www.pwc.

com

2012 Americas School of

Mines

Basics of Mining and Mineral Processing

W Scott Dunbar
University of British Columbia
Agenda

Geological Concepts

Mining Methods

Mineral Processing Methods

Mine Waste Management

Mining and Money

A Future of Mining
 Mining Methods: The Topics

Open pit mining

Underground mining

Mining equipment

Mining operations

PwC Mining Methods 3

 Open pit mining

Generally low grade, shallow orebodies

Mining rate >20,000 tonnes per day
Tailings
pond
Concentrator or
Processing plant
Waste dump Marketable
product

Waste

Possible Ore
expansion

PwC Mining Methods 4

 Open pit mining

Open pit mines are used to exploit low grade, shallow ore bodies. However, some pits are
quite deep – about 1 km.

The mining rate is greater than 20,000 tonnes per day (tpd) but is usually much greater.
Some pits operate at a rate of more than 100,000 tpd

Open pit mining results in two waste streams: waste rock which contains no economic
quantity of minerals but which must be removed to gain access to the orebody, and tailings
which are the result of a mineral separation process in the concentrator or processing
plant. The mining rate includes the mining of both waste and ore.

Open pit mining is non‐selective – all high and low grade zones of the orebody are mined

The significant design issues of an open pit mine are: location of haul roads, equipment –
size of trucks and fleet, pit slope angle and stability, control of water

PwC Mining Methods 5

 Bagdad Pit, Arizona – looking west

Porphyry copper 170,000 tpd 9,200 ft  5,800 ft pit

828 Mt sulfide and oxide reserves: 0.28% Cu, 0.022% Mo (2007 10K filing)
Copper and Molybdenum concentrates
Pressure leach facility for concentrate, SX/EW leach plant for oxides
PwC Mining Methods 6
 Notes: Bagdad Pit Arizona – looking west

First claims staked in 1882. Property changed ownership numerous times through first half
of 20th century. First mill began operation in 1928 to process ore from the underground
mine. Transition to open‐pit mining began in 1945. A $240 million expansion in 1973
included new haul trucks, shovels, nearly 400 housing units and concentrator. Bagdad
became part of the Phelps Dodge mining portfolio in 1999 with the acquisition of Cyprus
Amax Minerals Co. In 2007, Freeport McMoran merged with Phelps Dodge.

The ore is a porphyry with disseminated primary sulfides (chalcopyrite and molybdenite)
with gold and silver. Low grade secondary sulfide and oxide ores are present which are
soluble by acid.

Copper and molybdenum concentrates with gold and silver credits are produced and
smelted at the Miami smelter. Copper is produced at a SX/EW plant for oxide ore
(operating since 1970) and at a new (2003) concentrate leach facility, the world’s first.
Source: http://www.fcx.com/operations/USA_Arizona_Bagdad.htm

PwC Mining Methods 7

 Highland Valley Pit, British Columbia

H‐H tailings dam

Concentrator

Valley Pit

Porphyry copper, 170,000 tons mined/day (tpd)

451 Mt reserves: 0.38% Cu, 0.007% Mo (2007 Teck Cominco report)
90% of production from Valley pit
Copper concentrate with gold and silver, Molybdenum concentrate
PwC Mining Methods 8
 Notes: Highland Valley Pit British Columbia

The Highland Valley Copper mine, located in British Columbia, 60 km southwest of

Kamloops is 97.5% owned by Teck Cominco.
Operations at Highland Valley began over 20 years ago by predecessor companies. The
present operation is a combination of the Lornex mine and mill, the Valley Copper orebody
and the Highmont mine and mill. The present mill is the old Lornex mill into which
Highmont mill equipment was integrated.
The Valley pit contains two in‐pit crushers feeding a 12,000‐tonne per hour conveying
system that delivers ore to stockpiles at the mill. Ore from the Lornex mine is hauled to two
permanent crushers with discharge to common stockpiles.
Concentrates are transported by rail eastward to domestic markets and to Vancouver for
shipment to overseas markets.
The life of the mine has been extended from 2013 to 2019. The new mine plan will require
a push‐back of the west wall of the Valley pit. Total capital costs of the expansion project
are estimated at $300 million, including $130 million for capital equipment and the balance
in pre‐production stripping over the period of 2009 through 2013. Approximately $50
million of mobile mining equipment will be ordered in 2007 to permit waste stripping to
commence in 2009.
Source: Teck Cominco 2006 Annual Report

PwC Mining Methods 9

 Cortez Gold Mine, Nevada

Crescent pit

Crescent pit

Three deposits in area: Pipeline, Cortez Hills, Pediment

14.5 Moz reserves, ore grade: 0.046 oz/t
Gold production 2010: 1.14 Moz
PwC Mining Methods 10
 Bingham Canyon, Utah

Porphyry copper deposit

4 km diameter, 1,200 m deep

PwC Mining Methods 11
 Red Dog mine, Alaska

Antamina, Peru

PwC Mining Methods 12

 Coal and Oil Sands Mines
Suncor mine
Fort McMurray, Alberta

Eagle Mountain, BC
Fording Coal

PwC Mining Methods 13

 Notes: Coal and Oil Sands Mines

Coal and tar sands operations typically involve moving large amounts of waste (often
called overburden) to gain access to the economic mineral.
Eagle Mountain is part of the Fording River operations in southeastern British Columbia.
Fording River produces both metallurgical (coking) coal for the steel industry and thermal
coal for power plants in Alberta. Fording River's measured and indicated reserves total
over 200Mt of clean coal plus a further 286Mt in resources, over 65% of which is
contained in the Eagle Mountain deposit. The coal has a low sulfur content and its volatile
content ranges from medium to high. Three distinct coking coal types are available at
Fording River. Fording River can mine at a rate of 10Mt/year or about 28,000 tpd.
Source: http://www.mining‐technology.com/projects/fording
Oil sand is a mixture of bitumen (a thick sticky form of crude oil), sand, water and clay. The
Suncor Mines extract oil sand from mines north of Fort McMurray in Northern Alberta.
Using shovels with 100 ton buckets and 240 and 360 ton trucks the mine extracts about
450,000 tonnes of oil sands per day. The material is crushed and sized and made into a
slurry which is delivered to the processing plant via 86 km (54 mi) of pipelines In the plant,
the sands are mixed with hot water to separate the oil from the sand. In 2005 the Suncor
Mines produced 171,300 barrels of bitumen per day, which, after upgrading, is ready for
refining. Suncor’s leases contain a resource of more than 13 billion barrels of bitumen.
Source: www.suncor.com
PwC Mining Methods 14
 March 2, 2012
Pre-stripping at Oyu Tolgoi, Mongolia

March 2, 2012

March 30, 2012

Source:
www.ivanhoemines.com

PwC Geological Concepts 15

 At the beach

~30˚

Angle of repose of sand

PwC Mining Methods 16

 Why the benches?

Rock is stronger than sand so

its angle of repose is larger
45˚ usually the maximum

Pit slopes are benched to achieve locally steeper slopes

Allows pit to intersect ore zone
PwC Mining Methods 17
 To go deeper, you need to pushback

Mine some waste to get to ore

pushbacks

35‐45˚

ore

PwC Mining Methods 18

 Notes: Pushbacks and benches

An open pit mine is developed as a series of nested pits, each larger in area than the
previous pit. A pushback is the removal of material required to proceed from one pit to the
next. The revenue from the ore must pay for the cost of excavating the waste from the
pushback and for excavating the ore. But the slope cannot exceed 45˚ and remain stable so
at some point it becomes impossible and/or uneconomic to continue mining.
The slopes of a deep pit are cut into a series of locally steep slopes (> 450) each about 5‐15
meters high depending on the stability of the rock and the equipment in use. Such steep
slopes can become unstable and therefore benches are formed at the bottom of each slope
to contain any slope failures. Although parts of the slope are steep, the overall slope angle
is low, say 30‐400 .
In some pits the rock may be strong enough to allow “double‐benching” where slopes
about 20‐30 meters high are built. The available equipment must be able to excavate such
heights. The objective is to minimize waste excavation, but design and monitoring of such
slopes can be difficult.
The need for locally steep slopes is illustrated by the following example. For a 500 m deep
pit, the difference in volume for a pit slope of 45 slopes and a pit slope of 40 is about 25
million m3. If the rock density is 2.7 t/m3, that is equivalent to 67.5 Mt. Since it costs $2‐3
to move a tonne of rock, the extra volume amounts to quite a large amount of money.

PwC Mining Methods 19

 The Bagdad pushback on Sept 23, 2009

PwC Mining Methods 20

 Highland Valley Mine – pushback of west
wall

PwC Mining Methods 21

 Straight faults and circular holes

Pit rim
Slope failure in March 1983

North Pit, Homestake Pitch Mine, Sargents Colorado

PwC Mining Methods 22

 23

Notes: Straight faults and circular holes

As the magma containing the minerals for an orebody rises up, it generates stresses in the
host rock, rupturing it and causing faults. Thus most orebodies are related to faulting in the
earth’s crust. Faults are long linear features and so if an orebody is mined with a circular
pit, it is likely to intersect a fault. This can lead to instability in at least two parts of the pit
slope.

In the case of the Homestake Pitch uranium mine, pit excavation near the fault on the
northeast slope led to a series of slope failures soon after mining started in 1977 and
continuing through to 1980. In 1983 extreme climatic conditions led to an excess
accumulation of water which weakened the northeast slope and led to the failure shown in
the picture. The mine was placed under reclamation soon after the 1984 failure.

Source:
Cremeens, J., 2003. Geologic controls on complex slope displacement at the Pitch
reclamation project. Engineering Geology in Colorado, Contributions, Trends, and Case
Histories. AEG Journal

PwC Mining Methods

 Pit Wall Stability at Bagdad

West wall (2007)

North wall (2008)

PwC Mining Methods 24

 Dewatering pump at Cortez Nevada

pump

water table is
drawn down to
keep pit dry

There are 40 of these around the Cortez pit pumping water out of the ground at a total rate of 30,000 gallons per
minute in order to keep the pit dry. Dewatering also helps to keep the slopes dry and more stable.

PwC Mining Methods 25

 Strip Ratio

Applies to an open pit mine

Waste
Strip ratio =
Ore
SR is the mass of waste to be mined to obtain one unit mass of ore.
(ore that goes to concentrator)
Examples:
Oil sands deposits in Alberta: SR = 1.0‐1.5
Highland Valley: SR ~0.45 (2007 Teck annual report)
Bagdad mine: SR =1.4 (2007 FCX 10K filing, p.5, but oxide ore
also mined – see notes)
Red Dog mine: SR = 0.8
Cortez mine: SR = 2.2 (2007 Barrick annual report)

PwC Mining Methods 26

 Notes: Strip Ratio

Mistakes are often made when computing the strip ratio. It’s all in the words and you have to watch
the flow of material and how it is classified. For example, according to Freeport McMoran’s 2007 10K
filing, the concentrator is capable of processing 75,000 metric tons per day of primary sulfide ore and
the mining fleet is capable of moving 180,000 metric tons per day. Thus If everything is working to
capacity (and it usually works close to capacity) and the material moved is assumed to be waste plus
primary sulfide ore, the strip ratio is (180‐75)/75 = 1.4.
However, the material moved includes waste plus oxide/secondary sulfide ore and primary sulfide
ore. The 10K filing and other information provided does not classify the amounts mined. However, the
2005 Phelps Dodge report states that Bagdad mined 64,093 thousand tons (kt) of material and
processed 26,592 kt in the concentrator. The report also states that 23,857 kt of ore
(oxides/secondary sulfides) was placed on the leach stockpiles. This means the waste is 64093‐26,592‐
23,857 = 13,644 kt, about 21% of the material mined. So does this mean their strip ratio, waste/ore =
0.21/0.79 ~ 0.27
Not so fast. According to footnote h on page 11 of the 2005 report the leach ore includes “previously
considered waste material that is now being leached.” This means that some leach ore was mined
prior to 2005 and was re‐classified from waste to ore. The report does not state how much was mined
in 2005 and placed on the leach stockpile but, according to a contact at Bagdad, the amount mined
was minimal – the 23,857 kt is mostly a re‐classification.
Hard to define a strip ratio when what was waste becomes ore and vice versa.

PwC Mining Methods 27

 Some strip ratio algebra

Total mined T  Ore  Waste  O  W

Example:
W
Strip ratio S   W  S  O T = 135 kt/day
O
S = 0.5
T  O  S  O  1  S  O
O = 90 kt/day
T W = 45 kt/day
O
1 S
S T
W
1 S

PwC Mining Methods 28

 Strip ratio changes over life of mine

2.4 Seabridge Gold Inc

2.2 Kerr‐Sulphurets‐Mitchell Mine, BC

2.0

1.8
Strip ratio

Life of Mine strip ratio = 1.6

1.6

1.4

1.2

1.0
Source: Preliminary Economic Assessment, 2009
0.8
0 5 10 15 20 25 30
Year of production

PwC Mining Methods 29

 Notes: Strip ratio changes over life of mine

During production, stripping costs may be either capitalized or expensed. If capitalized, the
amortization of the costs is based on the estimated value of the underlying ore and the
amortization schedule will change over the life of the mine as the value of the underling
ore changes. If expensed, production costs per ton of ore will vary over the life of the mine
as the amount of ore produced changes.

The pushback of the west wall of the Valley pit at Highland Valley, BC will provide access to
additional ore. The waste stripping associated with the pushback will be capitalized and
amortized based on the estimated value of the additional ore. However, the amounts of
waste and ore are subject to a number of uncertainties and could change over time. If the
amount and/or value of ore changes, the amortization schedule will have to be changed.

The cost of the north wall pushback at Bagdad is treated as a cost of current production
and is not related to the ore underlying the pushback. The cost per ton of ore will therefore
change as the current strip ratio changes. In effect, Bagdad is buying an option on the
underlying ore, the value of which is uncertain.

PwC Geological Concepts 30

 Underground mining
Concentrator or
Processing plant

Marketable
product
Tailings
pond

Generally high grade, deep orebodies

Mining rate <20,000 tonnes per day
Shaft

Ore Tunnels

PwC Mining Methods 31

 Notes: Underground Mining

Underground mines are used to exploit high grade, deep ore bodies. However, there is no
limiting grade above which underground mining is always done, nor is there a limiting
depth below which underground mining is always done. It depends on the mining method
used.

For underground mines the mining rate is typically less than 20,000 tonnes per day (tpd);
10,000 tpd is a large capacity (and highly mechanized) underground mine. However, the
block caving method can achieve mining rates much greater than 20,000 tpd.

Underground mining results in one waste stream: tailings which are the result of a mineral
separation process in the concentrator or processing plant. There is very little waste rock
generated as a result of sinking the shaft or driving the tunnels to gain access to the ore.
Underground mining is generally more selective than open pit mining, but the degree of
selectivity depends on the underground mining method.

The significant design issues of an underground mine are: geometry of underground

mining, ground support, and logistics of materials handling.

PwC Mining Methods 32

 Underground Mine Anatomy

Mined out
stopes
Shaft
Producing
stopes

Stopes under
Levels
development

Future
reserves?

PwC Mining Methods 33

 Notes: Underground Mine Anatomy

In general for underground mines:

Small output mines (<4,000 tpd) ‐ hauling is done on several levels, tonnage handled
on each level is small, and light equipment is used.
High output mines (>4,000 tpd) ‐ a main haulage level is used and all the ore is
dropped to that haulage level via ore passes.
A level includes all the horizontal workings tributary to a shaft station. Ore excavated in a
level is transported to the shaft to be hoisted to the surface.
Stopes are openings from which ore is mined. They may be backfilled with cemented waste
material.
Ore passes are sub‐vertical chutes for movement of ore. Declines or ramps are spiral or
inclined drifts.
Note the different types of drilling: development drilling to open up the orebody and
exploration drilling to better define the limits of the orebody.
The upper side of the orebody is called the “hanging wall” because that is where miners
used to hang their lamps while working. The lower side is called the “footwall” because
that is where their feet were planted. Nowadays, the illumination is provided by an electric
grid within the mine and all miners wear headlamps on their hardhats..

PwC Mining Methods 34

 Mine shaft and shaft sinking

www.camese.org
PwC Mining Methods 35
 Cut and Fill Mining

Stopes

“Fill” is some
combination of
tailings and cement

Source: Atlas Copco

PwC Mining Methods 36

 Notes: Cut and Fill Mining

Cut‐and‐fill mining removes ore in horizontal slices, starting from a bottom undercut and
advancing upward. Ore is drilled, blasted and removed from the stope. When a stope is
mined out, the void is backfilled with a slurry of tailings which is allowed to drain to form a
sufficiently solid surface. Cement may be added to form paste backfill. The fill serves both
to support the stope walls and provide a working platform for equipment when the next
slice is mined.

There are two types of cut and fill mining – overhand and underhand. In overhand cut and
fill, the ore lies underneath the working area and the roof is backfill. In underhand cut and
fill, it is the opposite, the ore overlies the working area and the machines work on backfill.

Cut‐and‐fill mining is applied to steeply dipping orebodies in stable rock masses. It is a

selective mining method and is preferred for orebodies with irregular shape and scattered
mineralization. Because the method involves moving fill material as well as a significant
amount of drilling and blasting, it is relatively expensive and therefore is done only in high
grade mineralization where there is a need to be selective and avoid mining of waste or low
grade ore.

PwC Mining Methods 37

 Cut and fill – a picture

This is the cut

This is the fill

Jon 'ShakataGaNai' Davis (http://commons.wikimedia.org/wiki/File:Miner_In_Raise_2.jpg)

PwC Mining Methods 38
 Narrow Vein Mining

Common in precious metals mines

An example:
“The Santo Niño vein was discovered by
drilling at a depth of 300m below the surface
and has now been traced for 2.5 km in length
and 500m in depth with a width varying from
0.1‐4.0m.”
Source: www.firstmajestic.com/s/LaParrillaProject.asp

www.silverlakeresources.com.au

PwC Mining Methods 39

 Notes: Narrow Vein Mining

Used for very narrow orebodies, as small as a half metre wide. Very selective method;
waste rock is left in the hanging wall and the footwall. In a wide vein, a standard LHD can
operate inside the drift. “Slim‐size” machines including drill rigs, jumbos, and 2 m3 bucket
LHDs, are available for working in drifts as narrow as 2.0 m. However, in such narrow veins
the use of machines produces waste which dilutes the ore. The alternative is to use a
manual technique to extract only the higher grade material in the vein. But manpower is
costly, difficult to find, and manual techniques are not efficient.

PwC Mining Methods 40

 Stoping
Sublevel stoping Longhole stoping

Drilling Drilling
and and
blasting blasting
Requires less
Stope Stope drilling than
sublevel stoping

Blasted ore Blasted ore

(muck) (muck)

Source: Atlas Copco

Source: Atlas Copco

PwC Mining Methods 41

 Notes: Stoping

Stoping is used for mining deposits with following characteristics:

•Steep dip, the footwall inclination must exceed the angle of repose
•Stable rock in both hanging wall and footwall
•Both competent ore and host rock
•Regular ore boundaries

Sublevel stoping recovers the ore from open stopes separated by access drifts each
connected to a ramp. The orebody is divided into sections about 100 m high and further
divided laterally into alternating stopes and pillars. A main haulage drive is created in the
footwall at the bottom, with cut‐outs for draw‐points connected to the stopes above. The
bottom is V‐shaped to funnel the blasted material into the draw‐points.
Short blastholes are drilled from the access drifts in a ring configuration. The ore in the
stope is blasted, collected in the draw‐points, and hauled away. The stopes are normally
backfilled with consolidated mill tailings. This allows for recovery of the pillars of unmined
ore between the stopes, enabling a very high recovery of the orebody.
Longhole stoping uses longer (~100 m) and larger diameter blastholes, thus requiring less
drilling than sublevel stoping. Greater drilling accuracy is required and non‐planar
irregularities in the orebody shape cannot be recovered. .
Development of the infrastructure for both these stoping methods is time‐consuming,
costly, and complex.
PwC Mining Methods 42
 Room and Pillar Oil Shale Mine in NE Estonia

back or roof

~2.5 m

Source: www.aapg.org/explorer/divisions/2006/05emd.cfm

PwC Mining Methods 43

 Potash mining – just grind away

back or roof

~3 m

Mosaic K1 mine near Esterhazy, Saskatchewan

Photo source: Martin Mraz (http://www.lightstalkers.org/martinmraz) used with permission
PwC Mining Methods 44
 Notes: Potash Mining – just grind away

Potash (used to make fertilizer) is so soft, it can be crushed and ground in place, eliminating
the need for blasting. The potash ore is transported by conveyor to the shaft and hoisted to
the surface.
This mine is at a depth of 1 km and there are almost 5000 km of tunnels in the mine. At
some tunnel intersections there are stoplights. conveyor

Four rotor boring machine

Three passes in potash seam to make 20
m wide room

PwC Mining Methods 45

 Longwall Mining of Coal

Plan view

Passageway
Entry
Coal
tunnels

PwC Mining Methods 46

 Notes: Longwall Mining of Coal

Longwall mining is a highly mechanized underground mining system for mining coal. A layer
of coal is selected and blocked out into an area known as a panel. A typical panel might be
3000 m long by 250 m wide. Passageways would be excavated along the length of the panel
to provide access and to place a conveying system to transport material out of the mine.
Entry tunnels would be constructed from the passageways along the width of the panel.
The longwall system would mine between entry tunnels. Extraction is an almost continuous
operation involving the use of self‐advancing hydraulic roof supports sometimes called
shields, a shearing machine, and a conveyor which runs parallel to the face being mined. A
typical configuration of a longwall mining system is illustrated below on the left.

PwC Mining Methods 47

 Sublevel caving

below a mined
out pit

PwC Mining Methods 48

 Notes: Sublevel caving

Sublevel caving is usually carried out underneath an open pit when it becomes uneconomic
to mine from the pit. The underground orebody is typically a relatively narrow slab that
dips at a steep angle. The method is similar to sublevel stoping except that the ore breaks
into fragments (caves) by itself after an initiating blast, i.e., the blast does not do all the
fragmentation.
Underground mining proceeds by constructing tunnels (drifts) through the orebody at
different levels below the bottom of the pit. Holes are drilled up into the roof of each
tunnel (longhole drilling), loaded with explosives, and blasted to cave the roof. After the
roof caves in, Load Haul Dump (LHD) vehicles transport the muck to an ore pass where it is
lifted to the surface. Drilling and blasting is sequenced in such a way that mining can take
place at different levels of the mine at the same time.
As the muck is transported to the ore pass, more blasting is done to cause ore to cave into
the drifts. This is repeated until the entire orebody is depleted. Ultimately rock from the pit
will cave into the underground.

PwC Mining Methods 49

 Block Caving – an “upside down open pit”

Induced cracking

Undercut
level

Production
level

http://technology.infomine.com/reviews/blockcaving/
PwC Mining Methods 50
 Notes: Block Caving – an “upside down open pit”

Applicable to large, deep, low grade deposits. A grid of tunnels is driven under the orebody.
This can take a significant amount of time, but the rewards are high in terms of production
rate. The rock mass is then undercut by blasting. Ideally the rock breaks under its own
weight. The broken ore is then taken from draw points. There may be hundreds of draw
points in a large block cave operation. Essentially block caving creates an underground
“inverted open pit”. Production rates are high. Surface subsidence can be a problem.

Mine Tons/day
El Teniente – Copper
South of Santiago, Chile
Esmeralda 45,000
Sub 6 35,000
4 South 35,000
Andina – Copper and Molybdenum 35,000
100 km north of Santiago, Chile
Northparkes – Copper and Gold 14,000
Australia
Henderson – Molybdenum 36,000
West of Denver, Colorado
Palabora – Copper 35,000
South Africa

PwC Mining Methods 51

 Fragmentation at Northparkes

Bad
Good

Source: SRK International Newsletter No. 28

Large fragments may cause “hang‐ups” stopping the flow of ore. They have to be broken up by secondary blasting
which can be costly because a set of draw points near the blasting has to be shut down..

PwC Mining Methods 52

 Block Cave Operations

PwC Mining Methods 53

 Why all these underground methods?

High Low
flexibility flexibility
High Low
operating operating
cost cost
Cut and fill Stoping Room and Longwall Caving
pillar
Backfill
support Controlled
No backfill collapse
Low operating cost, bulk mining operations such as block caving are desirable, but the capital costs for development
of mines that use these methods are significant. In addition, there is little flexibility in a bulk mining operation – it
must produce ore at a high rate almost without fail.

PwC Mining Methods 54

 A complex ore body

East Zone
West Zone

WARNING: Never lose sight of your guide if you go underground. The various twists and turns in an
underground operation make it very easy to get lost.

Source: Terry Gong and Daniel Avar, 2006. Resource Estimation and Mine Design. Feasibility Report written
for MINE 491 course at University of British Columbia.

PwC Mining Methods 55

 Same ore body – different mining methods

East Zone

West Zone

WARNING: Never lose sight of your guide if you go

underground. The various twists and turns in an
underground operation make it very easy to get lost.

Source: Terry Gong and Daniel Avar, 2006. Resource Estimation and Mine Design. Feasibility Report written for MINE
491 course at University of British Columbia.

PwC Mining Methods 56

 The Mining Cycle

Drill holes Load with

explosives

Survey
Blast
blastholes

Install support Ventilate

(underground) (underground)

Scaling Load, haul,

(underground) dump

PwC Mining Methods 57

 Underground drilling

Drill jumbo

Remotely operated rig drilling into a stope

A jumbo drill is several drills (up to five) mounted on one machine and powered by a single drive system. These
machines show conclusively that it is possible to do more than one thing at a time while underground.

PwC Mining Methods 58

 Drilling in an open pit

Air Rotary
Drill at
HVC

Tricone bit
Air is forced down the drill stem and out through holes in the
drill bit. The tricone bit may be cooled with water.

PwC Mining Methods 59

 Blasthole drilling at Bagdad Air

Tricone bit

PwC Mining Methods 60

 Blasting This might be venting where the explosive
energy is not transmitted to the rock.

Blast at Zaldivar mine, Chile

www.mining.ubc.ca/cimarchive/bymine.htm

Blast pattern at Highland Valley

It’s never good to see a blasting technician smiling when

standing next to a rock face loaded with explosives.

PwC Mining Methods 61

 Notes: Blasting

The picture on the left of the slide shows some cones in drilled holes ready for explosives
to be poured into them. Note the regular pattern of the blast holes. There is also a pattern
to the detonation times of the explosives in each blast hole. Typically the detonation times
of the explosives in two adjacent blast holes differ by a few milliseconds (called a delay
time) so that the blast proceeds in a particular direction within the blast pattern to avoid
blasting too much rock. (See diagram below.)
Blasts should not “vent” and be too spectacular. If they are, it is wasted energy. The goal is
to keep the blast energy in the ground to fracture the rock as much as possible. Ideally the
blast should just lift the rock up and then the fractured rock settles.

Detonate
Detonate these last
these first

Watch some detonation patterns :

www.youtube.com/watch?v=44tm26Fhqr8

PwC Mining Methods 62

 Ventilation

Propeller fans in large mine

Thayer‐Lindsley ventilation

Air pipe in mine tunnel

PwC Mining Methods 63

 Load Haul and Dump (LHD) – all in one

6.8 tonne
scooptram
~$500K

1.3 m

Terex MT6300AC truck

(400 ton, electric, $5‐6M)

PwC Mining Methods 64

 Shovel and Haul Truck

Bucyrus 495HF electric

shovel (90 t, $15M)

www.cbc.ca/news/business/story/2011/02/23/corporate‐profits.html

Caterpillar 797F
(363 t, $5‐6M)
www.im‐mining.com/2010/10/29/
PwC Mining Methods 65
 Notes: Load Haul and Dump

The Terex RH400 shovel (50 m3 capacity) is used to load Caterpillar 797B trucks (380 ton capacity) at Syncrude Mine
in Alberta. The Terex O&K RH400 shovel was designed specifically to meet Syncrude’s high capacity and durability
needs in the oil sands.
Image sources: www.terex.com www.atlascopco.ca
Cocktail party trivia:
•Every 24 hours at Syncrude there is enough metal worn off the mining equipment, by abrasive oil sand, to make two
full‐size pick‐up trucks. Source: www.syncrude.com
•The fuel tank of the Caterpillar 797 truck has a capacity of 6,800 litres (1800 gallons) – that’s 12,364 extra large cups
of coffee or 19,155 cans of pop.
•The Cat 797’s tires are nearly 4 m (13.1 ft) tall, weigh 15,422 kilograms (34,000 lb), and cost $50,000 each (US$).
The goal of large machines is to spread fixed costs over a larger unit, i.e., obtain economies of scale. However, there is
concern that maintenance costs of these large machines, particularly tire costs, are too high leading to diseconomies
of scale. One manufacturer has suggested 1000 ton haul trucks by 2020. Shovels will become correspondingly larger –
say 150 m3. But …
•It may not be possible to build tires for such large trucks
•New materials and new designs may be needed to build the trucks
•Space constraints on haul roads and maintenance facilities
•Total production and transportation costs increase with size
•There are reliability and flexibility issues – if one large machine breaks down, the system stops

PwC Mining Methods 66

 Shovel and trucks at Elkview

PwC Mining Methods 67

 Install support
Swellex
rockbolt

Water at
high pressure
Mesh
Rockbolts analogous to
rebar in concrete

Shotcrete
PwC Mining Methods 68
 Notes: Install support

Rock is strong when it is compressed – it takes a huge force to break rock by squeezing it. In the earth,
rock is subjected to very large compressive forces due to the weight of rock lying above it. However,
opening a hole in rock takes away this compressive force and the rock expands, maybe only a few
millimeters, but this expansion is enough to cause failures along cracks. The expansion actually pulls
the rock apart and rock is weak when this happens – it is said to be weak in tension.
Thus cracks form on the roof and walls of a mine opening and the rock mass begins to fall apart. This
might lead to large (dangerous) chunks of rock forming on the roof and walls. When these fall into the
opening, it is called spalling. The mesh prevents this.
A compressive force can be imposed on the rock mass around a mine opening by means of rock bolts.
These are long steel bars with wedges on one end that lock them into place at the end of a hole drilled
from the mine opening. A nut on the other end of the bolt is tightened to provide compression to the
rock mass by squeezing it together. Another type of rock bolt is the Swellex bolt which is compressed
against the sides of the hole by means of water pressure.
Shotcrete is a thin layer of concrete that is sprayed onto the rock face. It can take the place of mesh
and is easier to install, but it can be expensive. Sometimes short narrow plastic rods are embedded to
provide tensile strength to the shotcrete (Concrete is also weak in tension – that’s why rebar is used in
concrete construction.) Shotcrete can also provide some strength by preventing further expansion of
the rock mass into the opening.
What is used depends on the rock type and its conditions. It also depends on the use of the opening –
e.g., permanent or temporary.

PwC Mining Methods 69

 Grade control and dilution

Bench in Pit

Ore

Waste
Equal length blast holes
drilled into waste

Lack of selectivity of mining

method
PwC Mining Methods 70
 Notes: Causes of Dilution

It is often difficult to mine selectively and avoid dilution. In open pit operations, efforts are
being made to use global positioning satellite systems (GPS) to accurately position
individual shovel scoops and drills. Other methods are used to sense the ore‐waste
boundary so that drilling can stop at that point. In underground operations, some work is
being done to separate waste from ore at the source, i.e., before it goes up the shaft.

Dilution is defined as waste/(waste+ore), i.e., a percentage of the total material extracted.

Dilution is assumed to occur when and where ore is being extracted, that is the waste
produced during underground development or stripping before open pit mining is not
included. Dilution might be 5%‐10%, but this depends on the orebody type and its
geometry as well as on the level of dilution control.

PwC Mining Methods 71

 Artisanal Mining

Artisanal miners in Mongwalu,

north eastern DRC.

Boiling mercury to
separate gold

Gold‐mercury amalgam
www.pictures.reuters.com

www.rfi.fr/actuen/articles/110/article_2903.asp
PwC Mining Methods 72
 73

The horns of a miner’s dilemma

Many mining companies own a mine in an area where artisanal mining occurs.
Should they do anything about it? Common sense (and professional ethics)
suggests doing something about such unsafe practices. Options include re‐training
the artisanals to work in the mine, to do another job, or help them do the
artisanal mining in a better way. But doing this causes changes which can be
considered just as bad or worse. Here’s a quote from a newspaper article:

… a small but noisy contingent of activists insists that Barrick is the face of
corporate evil. … It has destroyed communities and wrecked the livelihoods of
small "artisanal“ miners.
⁞
As for the accusation that Barrick has destroyed "artisanal" mining, the truth
is that the rewards from crude surface mining with a pickaxe have long since
been exhausted. These days, "artisanal" mining often takes the form of
dangling a six‐year‐old kid down a hole with a rope.
From Our world needs more Peter Munks
Margaret Wente, Globe and Mail, June 11, 2011

PwC Mining Methods

 These things happen

Luckily the driver of the red truck was working

nearby when the haul truck drove over it.

A really stupid mistake

WARNING: Keep clear of haul trucks if you

find yourself in an open pit mine. The
driver’s field of view is very limited.

PwC Mining Methods 74

 END OF PART 2

PwC Mining Methods 75