Open Pit Mine Planning and Design, Two Volume Set & CD-ROM Pack

ISBN-13: 9781466575127 / Angielski / Miękka / 2013 / 1308 str.

William A. Hustrulid; Mark Kuchta; Randall K. Martin

Opis

Building on the success of its 2006 predecessor, this 3rd edition of Open Pit Mine Planning and Design has been both updated and extended, ensuring that it remains the most complete and authoritative account of modern open pit mining available. Five new chapters on unit operations have been added, the revenues and costs chapter has been substantially revised and updated, and the references have been brought fully up to date. In addition, the pack now also includes a fully working version of the MicroMODEL mine planning software package.

Volume 1 deals with the fundamental concepts involved in the planning and design of open pit mines. Subjects covered are mine planning, mining revenues and costs, orebody description, geometrical considerations, pit limits, production planning, mineral resources and ore reserves, responsible mining, rock blasting, rotary drilling, shovel loading, haulage trucks and machine availability and utilization.

Volume 2 includes CSMine and MicroMODEL, user-friendly mine planning and design software packages developed specifically to illustrate the practical application of the involved principles. It also comprises the CSMine and MicroMODEL tutorials and user s manuals and eight orebody case examples, including drillhole data sets for performing a complete open pit mine evaluation.

Open Pit Mine Planning and Design is an excellent textbook for courses in surface mine design, open pit design, geological and excavation engineering, and in advanced open pit mine planning and design. The principles described apply worldwide. In addition, the work can be used as a practical reference by professionals. The step-by-step approach to mine design and planning offers a fast-path approach to the material for both undergraduate and graduate students. The outstanding software guides the student through the planning and design steps, and the eight drillhole data sets allow the student to practice the described principles on different mining properties (three copper properties, three iron properties and two gold properties). The well-written text, the large number of illustrative examples and case studies, the included software, the review questions and exercises and the reference lists included at the end of each chapter provide the student with all the material needed to effectively learn the theory and application of open pit mine planning and design."

Spis treści

1 MINE PLANNING

1.1 Introduction
1.1.1 The meaning of ore
1.1.2 Some important definitions
1.2 Mine development phases
1.3 An initial data collection checklist
1.4 The planning phase
1.4.1 Introduction
1.4.2 The content of an intermediate valuation report
1.4.3 The content of the feasibility report
1.5 Planning costs
1.6 Accuracy of estimates
1.6.1 Tonnage and grade
1.6.2 Performance
1.6.3 Costs
1.6.4 Price and revenue
1.7 Feasibility study preparation
1.8 Critical path representation
1.9 Mine reclamation
1.9.1 Introduction
1.9.2 Multiple-use management
1.9.3 Reclamation plan purpose
1.9.4 Reclamation plan content
1.9.5 Reclamation standards
1.9.6 Surface and ground water management
1.9.7 Mine waste management
1.9.8 Tailings and slime ponds
1.9.9 Cyanide heap and vat leach systems
1.9.10 Landform reclamation
1.10 Environmental planning procedures
1.10.1 Initial project evaluation
1.10.2 The strategic plan
1.10.3 The environmental planning team
1.11 A sample list of project permits and approvals
References and bibliography
Review questions and exercises

2 MINING REVENUES AND COSTS

2.1 Introduction
2.2 Economic concepts including cash flow
2.2.1 Future worth
2.2.2 Present value
2.2.3 Present value of a series of uniform contributions
2.2.4 Payback period
2.2.5 Rate of return on an investment
2.2.6 Cash flow (CF)
2.2.7 Discounted cash flow (DCF)
2.2.8 Discounted cash flow rate of return (DCFROR)
2.2.9 Cash flows, DCF and DCFROR including depreciation
2.2.10 Depletion
2.2.11 Cash flows, including depletion
2.3 Estimating revenues
2.3.1 Current mineral prices
2.3.2 Historical price data
2.3.3 Trend analysis
2.3.4 Econometric models
2.3.5 Net smelter return
2.3.6 Price-cost relationships
2.4 Estimating costs
2.4.1 Types of costs
2.4.2 Costs from actual operations
2.4.3 Escalation of older costs
2.4.4 The original O’Hara cost estimator
2.4.5 The updated O’Hara cost estimator
2.4.6 Detailed cost calculations
2.4.7 Quick-and-dirty mining cost estimates
2.4.8 Current equipment, supplies and labor costs
References and bibliography
Review questions and exercises

3 OREBODY DESCRIPTION

3.1 Introduction
3.2 Mine maps
3.3 Geologic information
3.4 Compositing and tonnage factor calculations
3.4.1 Compositing
3.4.2 Tonnage factors
3.5 Method of vertical sections
3.5.1 Introduction
3.5.2 Procedures
3.5.3 Construction of a cross-section
3.5.4 Calculation of tonnage and average grade for a pit
3.6 Method of vertical sections (grade contours)
3.7 The method of horizontal sections
3.7.1 Introduction
3.7.2 Triangles
3.7.3 Polygons
3.8 Block models
3.8.1 Introduction
3.8.2 Rule-of-nearest points
3.8.3 Constant distance weighting techniques
3.9 Statistical basis for grade assignment
3.9.1 Some statistics on the orebody
3.9.2 Range of sample influence
3.9.3 Illustrative example
3.9.4 Describing variograms by mathematical models
3.9.5 Quantification of a deposit through variograms
3.10 Kriging
3.10.1 Introduction
3.10.2 Concept development
3.10.3 Kriging example
3.10.4 Example of estimation for a level
3.10.5 Block kriging
3.10.6 Common problems associated with the use of the kriging technique
3.10.7 Comparison of results using several techniques
References and bibliography
Review questions and exercises

4 GEOMETRICAL CONSIDERATIONS

4.1 Introduction
4.2 Basic bench geometry
4.3 Ore access
4.4 The pit expansion process
4.4.1 Introduction
4.4.2 Frontal cuts
4.4.3 Drive-by cuts
4.4.4 Parallel cuts
4.4.5 Minimum required operating room for parallel cuts
4.4.6 Cut sequencing
4.5 Pit slope geometry
4.6 Final pit slope angles
4.6.1 Introduction
4.6.2 Geomechanical background
4.6.3 Planar failure
4.6.4 Circular failure
4.6.5 Stability of curved wall sections
4.6.6 Slope stability data presentation
4.6.7 Slope analysis example
4.6.8 Economic aspects of final slope angles
4.7 Plan representation of bench geometry
4.8 Addition of a road
4.8.1 Introduction
4.8.2 Design of a spiral road – inside the wall
4.8.3 Design of a spiral ramp – outside the wall
4.8.4 Design of a switchback
4.8.5 The volume represented by a road
4.9 Road construction
4.9.1 Introduction
4.9.2 Road section design
4.9.3 Straight segment design
4.9.4 Curve design
4.9.5 Conventional parallel berm design
4.9.6 Median berm design
4.9.7 Haulage road gradients
4.9.8 Practical road building and maintenance tips
4.10 Stripping ratios
4.11 Geometric sequencing
4.12 Summary
References and bibliography
Review questions and exercises

5 PIT LIMITS

5.1 Introduction
5.2 Hand methods
5.2.1 The basic concept
5.2.2 The net value calculation
5.2.3 Location of pit limits – pit bottom in waste
5.2.4 Location of pit limits – pit bottom in ore
5.2.5 Location of pit limits – one side plus pit bottom in ore
5.2.6 Radial sections
5.2.7 Generating a final pit outline
5.2.8 Destinations for in-pit materials
5.3 Economic block models
5.4 The floating cone technique
5.5 The Lerchs-Grossmann 2-D algorithm
5.6 Modification of the Lerchs-Grossmann 2-D algorithm to a 2½-D algorithm
5.7 The Lerchs-Grossmann 3-D algorithm
5.7.1 Introduction
5.7.2 Definition of some important terms and concepts
5.7.3 Two approaches to tree construction
5.7.4 The arbitrary tree approach (Approach 1)
5.7.5 The all root connection approach (Approach 2)
5.7.6 The tree ‘cutting’ process
5.7.7 A more complicated example
5.8 Computer assisted methods
5.8.1 The RTZ open-pit generator
5.8.2 Computer assisted pit design based upon sections
References and bibliography
Review questions and exercises

6 PRODUCTION PLANNING

6.1 Introduction
6.2 Some basic mine life – plant size concepts
6.3 Taylor’s mine life rule
6.4 Sequencing by nested pits
6.5 Cash flow calculations
6.6 Mine and mill plant sizing
6.6.1 Ore reserves supporting the plant size decision
6.6.2 Incremental financial analysis principles
6.6.3 Plant sizing example
6.7 Lane’s algorithm
6.7.1 Introduction
6.7.2 Model definition
6.7.3 The basic equations
6.7.4 An illustrative example
6.7.5 Cutoff grade for maximum profit
6.7.6 Net present value maximization
6.8 Material destination considerations
6.8.1 Introduction
6.8.2 The leach dump alternative
6.8.3 The stockpile alternative
6.9 Production scheduling
6.9.1 Introduction
6.9.2 Phase scheduling
6.9.3 Block sequencing using set dynamic programming
6.9.4 Some scheduling examples
6.10 Push back design
6.10.1 Introduction
6.10.2 The basic manual steps
6.10.3 Manual push back design example
6.10.4 Time period plans
6.10.5 Equipment fleet requirements
6.10.6 Other planning considerations
6.11 The mine planning and design process – summary and closing remarks
References and bibliography
Review questions and exercises

7 REPORTING OF MINERAL RESOURCES AND ORE RESERVES

7.1 Introduction
7.2 The JORC code – 2004 edition
7.2.1 Preamble
7.2.2 Foreword
7.2.3 Introduction
7.2.4 Scope
7.2.5 Competence and responsibility
7.2.6 Reporting terminology
7.2.7 Reporting – General
7.2.8 Reporting of exploration results
7.2.9 Reporting of mineral resources
7.2.10 Reporting of ore reserves
7.2.11 Reporting of mineralized stope fill, stockpiles, remnants, pillars, low grade mineralization and tailings
7.3 The CIM best practice guidelines for the estimation of mineral resources and mineral reserves – general guidelines
7.3.1 Preamble
7.3.2 Foreword
7.3.3 The resource database
7.3.4 Geological interpretation and modeling
7.3.5 Mineral resource estimation
7.3.6 Quantifying elements to convert a Mineral Resource to a Mineral Reserve
7.3.7 Mineral reserve estimation
7.3.8 Reporting
7.3.9 Reconciliation of mineral reserves
7.3.10 Selected references
References and bibliography
Review questions and exercises

8 RESPONSIBLE MINING

8.1 Introduction
8.2 The 1972 United Nations Conference on the Human Environment
8.3 TheWorld Conservation Strategy (WCS) – 1980
8.4 World Commission on Environment and Development (1987)
8.5 The ‘Earth Summit’
8.5.1 The Rio Declaration
8.5.2 Agenda 21
8.6 World Summit on Sustainable Development (WSSD)
8.7 Mining industry and mining industry-related initiatives
8.7.1 Introduction
8.7.2 The Global Mining Initiative (GMI)
8.7.3 International Council on Mining and Metals (ICMM)
8.7.4 Mining, Minerals, and Sustainable Development (MMSD)
8.7.5 The U.S. Government and federal land management
8.7.6 The position of the U.S. National Mining Association (NMA)
8.7.7 The view of one mining company executive
8.8 ‘Responsible Mining’ – the way forward is good engineering
8.8.1 Introduction
8.8.2 The Milos Statement
8.9 Concluding remarks
References and bibliography
Review questions and exercises

9 ROCK BLASTING

9.1 General introduction to mining unit operations
9.2 Rock blasting
9.2.1 Rock fragmentation
9.2.2 Blast design flowsheet
9.2.3 Explosives as a source of fragmentation energy
9.2.4 Pressure-volume curves
9.2.5 Explosive strength
9.2.6 Energy use
9.2.7 Preliminary blast layout guidelines
9.2.8 Blast design rationale
9.2.9 Ratios for initial design
9.2.10 Ratio based blast design example
9.2.11 Determination of KB
9.2.12 Energy coverage
9.2.13 Concluding remarks
References and bibliography
Review questions and exercises

10 ROTARY DRILLING

10.1 Brief history of rotary drill bits
10.2 Rock removal action
10.3 Rock bit components
10.4 Roller bit nomenclature
10.5 The rotary blasthole drill machine
10.6 The drill selection process
10.7 The drill string
10.8 Penetration rate – early fundamental studies
10.9 Penetration rate – field experience
10.10 Pulldown force
10.11 Rotation rate
10.12 Bit life estimates
10.13 Technical tips for best bit performance
10.14 Cuttings removal and bearing cooling
10.15 Production time factors
10.16 Cost calculations
10.17 Drill automation
References and bibliography
Review questions and exercises

11 SHOVEL LOADING

11.1 Introduction
11.2 Operational practices
11.3 Dipper capacity
11.4 Some typical shovel dimensions, layouts and specifications
11.5 Ballast/counterbalance requirements
11.6 Shovel production per cycle
11.7 Cycle time
11.8 Cycles per shift
11.9 Shovel productivity example
11.10 Design guidance from regulations
References and bibliography
Review questions and exercises

12 HAULAGE TRUCKS

12.1 Introduction
12.2 Sizing the container
12.3 Powering the container
12.4 Propeling the container – mechanical drive systems
12.4.1 Introduction
12.4.2 Performance curves
12.4.3 Rimpull utilization
12.4.4 Retardation systems
12.4.5 Specifications for a modern mechanical drive truck
12.4.6 Braking systems
12.5 Propelling the container – electrical drive systems
12.5.1 Introduction
12.5.2 Application of the AC-drive option to a large mining truck
12.5.3 Specifications of a large AC-drive mining truck
12.5.4 Calculation of truck travel time
12.6 Propelling the container – trolley assist
12.6.1 Introduction
12.6.2 Trolley-equipped Komatsu 860E truck
12.6.3 Cycle time calculation for the Komatsu 860E truck with trolley assist
12.7 Calculation of truck travel time – hand methods
12.7.1 Introduction
12.7.2 Approach 1 – Equation of motion method
12.7.3 Approach 2 – Speed factor method
12.8 Calculation of truck travel time – computer methods
12.8.1 Caterpillar haulage simulator
12.8.2 Speed-factor based simulator
12.9 Autonomous haulage
References and bibliography
Review questions and exercises

13 MACHINE AVAILABILITY AND UTILIZATION

13.1 Introduction
13.2 Time flow
13.3 Availability – node 1
13.4 Utilization – node 2
13.5 Working efficiency – node 3
13.6 Job efficiency – node 4
13.7 Maintenance efficiency – node 5
13.8 Estimating annual operating time and production capacity
13.9 Estimating shift operating time and production capacity
13.10 Annual time flow in rotary drilling
13.11 Application in prefeasibility work
References and bibliography
Review questions and exercises

14 THE CSMine TUTORIAL

14.1 Getting started
14.1.1 Hardware requirements
14.1.2 Installing CSMine
14.1.3 Running CSMine
14.2 The Arizona Copper property description
14.3 Steps needed to create a block model
14.4 Data files required for creating a block model
14.5 CSMine program design overview
14.6 Executing commands with CSMine
14.7 Starting the tutorial
14.8 The drill hole mode
14.8.1 Reading the drill hole file
14.8.2 Defining the block grid
14.8.3 Creating a drill hole plan map
14.8.4 Creating a drill hole section map
14.9 The composite mode
14.9.1 Calculating composites
14.9.2 Storing and loading composite files
14.9.3 Drill hole section plots with composites
14.10 The block mode
14.10.1 Calculating block grades
14.10.2 Creating block value plots
14.10.3 Creating contour maps
14.10.4 Assigning economic values to the blocks
14.10.5 The Restrictions command
14.10.6 Pit plots
14.10.7 The Slopes command
14.10.8 The Save and Print commands
14.11 Conclusion
14.12 Suggested exercises

15 CSMine USER’S GUIDE

15.1 Basics
15.1.1 File types
15.1.2 The project file
15.1.3 Changing modes
15.1.4 Formatting the data screen
15.1.5 Sorting data
15.1.6 Printing data
15.1.7 Coordinate system description
15.2 Drill hole mode
15.2.1 Drill hole data file description
15.2.2 Reading a drill hole file
15.2.3 Plotting a drill hole plan map
15.2.4 Plotting a drill hole section map
15.3 Composite mode
15.3.1 How composites are calculated
15.3.2 Creating composites
15.3.3 Saving composite files
15.3.4 Reading composite files
15.3.5 Composite file description
15.4 Block model mode
15.4.1 Defining the block model grid
15.4.2 Surface topography
15.4.3 Assigning block values
15.4.4 Creating a block model
15.4.5 Saving a block file
15.4.6 Reading a block file
15.4.7 Block file description
15.5 Economic block values
15.5.1 How economic values are calculated
15.5.2 Evaluation of the default formulas
15.5.3 Creating an economic block model
15.6 Pit modeling
15.6.1 Surface topography restrictions
15.6.2 Geometric pit limit restriction and pit slopes
15.6.3 Positive apexed cone limits
15.6.4 Three-dimensional floating cone
15.6.5 Entering pit slopes
15.6.6 Turning pit restrictions on and off
15.7 Block plots
15.7.1 The Configure command
15.7.2 The Next command
15.7.3 The Previous command
15.7.4 The Return command
15.7.5 Controlling which blocks are plotted
15.8 Contour plot
15.8.1 The Configure command
15.8.2 The Next command
15.8.3 The Previous command
15.8.4 The Return command
15.9 Plotting pit profiles
15.9.1 The Configure command
15.9.2 The Surface command
15.9.3 The Geometric command
15.9.4 The Outer_Economic command
15.9.5 The Floating_Cone command
15.9.6 The Return command
15.10 Block reports
15.10.1 The Restrictions command
15.10.2 The Configure command
15.10.3 The Return command
15.11 Summary statistics
15.11.1 The EX1.CMP data set
15.11.2 The EX2.CMP data set
15.11.3 Summary statistics description
15.11.4 Is a distribution normal?
15.11.5 Is a distribution lognormal?
15.11.6 The Transform command
15.11.7 The Statistics command
15.12 Variogram modeling
15.12.1 Introduction
15.12.2 Experimental variogram modeling
15.12.3 Anisotropy
15.12.4 The Variogram command
Reference

16 THE MicroMODEL V8.1 MINE DESIGN SOFTWARE

16.1 Introduction
16.2 Program overview
16.2.1 Introduction
16.2.2 Data Entry Module overview
16.2.3 Surface Modeling Module overview
16.2.4 Rock Modeling Module overview
16.2.5 Drill Hole Compositing Module overview
16.2.6 Grade Modeling Module overview
16.2.7 Pit Generation and Reserves Evaluation Module overview
16.3 Data Entry Tutorial
16.3.1 Introduction
16.3.2 Some notes on input files
16.3.3 Getting started
16.3.4 Starting a demo project
16.3.5 Some special considerations
16.3.6 Constructing the Ariz_Cu model
16.4 Pit Generation tutorial
16.4.1 Introduction
16.4.2 Surface topography
16.4.3 Rock modeling
16.4.4 Compositing
16.4.5 Grade modeling
16.4.6 Pit creation
16.4.7 File manager
16.4.8 Happy times
16.5 Other data sets – Continuation

17 Orebody case examples

17.1 Introduction
17.2 The Arizona Copper property
17.2.1 Introduction
17.2.2 Historical background
17.2.3 Property topography
17.2.4 Geologic description
17.2.5 Mineralization
17.2.6 Drill hole data
17.2.7 Mining considerations
17.3 The Minnesota Natural Iron property
17.3.1 Introduction
17.3.2 Access
17.3.3 Climatic conditions
17.3.4 Historical background
17.3.5 Topography
17.3.6 General geologic setting
17.3.7 Mine-specific geology
17.3.8 An initial hand design
17.3.9 Economic basis
17.4 The Utah Iron property
17.4.1 Background
17.4.2 Mining history of the district
17.4.3 Property topography and surface vegetation
17.4.4 Climate
17.4.5 General geology
17.4.6 Mineralization
17.4.7 Mineral processing
17.4.8 Pit slopes
17.4.9 Initial cost estimates
17.4.10 Other considerations
17.5 The Minnesota Taconite property
17.5.1 Introduction
17.5.2 Location
17.5.3 History
17.5.4 Topography and surface conditions
17.5.5 General geology
17.5.6 Structural data
17.5.7 Mining data
17.5.8 Ore processing
17.6 The Kennecott Barneys Canyon Gold property
17.6.1 Introduction
17.6.2 Geologic setting
17.6.3 Resource definition
17.6.4 Geotechnical data
17.6.5 Topography and surface conditions
17.6.6 Climate
17.6.7 Ore processing
17.6.8 Mining data
17.7 The Newmont Gold property
17.7.1 Introduction
17.7.2 Property location
17.7.3 General geologic setting
17.7.4 Deposit mineralization
17.7.5 Topography and surface conditions
17.7.6 Local climatic conditions
17.7.7 Initial pit modeling parameters
17.8 The Codelco Andina Copper property
17.8.1 Introduction
17.8.2 Background information
17.8.3 Geology
17.8.4 Structural geology
17.8.5 Geotechnical slope analysis and design
17.8.6 Unit operations and initial costs for generating a pit
17.9 The Codelco Norte Copper property
17.9.1 Introduction
17.9.2 Location and access
17.9.3 Geology
17.9.4 Geotechnical information
17.9.5 Open pit geometry
17.9.6 Material handling systems
17.9.7 Metallurgical testing/process development
17.9.8 Leach pad design and operation
17.9.9 Mine design and plan
17.9.10 Unit operations and manpower
17.9.11 Economic analysis

References
Index

O autorze

William Hustrulid studied Minerals Engineering at the University of Minnesota. After obtaining his Ph.D. degree in 1968, his career has included responsible roles in both mining academia and in the mining business itself. He has served as Professor of Mining Engineering at the University of Utah and at the Colorado School of Mines and as a Guest Professor at theTechnical University in Luleå, Sweden. In addition, he has held mining R&D positions for companies in the USA, Sweden, and the former Republic of Zaire. He is a Member of the U.S. National Academy of Engineering (NAE) and a Foreign Member of the Swedish Royal Academy of Engineering Sciences (IVA). He currently holds the rank of Professor Emeritus at the University of Utah and manages Hustrulid Mining Services in Spokane,Washington.

Mark Kuchta studied Mining Engineering at the Colorado School of Mines and received his Ph.D. degree from the Technical University in Luleå, Sweden. He has had a wide-ranging career in the mining business. This has included working as a contract miner in the uranium mines of western Colorado and 10 years of experience in various positions with LKAB in northern Sweden. At present, Mark is an Associate Professor of Mining Engineering at the Colorado School of Mines. He is actively involved in the education of future mining engineers at both undergraduate and graduate levels and conducts a very active research program. His professional interests include the use of high-pressure waterjets for rock scaling applications in underground mines, strategic mine planning, advanced mine production scheduling and the development of user-friendly mine software.

Randall K. “Randy” Martin studied Metallurgical Engineering at the Colorado School of Mines and later received a Master of Science in Mineral Economics from Mines. He has over thirty years of experience as a geologic modeler and mine planner, having worked for Amax Mining, Pincock, Allen & Holt, and Tetratech. Currently he serves as President of R.K. Martin and Associates, Inc. His company performs consulting services, and also markets and supports a variety of software packages which are used in the mining industry. He is the principal author of the MicroMODEL® software included with this textbook.