY:

56. Deals with effects of
Methane and other gases
Heat
Dust
VENTILATION PLANNING:
Prepare mine working plans
Project at each life stages of mine the proposed extent of mine workings – U/G roadways, working
districts, drifts, dev.headings, raise/winze, substations, pump houses, loco garage, first aid rooms,
haulage rooms, miners stations etc…
Link all these to period of major change – drifts, horizons, stopes, depillaring, etc…
Random interval can also be selected – 5 yrs interval upto 25 years.
VOLUME FLOW:

Quantity of air required at different places estimates based on methane emission, volume of
production, no of persons working U/G / man shift, wet bulb temp, dust SPM

Calculate the resultant velocities on each roadway to ensure this flow & reqd velocity at working
places – not too high / nor too low, adequate to control dust also.

Allow for all leakages, S/P at airlock, pit bottom dons, intake to return – which increase with extended
working and WG. Estimate VEQ % overall air to air at face. 50% VEQ is good ventilation standard

MINE RESISTANCE:

Calculate roadway resistance as per formulae and then series / parallel for all circuits – nodal point
resistances.

Evaluate total resistance. Chart variation in mine resistance through mine life.
VENTILATION PRESSURE:

Small pressure only observed at face – balance due to rest. all along roadways / shafts etc…

VENTILATION NETWORK:

Identify nodes, branches, tabulate for all the stage of life plans. Allow for leakages

57. system resistance and equivalent orifice can be calculated.


STATUTORY REQUIREMENT:
Heat and Humidity

Wet bulb temp – 30.5º C

Velocity not less than 1 m/s

No deployment of mess when wet bulb temp is over 33.5º C

Dust is controlled best with velocity 1.5 to 2 m/s. Gas dilution – keep methane below 0.5% at face.
Virgin rock temp to be considered.

Indian Coal Fields:
Geothermic gradient 1º C per 36m depth commencing at 18m depth 27.2º C constant VRT at 100m =
27.2 + (100 – 18) / 36 = 29.42º C
CONTROL OF DUST AND GASES:

58. Explosion and Fire hazard

Health risk

Nuisance value – irritation of skin, eyes, ears, nose – machine relays, bearings circuitry, Visibility –
dust cloud.

Primary cause:
Mechanical breakage and disintegration during mining operations, also release & dispersion of dust
present – slip planes
Degradation and agitation of material during transport – respirable dust, is that aims airborne ( less
than 10 micron in diameter ).

MINE SUPPORT PLANNING


Supports in UG in mines are designed to support the load coming from the “IMMEDIATE ROOF”
only.(not the total load above it).

So supports have to be designed to carry the load from pressure arc, not the total load above
excavation.

CAVABILITY: its the most important factor in designing the supports.

CMRI: CAVABILITY INDEX=I=t0.6(∂*m)n
Where , t=thickness of the strong bed
∂=compressive strength
m=parameter of massiveness=(RQD+10)/100
n=factor depend on RQD=1.1-1.3.

ESTIMATION OF SUPPORT REQUIRMENT FOR LONGWALL FACE
NCB METHOD

FORMULAS:

59. 1) SUPPORT LOAD /UNIT AREA = P= (VLM)/(K-1)
Where,
V= average density in t/m3
L= Longwall face length in m
M= average face length in m
K= bulking factor
2)HEIGHT OF IMMEDIATE ROOF=IR=T/(K-1)
where,
T= thickness of extraction.
K= Bulking factor.
3) TOTAL LOAD ACTING
Load = Density *Height of immediate roof*(Length of the face + Gate roadway width on both
sides)*span
FOR GIVEN DATA OF :
Density of coal = 1.2 t/m3,Bulking factor = 1.2,Length of the face = 120 m ,
Width of gate roadways=4+4= 8 m, Span = 8 m. Extraction height/thickness=3m.
Calculation:
Assuming the width of the support is = 1.5 m
immediate roof height = t/(k-1)=3/(1.2-1)=15
Load = Density *Height of immediate roof*(Length of the face + Gate roadway width on both
sides)*span
=1.2*15*(120+8)*8 = 18432 t

NUMBER OF SUPPORTS REQUIRED =Total face length/width of support
=128/1.5=
85
LOAD ON EACH SUPPORT = Load acting/No.of supports
=18432/85
= 217 t
To have a factor of safety above one ,
the load bearing capacity of each support is taken as 250 t.

THUMB RULE:

60. Loading acting at a particular depth(d) = 0.025*d.

If strata is inclined =0.025*d*cos(angle)
MINE RECLAMATION PLANNING

“Land reclamation is the treatment of the land ,creating conditions for putting the land to its
pre-mining use or other useful working.”

A reclamation area both aesthetically attractive as well as useful is more desirable.

The reclamation process serves a binding agreement between the management and the government
agencies.

However there may be some changes in the over all life of the project –usually techniques and
methodology.
Reclamation plan purpose
Provide detailed guideline for reclamation process and fulfill all the statutory requirements.

Plans for the use during entire operational period and subsequent to the cessation of exploration,
mining and possessive activities.

Reclamation planning should provide direction and standards to assist on monitoring and compliance
evaluations.
Reclamation plan content
A logical sequence of steps for the completing the reclamation purpose

The specifics of how the reclamation standards will be achieved.

As the estimation of the specific costs of reclamation

Sufficient information for development of the basis of the inspection.
Reclamation standards-
Waste management
All undesirable materials(all toxic sub soil contaminated soil , fluids process residue, refuse)shall be
isolated \recovered\buried or appropriate disposal

61. A)Area protected from future contamination from mining activities.
B)No contamination materials remaining near S\F
C)Remove \isolate ]bury inappropriate manner all the toxic substance
D)Adopt acceptable waste disposal practices

Subsurface
To be properly sterilized, holes in U\G working property plugged and sub surface integrity
ensured

Site stability
Reclaimed area should be stable and should not exhibit—large rills or gullies, soil movement,
slope instability.





Reclamation planning steps…..
Make an inventory of the pre-mining conditions.
Evaluate and decide the post-mining requirements of the region with due considerations of
needs and desires of the affected group.
Analyze alternative mining and reclamation schemes best of the objective.
Develop an acceptable mining, reclamation and land use scheme that is most suitable under
technical, social and economic conditions.

Information requirements
Natural land use factor
 Topography
 Climate
 Altitude
 Exposure
 Hydrology
Surface hydrology
Ground water hydrology

62.  Geology
 Soils
Agricultural character
Engineering character
 Terrestrial ecology
 Aquatis ecology

 Cultural factors
 Location
 Accessibility
 Size and shape of the site
 Surrounding land use
 Land ownership
 Type, intensity and value of use
 Population characteristics
Process of Reclamation
TECHNICAL RECLAMATION
This includes back filling of the excavations, spreading of the subsoil and top soil,
grading of the backfilling and waste dump .
BIOLOGICAL RECLAMATION
Restore the fertility and biological productivity of the disturbed lands
This phase takes 3 to 5 years
During this favorable spices are grown which depend on the climate depth and nature of the topsoil
and subsoil, local type of farming etc.

63. UNIT-5
EQUIPMENT FOR DRILLING AND BLASTING
Factors in drill performance
Operating variables (drill, rod, bit and fluid)
(a) Drill power, blow energy and frequency, rotary, speed, thrust and rod design;
(b) Fluid properties and flow rate.

Drillhole factors (hole size, length, and inclination)
Hole diameters,
in surface 6 – 18 in. (150-450mm)
in underground 1.5-7 in. (40-175 mm)
 Rock factors
Properties of the rock,
Geological conditions
State of stress acting on the drill hole.

 Service factors
Labour and supervision,
Power supply
Jobsite,
Weather
Drill performance parameters

There are four parameters are measured or estimated most frequently:
Process energy and power consumption
Penetration rate
Bit wear (life)
Cost(ownership + operating = overall)
DRILL SELECTION
Type of drill
Type of bit

64. Size of bit
Power source
Drillability (rate of penetration)
Blasting factor
Drilling factor
Determine and specify the conditions under the conditions under which the machine will be
used,
such as the job - related factors (lobor, site, weather, etc...), with safety the ultimate
consideration.
State the objectives for the rock breakage
tonnage, fragmentation, throw, vibrations
Based on blasting requirements, design the drill hole pattern for surface mining or drill round if
underground (hole size and depth, inclination, burden, spacing, etc...)
Determine the drillability factors, and, for the kind of rock anticipated identify the drilling
method candidates that appear feasible
Specify the operating variables for each system under consideration including drill, rod, bit, and
circulation fluid factors.
Estimate the performance parameters, including machine availability and costs, and compare.
Cost /meter.
Consider the power source and select specifications.

Selection also includes….
Machines capability (pulldown, rotary torque, etc.) must exceed formation penetration
requirements.
Maximum hole size capability increases with machine size.
Larger machines are more rugged and can generally drill in harder formations.
A machine that can handle drill pipe long enough to permit single pass drilling can significantly
improve productivity.
The production rate is dependent both on the actual penentration rate and on the time
required for pipe changes and machine repositioning.
Electric drives have the lowest operating cost, the longest service life and the best track record
for reliability.
Electric drives require an in-pit power distribution system.
Three levels of pit and area mobility are available; low speed crawlers (electric machines),
medium speed crawlers (diesel machines) and roadable high speed carriers (wheel mounted
units)

65. Dust control requirements are dictated by regulations.
Optional equipment such as powered cable reels, automatic lubrication, automated controls. Etc.,
can increase the efficiency of the drilling operations.
Long term productivity is dependent on the ruggedness, reliability and maintainability of the
design.

66. EQUIPMENT FOR EXCAVATION