Open Pit Lead

7/29/2019 Open Pit Lead

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MinE416FinalReport

Supervisor:Prof.Dr.H. ebnemDZGN

brahim Semih KAYAGkhan KUTLUBAY

Taylan UZUNOULLARIYusuf YACI31/05/2011


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TableofContents1.General Information about Mine Site...................................................................................................... 61.1. Location................................................................................................................................................. 61.2. Topography........................................................................................................................................... 61.3. Population Centers and Labor Force................................................................................................... 71.4. Socioeconomical Properties............................................................................................................... 91.5. Power Supply...................................................................................................................................... 101.6. Climate................................................................................................................................................. 101.7. Transportation.................................................................................................................................... 12

1.8. Water Availability............................................................................................................................... 14

1.9. Other Resources.................................................................................................................................. 141.10. Financial and Taxation..................................................................................................................... 141.11. Commodity........................................................................................................................................ 152. Geological, Hydrological and Rock Engineering Studies.................................................................... 172.1. Topographic Maps.............................................................................................................................. 172.2. Geology................................................................................................................................................ 192.3. Hydrology............................................................................................................................................ 242.4. Rock Engineering Studies................................................................................................................... 263. Reserve Evaluation................................................................................................................................ 293.1. Evaluation of DrillHole Logs............................................................................................................. 293.2. Reserve Calculation by Conventional Methods................................................................................ 293.3. Reserve Calculation by Micromine Software.................................................................................... 303.4. Mine Life, Yearly Production and Demand....................................................................................... 404. Mining Method Selection....................................................................................................................... 40

4.1. Underground vs. Surface Mining Method Selection......................................................................... 40

4.2. Cutoff Grade Estimation.................................................................................................................... 434.3. Open Pit vs. Open Cast Selection........................................................................................................ 435. Development Design.............................................................................................................................. 455.1. Mine Layout Design............................................................................................................................ 455.1.1. Dumpsite Selection.......................................................................................................................... 455.1.2GeneralLayout................................................................................................................................... 47

6.ProductionSchedulng............................................................................................................................. 47


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7.Stability.................................................................................................................................................... 57

7.1.FailureTypes......................................................................................................................................... 59

7.1.1Plane

Failure

.......................................................................................................................................

59

7.1.2.Wedge............................................................................................................................................... 63

8.MaterialsHandlingandEquipmentSelection......................................................................................... 65

8.1.OreProduction..................................................................................................................................... 66

8.1.1.ShovelSelection................................................................................................................................ 66

8.1.2TruckSelection.................................................................................................................................... 68

8.2.OverburdenRemoval........................................................................................................................... 72

8.2.1.ShovelSelection................................................................................................................................ 72

8.2.2.TruckSelection.................................................................................................................................. 74

8.3WorkingBenchDimensions................................................................................................................... 77

8.3.1WorkingBenchDimensionsforOverburdenRemoval....................................................................... 77

8.3.2.WorkingBenchDimensionsforOreProduction............................................................................... 78

8.4.RoadDesign.......................................................................................................................................... 78

8.4.1.Designoftheroadsforoverburdenremoval:................................................................................... 78

8.4.2.Designoftheroadsfororeproduction:............................................................................................ 81

9.Drilling

and

Blasting

Design

.....................................................................................................................

84

9.1.OverburdenRemovalBlastingDesign.................................................................................................. 85

9.2.ProductionBlastingDesign................................................................................................................... 89

9.3.Initiation............................................................................................................................................... 92

9.4.DrillingEquipmentSelection................................................................................................................ 93

9.5.DelayTiming......................................................................................................................................... 94

10.TruckDispatching.................................................................................................................................. 95

10.1.Truck&Shoveldispatchingforstripping........................................................................................... 95

10.2.Truck&Shoveldispatchingfororeproduction................................................................................. 96

11.MineWideMonitoring&Control......................................................................................................... 97

11.1.Monitoring,ControlandManagement.............................................................................................. 97

11.1.1.SoilMonitoring................................................................................................................................ 97

11.1.2.WaterMonitoring............................................................................................................................ 98

11.1.3.EarlyWarningSystem.................................................................................................................... 100

11.1.4.MicroseismicMineMonitoring..................................................................................................... 100


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11.1.5.DustMonitoring............................................................................................................................ 101

11.2.WirelessCommunicationSystem..................................................................................................... 105

11.3.Truck

Dispatching

Monitoring

..........................................................................................................

106

12.MineWaterDrainage.......................................................................................................................... 107

12.1.Drainage........................................................................................................................................... 107

12.1.1.WaterDrainage............................................................................................................................. 108

12.2.SumpDesing..................................................................................................................................... 112

13.EnvironmentalConsiderations............................................................................................................ 113

13.1.LawsandRegulations....................................................................................................................... 113

13.1.1PrinciplesforEstablishingaBalancebetweenMiningandEnvironment....................................... 115

13.1.2.IndependentEnvironmentalManagement................................................................................... 117

13.1.3.Communication............................................................................................................................. 118

14.MineClosureandReclamationPlanning............................................................................................ 118

14.1.ExplorationStage.............................................................................................................................. 118

14.2.DevelopmentStage.......................................................................................................................... 118

14.3.OperationStage................................................................................................................................ 118

14.4.RehabilitationofTailingPond.......................................................................................................... 118

14.7.Closure

and

Vegetation

Plan

for

Pit

Area,

Dump

Site

and

Tailing

Dam

...........................................

121

15.Illumination......................................................................................................................................... 124

16.ElectricitySupply................................................................................................................................. 127

17.EconomicalAnalysis

17.1.FixCapitalCostInvestment

17.1.1.MineralRightsAcquisitionsandLegalFees.................................................................................. 127

17.1.2.SiteClearingandAccessRoadCost............................................................................................... 128

17.1.3.ProcessingPlantandTailingStorageCost..................................................................................... 128

17.2.Equipment

Cost

................................................................................................................................

129

17.3.BuildingCost..................................................................................................................................... 130

17.4.MonitoringandEarlyWarningSystem............................................................................................ 130

17.5.MineClosureandReclamation......................................................................................................... 131

17.6.FixedCapitalCost............................................................................................................................. 132

17.7.OperatingCost.................................................................................................................................. 132

17.7.1.ProcessingCost.............................................................................................................................. 132


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17.7.2.DrillingandBlasting....................................................................................................................... 132

17.7.3.TireChangeCost............................................................................................................................ 132

17.7.4.Spare

Parts

....................................................................................................................................

133

17.7.5.Electricity........................................................................................................................................ 133

17.7.6.PersonalPayments......................................................................................................................... 133

17.7.7.MaintenanceandRepairCost....................................................................................................... 134

17.8.MineClosureandReclamationCost................................................................................................. 134

17.9.FuelConsumption............................................................................................................................. 135

17.9.1.OilConsumption............................................................................................................................. 136

18.FeasibilityAnalysis............................................................................................................................... 136

18.1.Annualrevenue................................................................................................................................ 136

18.2.SensitivityAnalysis........................................................................................................................... 140

19.Conclusion........................................................................................................................................... 141

20.References........................................................................................................................................... 142AppendixACashflowanalysis................................................................................................................ 145

AppendixAFutureValue&PresentValueResults................................................................................... 148

AppendixASensitivityAnalysis................................................................................................................. 148

AppendixB

Conventional

Calculations

of

Ore

Reserve

Evaluation

..........................................................

149

FIGURES..................................................................................................................................................... 153

TABLES....................................................................................................................................................... 156


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1. GeneralInformationaboutMineSite

1.1.LocationBalya County is located 15 km west of Balkesir. The county is neighbor to Gnen and Manyascounties at northern side and Havran and vrindi counties at the southern side.

Figure1: Balkesir County Map (http://www.turkcebilgi.com/bal%C4%B1kesir/haritasi)1.2.Topography

Anatolian Peninsula formed under the influence of Alpine mountain formation (orogenesis), giventhat the North West of the peninsula in the province of Balikesir in Alpine orogeny began tooccur with the formation of Alpine mountain and after the effects of the Alpine mountain formationthe region has the existent topography. The region shows feature a rugged topography witha general outline of the field.Balya has the area of 952 sq. km and as much as %70 of Balya comprises mountainous areas, therest of where comprises rugged areas. There is Konak county in the northwest of Balya, at westEkizce, at east Akal Mountains exist. The average elevation is 225 meters,the highest peak is theAkal Hill (642m) that located east of Balya. Erosional surfaces that showing plateau features haveextensive amount of the area within Balya boundaries.The most important river of Balya, Koca ay (Avar) , comes from the mountains ofGeyikli,Musluk,Uzunca Bayr, Balopda,Sularya and then, follows the way towards to vrindi ,Balya


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,Avar villages and finally flows into lake in the region of Manyasn Iklar Bosporus and KouPnar.The length of the river is 160 km.Balya Belediyesi ,Sosyal ve Ekonomik Durum (http://balya.meb.gov.tr/gec.htm,2007)1.3.PopulationCentersandLaborForce

In 2000, the population of the center of the county is (1,916 subdistrict and villages population16,953) totally 18,869. According to the 31.12.2007, the county population is 2,084 at center,13,241 in the villages and totally 15,325 people living there.Between years of 19902000, the increase rate of population is %8.76 at county center, and %

21.89 in the villages. The increase rate of population totally is %18.78. The %14 of the totalpopulation still lives at county center, and %86 of the population in the villages.At Balya center 1,916, in the villages 16,953, totally 18,869 live in Balya county. Distribution of the

population according to the villages is in the table below.Table 1.Population States of Balya County and VillagesSettlement Population Settlement Population Settlement Population

Akbas 195 Globa 200 Koyuneri 460Alidemirci 359 Gktepe 120 Mstecap 245Bengiler 474 Gkmusa 133 Medrese 136akallar 383 Habipler 387 Manclk 548alova 253 Hachseyin 602 Narl 361

amavsar 773 Havutbas 258 Orhanlar 406amucu 506 Karacahisar 136 renky 202igdem 117 Kayalar 538 Patlak 63ukurcak 81 Kadky 208 Semizky 146Dereky 834 Kask 92 Sbcealan 67Doganlar

504 Kavakalan 209 Yaylack 374Drtyol 629 Kocabk 254 Yarsalan 171Dansment 501 Yazlk 103 Farsak 161Karlk 58 Kayapnar 140 Yenikavak 582

(source: Balkesir Environmental Evaluation Report, 2003)Balkesir province can be divided into three geographical and economical regions; coastal regions,

plain regions, mountainous regions. Population increase generally takes place in coastal regions likeEdremit, Bandrma, Erdek, Burhaniye, Ayvalk. In lowland regions like Gnen, Manyas, Savatepe,

Sndrg, Susurluk ,where exist increase in the population rate because of the transportation


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easiness , production of the kinds of the agricultural crops, animal husbandry and trade intensity. InDursunbey,Balya, Bigadi ,vrindi and Kepsut counties, because of the mountainous regions withrespect to locations, slowing population increase is observed.Table 2: Exact Migration rates of the Aegean Regions Provinces (2000)Province Exact Migration Rate ( /thousand)Afyon 22.55Aydn 25.45Balkesir 4.85

anakkale 27.39Denizli 19.86zmir 39.88Ktahya 1.76Manisa 3.21Mula 70.20Uak 6.90Aegean Region Average 15.96

(Dedeman Madencilik ,Balya , Kadky Ky,Mineral Processing Project ,2010)


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Table3.Balya County Population List

(Eczacba Esan Holding (2010), Maden zenginletirme tesisi ve atk depolama sahas kapasiteartrm projesi,ed Bavuru Dosyas, Balkesir , Balya ilesi )

1.4.Socio-economicalProperties

The main source of income for Balya population is agriculture. The legalization of hashish plantingin 1998 provides an opportunity for the improvement of agriculture. The livestock of the Balya isalso very important in terms of financial aspects. There are 5 dairies that treat the milk of thelivestock of the Balya. Also, there is a flour plant at the center of Balya County that treats theagricultural product of the county.There 13 agricultural improvement associations in center of Balya County and Ilca, Manclk,Deirmendere, Dereky, Doanlar, Bengiler, Havutba, amucu, amavar, Drtyol, Orhanlar,Yenikavak villages. Moreover, there are 3 agricultural loan associations in center of Balya Countyand Ilca village and Orhanlar village. There is no main industrial practice in the Balya County. The most possible improvement in thecounty is the lead resource which has found and confirmed by the drilling study of the MTA. (Balyamunicipality http://www.balya.pel.tr/sosyal.asp)

BalyaCountyPopulationList

2009 2008 2007 2000 1990 1985 1980 1975 1970 1965

BALYA

Total: 15.465 15.961 16.712 18.869 21.781 23.815 24.814 25.577 26.355 26.333

Men: 7.711 7.975 8.393 9.335 11.045 11.995 12.549 13.164 13.497 13.446

Women: 7.754 7.986 8.319 9.534 10.736 11.820 12.265 12.413 12.858 12.887

County

Center:

1.901 2.038 2.084 1.916 2.248 2.211 2.014 2.362 1.686 1.434

Villages: 13.564 13.923 14.628 16.953 19.533 21.604 22.800 23.215 24.669 24.899


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1.5.PowerSupply

There is a hydroelectric power plant in Gnen which is located at 25 km away from Gnen in

southwest direction. It was constructed between 1979 1997. The Gnen Hydroelectric Power Plantproduces 47.5 GWh electricity yearly with a reservoir capacity of 164 hm3. This power plant couldbe sufficient for required mining operations.(DS http://www.dsi.gov.tr/bolge/dsi25/balikesir.htm#balya)

1.6.Climate

Balkesir is in the transition zone between Mediterranean and Black Sea climates. Since it is possibleto observe the effects of both climates, the climate designates to tend terrestriality towards toforwarding inside regions from coastal zones and winters are cold.Wind: The days that wind speed is between 10.8 m / s and 17.1 m / s are totally 50 days in a year inthe province. The wind speed values are given in the following table.Table 4; Average Wind Speed, the Fastest Wind Speed, the Fastest Wind Direction in BalkesirProvince

Months 1 2 3 4 5 6 7 8 9 10 11 12 AnnualAverage WindSpeed (m/sec.) 2,7 2,8 3,1 2,5 2,1 2,7 3,7 3,7 3,1 2,4 2 2,4 2,8The fastest windspeed 27,2 28,1 29,6 26,8 24,7 23,2 25,3 26,9 28,2 26,1 28,2 27,8 29,6The fastest winddirection(m/sec) SW W NE,SSW SW SSW N NNE N NNE NE NW SSE,S,SSW NE,SSW

(Esan Eczacibasi Endstriyel Hammaddeler San. Ve Tic. A.S., Balikesir Balya, Mineral ProcessingPlant And Waste Stock Plant Extension Project, ed Application File, 2010)Pressure: Annually average actual pressure value is 997.9 mPa .The height of Balkesir station is147m.

Table5. Annually average actual pressure values in BalkesirMonths 1 2 3 4 5 6 7 8 9 10 11 12 Annual

Annual ActualPressure (mPa)

999 999

998

997 996

996

994

995 998 1000 1001 1000 998

(ESAN ECZACIBASI ENDSTRIYEL HAMMADDELER SAN. ve TC. A.S., BALIKESR BALYA, MINERALPROCESSING PLANT AND WASTE STOCK PLANT EXTENSION PROJECT, ED APPLICATION FILE,2010)


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Temperature: The annual average temperature is 14.5C in Balkesir.The lowest temperature is4.8 that takes place in January, the highest temperature is 24.5C that takes place in July.Table6.The highest, the lowest, the average and the average high temperature in Balkesir Province

Months 1 2 3 4 5 6 7 8 9 10 11 12 AnnualThe highesttemperature(C) 23,3 23,4 30,7 35,2 38,5 39,8 41,7 43,7 39,4 36,1 28,7 25,7 43,7

The lowesttemperature(C) 21,8 13,1 7,9 2,8 0,6 4 9,1 6 4,5 2,3 7,6 12,9 21,8

The averagetemperature(C) 4,8 6 7,9 12,8 17,8 22,2 24,5 24,3 20,4 15,6 11 6,8 14,5The averagehightemperature(C) 8,6 10,5 13,2 18,9 24,5 28,8 30,9 31 27,2 21,8 16,2 10,8 20,2

The average lowtemperature(C) 1,5 2,3 3,4 6,9 11,1 14,8 17,3 17,6 14 10,2 6,9 3,4 9,1

(ESAN ECZACIBASI ENDSTRIYEL HAMMADDELER SAN. ve TC. A.S., BALIKESR BALYA, MINERALPROCESSING PLANT AND WASTE STOCK PLANT EXTENSION PROJECT, ED APPLICATION FILE,2010)Rainfall: %45 of all rainfall occurs in winter months, %5 of all rainfall occurs in summer months inBalkesir.Maximum rainfall amount is seen in December, January months therefore while designingslope stability , tension crack problems, transportation, precipitation should be taken intoconsideration.


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Table7. Rainfall amount and daily rainfall amount in BalkesirMonths 1 2 3 4 5 6 7 8 9 10 11 12 Annual

Monthly

Average

Rainfall

Amount

(kg/m2)

93,7 75,1 60,9 50 42,6 25,1 9,1 8,7 21 42,8 74,8 98,4 602

Maximum

Monthly

Rainfall

Amount

(kg/m2)

77,9 56,4 63,9 41,1 53,9 41,8 50,1 40,1 39,6 68,3 118 97,2 118


Moisture: Annual average relative moisture value is %69 in Balkesir.Table 8.Annual average moisture amount in Balkesir

Months 1 2 3 4 5 6 7 8 9 10 11 12 AnnualAverage relative moisture (%) 82 78 74 68 65 58 55 56 62 69 78 82 69Lowest relative moisture (%) 24 25 14 10 11 12 11 4 9 5 15 26 4


1.7.Transportation

Balkesir is a city in interior Southern Marmara, Turkey. Nearest airport is Edremit Krfez Airportlocated near Edremit, about 90100 km west. Balkesir lies on the junction of railroads stretching tonorth and to east from Izmir.


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Table9. The distances from Balya Balkesir to Big Cities

(Dedeman Madencilik San. Ve Tic A. ,Kuruninko Maden Ocai Ve Zenginletirme(Flotasyon)Tesisi,Balikesir li, Balya lesi, Kadiky Ky)Balkesir is a city that has shores on the Aegean and Marmara Seas. It is easy to reach from Ankara,stanbul, Bursa and zmir by motorway or railway. There are regular coaches from stanbul, Ankaraand zmir. Balkesir have got lots of small coastal towns.Balkesir is joined to Bursa and zmir by a quality motorway. Also there is Krfez Airport. Onaccount of the Krfez Airport has begun to the service.

Figure 2.Balkesir Roadways Map (http://www.imagesturkey.com/buyuk_istanbulassosMap.jpg)

City Distance

Ankara 530 kmstanbul 390 kmBursa 151 kmzmir 173 kmAntalya 510 kmAdana 894 kmanakkale 207 kmManisa 137 kmKtahya 221 kmTrabzon 1232 km


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1.8.WaterAvailability

The Balkesir region is very rich in water sources. The required water for mining applications can be

conducted by nearby ponds and streams.The most important creek in the area is Kocaay (Eenay). The average flow rate of the Kocaaycreek is 44.5 m3/sec. (http://www.belgeler.com/blg/xem/esencayikocacaysukalitesininfizikselkimyasalvebiyolojikacidanincelenmesideterminationofthewaterqualityofesenriverkocacayfromphysicalchemicalandbiologicalviewpoints)

1.9.OtherResources

In Balkesir, there are lots of mineral resources and lignite resources. The known reserves of ligniteare given below.

Table 10.Reserves of Lignite in Balkesir RegionLocation Tonnage

BalyaBelginler 300,000BalyaDeirmendereManclk 7,200,000DursunbeyKavackakrca 5,250,000DursunbeyKavackHamzack 15,335,000DursunbeyKavackOdaky 14,094,000GnenSebepli 570,000Gnenaroluk 600,000(Balkesir Environmental Evaluation Report, 2003)The Balkesir region is very rich in mineral resources. The minerals which have resources atBalkesir are; AuAg, Antimony, Hg, PbZn, Fe, Magnetite, Chromite, Boron, Gypsum, Kaolinite,

Magnetite, Dolomite, Perlite, Bentonite, Halloysite, Marble, Talc. (Balkesir Environment EvaluationReport, 2009)

1.10.FinancialandTaxation

According to The Turkish Governments tax regulation state royalty and private administration isdetermined in to five categories. They are:GroupI,Building and road construction materials. State royalty of the sales is 4 %.


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GroupIIMarble, Decorative stones, Travertine, Limestone, Dolomite, Calcite, Granite,Syenite, Andesite, Basalt. State royalty 2% of the salesGroupIIISalts state royalty 2 % of the sales.GroupIVMetallicmineralslikecopper.Stateroyaltyofthesalesis2%.

GroupVSpecious minerals like diamond, sapphire, ruby and beryl. State royalty of the sales is 4%.

Our project is about metallic mineral (group 4), state royalty of the sales will apply to 2% in theproject. (General Directorates of Mining Affairs, 2010)

Annual license fee must be paid to the state to take the license of the operating site. Annual licensefee is determined according to size of the site, license stage and duration. License guarantee is 0,3 %of the annual license fee per hectare depending on the license stage and duration. The Council ofMinisters is authorized to increase or decrease this rate by 50%.

1.11.Commodity

Lead: Is one of the major metals used in industry. It is used made of batteries, fuels, printing,ammunition, and pipe. Restrictions are made on the use of lead due to the effects of environmentalpollution but production of lead increase in recent years.Table11: Uses of lead in world metal

(Source: MB, Trkiye Kurun Envanteri, Edt: A. E. Yce, 1998)


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Visible metal lead 100 million tons of reserves in the world, Turkey is estimated to be0.8 million tons. The countries which are the largest lead reserves are Australia, the UnitedStates, Kazakhstan, Canada and China.Zinc:One of the most widely used metal in industry. It is used for increasing resistance of iron andsteel korrazyona, special alloys used in making foundry industry, tires and batteries are used inmaking significant amounts of zinc.

Visible metal, about 200 million tons of zinc reserves in the world, in Turkey, 2.3 million tonsAustralia, the United States, Canada, China, with most countries of zinc reserves. 8 million tonsof zinc ore production in the world and production of scarp zinc is 0.5 million tons.


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2.Geological,HydrologicalandRockEngineeringStudies

2.1.TopographicMaps

Figure 3.Contour Map of MineSite Balya


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Figure4: Micromine DTM image of topographyIn the mining region, elevations changes from 200 m to 775 m. The highest elevations can be seen atthe northeast side of the area.

m


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2.2.Ge

Fig

m

As can

commo

Carboni

sedime

In the a

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tertiary

they ca

In the r

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re 5.Geolo

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agmatic a

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(Akyol, Z. (

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impression that ore potential of Balya area is quite high. Skarn mineralizations related to graniticand dacitic rocks are important for leadzinc mineralizations, so these formations are available forBalya area.Stratigraphy

The rock formations occurring in the Balya area comprise: Permian limestone (and arkoses), Triassic shales, sandstones, and conglomerates, Tertiary volcanic rocks.

Faults

Figure 6.Mine site Area (http://www.mta.gov.tr/mta_web/harita/bouger/dirifay.jpg)According to the research done in the Balya area, many kinds of characteristics of faults aredetermined. General fracture lines have strikes along NESW direction. Besides in the region, smallfaults are observed that comes perpendicular to this direction (dip). The greatest fracture zone iscalled The Great Fault and that passed towards the Krmz Tepe. According to the research, thisfault is extending further in northeast direction. This fault is found in the contact area among thePermian Limestone, Upper Trias Deposition and Dacites , Andesites. This fault is considered that is


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inclined towards to Northwest and slope angle is around 50and also this fault plays an importantrole in mineralization.Another fault is extending in NESW direction in north of Balya.This fault is cut by a young strikeslip fault. Also, in south and southeast of Balya, a set of steep faults are observed.

Figure 7. ProfileofArShaft,Kzltepe-BahelerValley(Akyol, Z. (1997 ):Balya madeni civarnnjeolojisi, Jeoloji mhendislii ekim,Maden tetkik ve arama enstits,Ankara)

According to the research conducted in the area also demonstrates that, in the Balya mines, theTriassic series are in the hanging of the Permian limestone. The Triassic rocks are repeated, andthey exhibit a certain degree of symmetry, indicating an overturned fold.

TheVolcanicActivityandMineralization

The Balya leadzinc ore presents a very good example of subvolcanic mineralization. Differenttypes of ore occur, but they are all closely connected to the volcanic rock or its contacts with thesediments. The deposits of Balya seem to be typical samples of subvolcanic mineralization. The mostintense mineralization probably occurred at an altitude of 0 to 300 m. The trace of the Tertiarysurface, on which the extrusives were deposited, is to be found 600 m W of the square of the villageof Balya, at an elevation of 270 m. Moreover, the mineralization, then, occurred at an actual depth of1.6001.900 m. Now the lead deposits of Balya Mine probably belong to a transition stage betweenepithermal and mesothermal deposits, as shown by the existence of grossularite garnet among thegangue minerals of the deeper levels.


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Figure8.ThecrosssectionsofdrillholesconductedinBalya.(Akyol, Z. (1997 ):Balya madenicivarnn jeolojisi, Jeoloji mhendislii ekim,Maden tetkik ve arama enstits,Ankara)

MineralizationofBalyacanbedividedinto3parts:

1. Contact Metasomatic (Porphyry ore) type mineralization. (One of the main local processes ofthermal metamorphism that is related to intrusion of magmas; takes place in rocks or near theircontact with a body of igneous rock.)2. Disseminated, emprenye type mineralization. (An important class of ore deposits is that in whichthe valuable minerals occur as minute particles, or narrow seam lets, or stringers, throughout alarge mass of enclosing country rock.)3. Vein type mineralization. (A veintype deposit is a fairly well defined zone of mineralization,usually inclined and discordant, which is typically narrow compared to its length and depth. Mostvein deposits occur in fault or fissure openings or in shear zones within country rock.)


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Figure 9.LithologycolumncrosssectionbelongtoBalyaarea (Akyol, Z. (1997 ):Balya madenicivarnn jeolojisi, Jeoloji mhendislii ekim,Maden tetkik ve arama enstits,Ankara)


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2.3.Hydrology

Figure 10.ThetotalrainfallofmanyyearsaverageinBigaPeninsula(http://www.tkgm.gov.tr/tufuab2011/TUFUAB/bildiri/ozturk_batuk_SCS%20%5BUyumluluk%20Modu%5D.pdf)

TheLocationOfTheMineSiteWithRespectToLakes,Dams,Ponds,StreamsAndOther

WateryAreas

There is no water source in mine site around because of the topographical and geologicalproperties. At mine site, small streams that are affluents of Kadky (Selek) Creek, small resourcesand locality rock aquifers that possess weak underground water source are available. Lake andswamp are not found in the mine site. But Alaam Mountains are rich in terms of water sourcesfrom where average 10 l/w is given to Dursunbey.RIVERS

The most important river located in the region is Kadky (Selek) creek. Kadikoy Creek is formed bytaking some affluent and flowing toward to westward and emerging from the karst water source inthe Ttnlk Mountains border and placed in the northwest of the mine site in alova village. Then,the creek combined with Maden Creek that is located in Kadky around. Kadky Creek , rainfall


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area is approximately is 40 km2, average flow rate is 0.5 m3/sec., monthly minimum average flowrate happens in September that is 0.1 m3/sec., monthly maximum average flow rate happens inApril that is 6m3/sec. The creeks that pass through the mine site is Maden Dere (Sarsu), YargkDere and Kocapaa , Harmanck creeks.Table12 .The information about Maden CreekParameter No of

MeasurementMinimum Average Maximum

Flow Rate (l/sec.) 12 3 143 829PH 12 6.5 7.2 8.1

EC (elect. cond.mS/cm ) 12 805 1622 2588(Dedeman Madencilik San. Ve Tic A. ,Kuruninko Maden Ocai Ve Zenginletirme(Flotasyon)Tesisi,Balikesir li, Balya lesi, Kadiky Ky)SOURCES

Small water sources are available in the mine site and its environment. The flow rates of thesesources are between 0.1 0.2 l/sec.These sources emerges from the contact zone of andesite,limestone and sediments.Table14. Some sources in Balya region

(Dedeman Madencilik San. Ve Tic A. ,Kuruninko Maden Ocai Ve Zenginletirme(Flotasyon)Tesisi,Balikesir li, Balya lesi, Kadiky Ky)According to the mining boreholes done in previous times, underground water level is between 27meters. The most important source in the mine site is Patlak source. Maximum flow rate isapproximately 50l/sec.It is a seasonal source, so it dries in summer months. Besides, around minesite, there are lots of small water source used for fountain that come from limestone, slope rubbles,sandstone, conglomerate and igneous rocks.

Name SourceType FlowRate(l/sec.)

Baheler Slope source 0.1Patlak Contact zone 0.15Patlak Contact zone 0.1Patlak Seasonal karst 50Akal Contact zone 0.2


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Table14.Underground Water Statement

(Dedeman Madencilik San. Ve Tic A. ,Kuruninko Maden Ocai Ve Zenginletirme(Flotasyon)Tesisi,Balikesir li, Balya lesi, Kadiky Ky)In the region of Balya, Patlak and Kadky water resources and wells are in the authorized area but

these wells and resources are far from the mining area which leads to an artificial drawing of waterfrom some other wells.SHAFTS

Shallow shafts are found in the mine site. These shafts were opened for the need of water ofmunicipality, some facilities, mukhtarship around Kadky .Moreover these shafts also were openedfor alluvium.

2.4.RockEngineeringStudies

Ore reserve is located by limestone and sandstone as a footwall. Rock engineering studies andlaboratory analysis designates that physical properties of the rock types are as in the followingtable.

Table 15.Physical Propertiesof the rock types(Prof.Dr. ebnem DzgnLecture Notes, Rock

Mechanics)

Feeding hm3/year % Discharging hm3/year %Drainedfromtherain 1.9 56 Dischargingtosources 0.40 16Fromthesurfaceflow 1.5 44 Dischargingto

rivers2 56

Artificialdrawing 1 28Total 3.4 100 3.4 100

PhysicalProperty Limestone Ore Sandstone

Compressive Strength (Mpa) 60 70 120Tensile strength (Mpa) 8 9 14

Shear Strength (Mpa) 18 20 30Hardness 3 3 5Cohesion (Mpa) 6 7 10

Internal Friction Angle 32 36 40Specific gravity (t/m3) 2.65 3 2.65

RMR 60 30 70


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Table 16. Physical Properties of AndesitePhysicalProperty Andesite

Compressive Strengths (Mpa) 120Tensile strength (Mpa) 18Shear Strength (Mpa) 80

Hardness 5.5Cohesion (Mpa) 15

Internal Friction Angle 28Specific gravity (t/m3) 2.75RMR 45

(Comparison of Rock Types (OPEN PIT MINE PLANNING and DESIGN, p.129, 1979, Crawford,Hustrulid)

ROCKMASSRATING

Table17.Rock mass classes determined from total ratings and meaningRMR Ratings 81 100 61 80 41 60 21 40 < 20Rock mass class A B C D EDescription very good rock good rock fair rock poor rock very poor

rockRock masscohesion(KPa)

> 400 300 400 200 300

100 200

< 100

Rock mass frictionangle

> 45 35 45 25 35 15 25 < 15(http://lmrwww.epfl.ch/en/ensei/Rock_Mechanics/ENS_080312_EN_JZ_Notes_Chapter_6.pdf)

According to the rock mass rating values Limestone is in the range of fair rock, sandstone good rock,andesite fair rock.


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ROCKMASSCLASSIFICATION

Rock Types:The most widespread rock types and their properties rock mass rating, cohesion, strength valuesare important for drilling place selection, pit slope angle and various other open pit design criteria.Reliable estimates of the strength and deformation characteristics of rock masses are required for

almost any form of analysis used for the design of slopes, foundations and underground excavations.Andesite: Andesite structures are seen in Balya mine site.Andesite is common in most of the world'svolcanic areas. Andesites occur mainly as surface deposits and, to a lesser extent, as dikes and small

plugs.Particular reference was made to the Geomechanics or Rock Mass Rating (RMR) System forthe assessment of rock mass conditions.The andesite rock mass investigated (RMR values between43 and 52 with an average of 45) falls within the moderate rock mass category.Andesite most commonly is finegrained, usually porphyritic. In composition, andesites correspondroughly to the intrusive igneous rock diorite and consist essentially of andesine (a plagioclasefeldspar) and one or more ferromagnesian minerals, usually amphibole or biotite. There are threesubdivisions of this rock family: the quartzbearing andesites, or dacites, sometimes considered tobe a separate family; the hornblende and biotiteandesites; and the pyroxeneandesites.Limestone: Limestone is a rock type that can be classified into hard to drill class. Limestone is asedimentary rock that is mostly composed of CaCO3 calcite. Because of the large reserve amountsthroughout the world, an exact approximation of limestone reserve is impossible to be declared.Although the depositional environment varies for limestone, marine environments (previous lake,sea habitats) are mostly inclined to contain limestone reserves.In mining; limestone is mostly extracted by open pits, quarries as well as underground mining

operations which contribute with a minor amount.Sandstone: Sandstone forms where sand is laid down and buriedbeaches, dunes and seafloors.Usually sandstone is mostly quartz.


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3.ReserveEvaluation

3.1.EvaluationofDrill-HoleLogsIn the given drillhole pattern we have 98 drillholes. 39 drillholes did not cut the ore layer so thereare only 59 drillholes that we have samples. The trace of drill hole shows that ore body has twoseparate deposits. Major deposit has a maximum thickness of 14.5 m and a minimum thickness of5.3 m with an average of 9.8 m and the minor deposit has a maximum thickness of 6 m and aminimum thickness of 1.5 m with an average of 3.29 m. The thickness values of the body show thatore body has a seam shape. The depth of the drillholes changes from 10.5 meters to 194.2 meterswith an average of 95.8 meters. After the evaluation it is found that the ore body has two separateparts. Major deposit has an average Pb grade of 4.68% and Zn grade of 4.23%. The minor deposithas an average Pb grade of 1.96% and Zn grade of 1.46%.

3.2.ReserveCalculationbyConventionalMethods

As conventional method, we choose to apply polygon method. Polygon method is simply assigningarea of influence for each drillhole and evaluating the values of the ore body using these influenceareas. Since the given ore body geometry results in 2 different bodies, we calculated followingvalues for both bodies using excel application. (Specific gravity of the ore body is 3)Table 18: Results of conventional drill hole evaluation

TotalOreVolume(m3)

TotalOreTonnage(ton)

PbMetal(ton)

ZnMetal(ton)

AveragePbGrade(%)

AverageZnGrade(%)

MajorDeposit

27,642,825.00 82,928,475.00 3,927,413.40 3,542,821.50 4.74 4.27MinorDeposit

2,292,200.00 6,876,600.00 140,778.63 103,503.65 2.05 1.51


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3.3.ReserveCalculationbyMicromineSoftware

DIGITIZINGTHETOPOGRAPHICMAP

The given topographic map is digitized by string operations in Micromine. String operation is shownin below figure.

Figure11: Digitizing Topographic Map in Micromine


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CREATINGDIGITIZEDELEVATIONMODEL

Using previously created strings, a 3D topography image is created. 3D topography model is shownin following figures.Figure 12: DTM of Topography

m


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CONSTRUCTINGDRILL-HOLETRACE

Before constructing the DrillHole trace analyze, lithology and coordinate files of drill holes arecreated from the given drillhole data and they are introduced to the software. Then, drillhole traceand hatch are constructed.Figure13: DrillHole Trace

Figure14: DrillHole Hatches


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3DMODELINGOFOREBODYANDORERESERVEESTIMATION

Since the ore body has two separate parts, two solid bodies are created. Since the ore body has aseam type shape, for bodies, top and bottom surfaces are created and using these surfaces, solidmodels are created. For major deposit, 85,047,561.71 tons of ore are calculated. For minor depositonly, 7,249,874.75 tons of ore are calculated.Figure 15: 3D model of Ore Deposits


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Figure 16: Volume and Tonnage Calculation in Micromine of Major Deposit

Figure 17: Volume and Tonnage Calculation of Minor Deposit


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Figure 18: Major Deposit Zn Grade Distribution

Figure19: Major Deposit Pb Distribution


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Figure20: Major Deposit Average Grades

Figure21: Major Deposit Grade Distribution


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Figure22: Minor Deposit Zn Distribution

Figure23: Minor Deposit Pb Distribution


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Figure24: Minor Deposit Average Grade

Figure25: Minor Deposit Grade Distribution


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Figure26: Outcrop Features

As shown in the image taken from the Micromine, the major deposit show some outcrop features.


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3.4.MineLife,YearlyProductionandDemand

Mine life is estimated by the use of Taylors mine life rule. This rule estimates mine life by use of

forth root of ore tonnage. 0.2 0.2 85,047,561.71 19 Operating time is assumed to be 300 days/year with 75% availability.The mine will work in 3 shift/day with 8 hours/shift. Therefore;

85,047,561.7119 4,476,187.5 tons/year

4,476,187.5300 14920.62

14920.62240.75 828.9 /Since Taylors mine life rule gives a rough estimation, these values will be controlled and revised atproduction scheduling part.

4.MiningMethodSelection

4.1.Undergroundvs.SurfaceMiningMethodSelection

The essential of designing a mine is to select the mining method appropriately in order to have themaximum profit out of it, also concerning the safety and the productivity of the mining work.

When the commercially useful deposit of minerals or rock is located near the surface, surfacemining is applied. On the contrary, if the overburden is thick or the mineral occurs as veins deep

below the surface, underground mining methods are used to extract the valuable material.Surface mining has relatively lower cost, greater safety, and mechanically easier operations whencompared to underground mining.

We are concerned with the Economic S/R (ESR), Maximum Allowable S/R (MASR) and with theOverall S/R.EconomicS/R(ESR) determines pit limits.


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MASR = /

, / , .Underground Mining Cost = $30/tonSurface Mining Cost = $8/tonStriping Cost = 3 $/m3 = 7.95 $/ton (SG of overburden = 2.65) $30 $8/$3/ 7.33

In order to calculate overall stripping ratio, we need to calculate the total overburden volume forboth ore body. We measured the longest horizontal axis of the ore bodies by the use of measure toolof Micromine Software. After that we define average overburden thickness and take overall pit angleas 55. For major deposit longest axis is determined as 2050 m and it is taken as base area diameterof truncated cone. The top surface diameter is calculated as 2154 m. Then, overburden volume formajor deposit is calculated as 256,153,474 m3.Figure27: overburden calculation major deposit.

Same procedure is applied to minor deposit. The longest axis is measured as 1400 m. Again, overallpit slope angle is estimated as 55 and the average thickness of overburden is defined as 126.1 m.Top surface diameter is calculated as 1576.6 m. Then overburden volume is calculated as219,645,319 m3.


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With Micromine software, we calculated ore tonnages for major and minor deposits. Therefore, wecan calculate overall stripping ratios for both deposits.

3.01 ; 30.29 OSR value for major deposit shows that it is more economical to excavate this deposit by surfacemining methods. However, for minor deposit it is suitable to apply an underground mining method.At this point we can calculate an economic stripping ratio for major deposit. In previous calculations

we assume surface mining cost as $8/ton of ore, and stripping cost as $3/ ton of ore.Prof. Dr. mit Atalay suggested taking processing cost as $12/ton of ore in our case. Therefore; 8 12

$20 We take the price of %65 Pb concentrate as $1382.4/ton and price of %50 Zn concentrate as$899.1/ by the use of the method that is suggested by Prof. Dr. mit Atalay. We take 100% metalprices from LME as $2663/ton for Pb and $2298/ton for Zn. After that we subtracted $300/ton for

smelting and assume 90% recovery. Using ratio between concentrate percentage and 100% ratio,we calculated the prices of concentrates.We calculate the average grades of major deposit from Micromine software. Average Pb grade ofmajor deposit is 4.68% and average Zn grade of major deposit is 4.23%.Therefore, 1 ton of ore r.o.m ore contains (1000 kg x 4.68/100) 46.8 kg Pb metal content and (1000kg x 4.23/100) 42.3 kg Zn metal content. Assuming a metal recovery of 85%, these values arereduced to 39.8 kg of Pb metal content and 36.0 kg of Zn metal content.

For %65 Pb concentrate;. 61.2 of %65 Pb concentrate is included in 1 ton of r.o.m ore.For %50 Zn concentrate;. 72 of %50 Zn concentrate is included in 1 ton of r.o.m ore.


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Since 1 ton of %65 Pb concentrate has a value of $1382.4, 61.2 kg of %65 Pb concentrate is $84.6. Ina similar way, 1 ton of %50 Zn concentrate has a value of $899.1 so 72 kg of %50 Zn concentrate is$64.7. So value of 1 ton of r.o.m ore is $137.83. 1 . . $149.3 $20 $7.95 $121.35/

121.357.95 15.26

4.2.Cut-offGradeEstimation

Cutoff grade is grade at which cost and revenue is equal which means at the cutoff grade value orebody has no profit or no loss in terms of economical aspects.

. . , . . ,2002 $20 $7.95 $27.95/%65 $1382.4 $1.38 %50 $899.1 $0.899/Recovery is assumed to be 90%. $27.95/$1.38 0.9 22.5 2.25%

$27.95/$0.899 0.9 34.6 3.46%

4.3.OpenPitvs.OpenCastSelectionAmong the surface mining methods, a decision must be done between open cast and open pitmining methods.OPENCASTMINING

Tabular, lensshaped, or layered mineral reserves are released with open cast mining by extractingoverburden. Coal and other sedimentary origined rocks are extracted mostly by open cast mining. Inan open cast mine the height of highwall is between 30 m and 60 m with slope of 600 to 700 and


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width of the cut is 23 to 45 m. Overburden is excavated in rectangular blocks called pits. The pits areadjusted parallel and adjacent to each other. Overburden is laterally moved to the adjacent emptypit from where the mineral has been extracted. Explosives, draglines, bucket wheel excavators,stripping shovels, dozers, and other equipments accomplish the movement of overburden. Whenreclamation is considered open cast mining guarantees the compatibility of the minedland.(MinE 202Surface Mining Lecture Notes; KARPUZ,C.; 2005; M.E.T.U.)(Open Pit Mine Planning and Design, Crawford, John.T; Hustrulid, William; AIME; New York1979,p.129)OPENPITMINING

In open pit mining method, using one or more horizontal benches help to extract the deposit. Otherthan coal and other bedded deposits, metallic and nonmetallic ore deposits are extracted by openpit mining. It is mostly applied to Gold, copper and iron deposits having shallow to intermediatedepths. Rock strength of the ore is not an obstacle. Deposits with low inclination are preferable andbench height may differ between 5 m and 20 m.(MinE 202Surface Mining Lecture Notes; KARPUZ,C.; 2005; M.E.T.U.)

(Open Pit Mine Planning and Design, Crawford, John.T; Hustrulid, William; AIME; New York1979,p.129)OPENPITvs.OPENCASTSELECTION

There is no way back once the method is selected due to economical and time considerations. Mostimportant and evaluated factors are economy, safety, environmental issues, applicability of themethod. Detailed and careful examination must be done before deciding about the method. Alsotopography, geological conditions and rock mechanics properties should be investigated to select a

method.Open cast mining is required when we consider the deposit as a layer type deposit. However, thereis a conflicting condition which is; the requirement of largescale equipment; that are preferred forextensive deposits. The deposit to be extracted does not match with this requirement. As a result,open cast mining method is eliminated.


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So, the chosen method for the case is open pit mining method. We have an average overburden of 74m, average ore thickness of 10 m and overall pit slope of 550, the deposit has tendency to beextracted by open pit mining method.

AdvantagesofOpenPitMining

High production & recovery Low cost and labor force Low rock breakage cost Flexible & safe

Requires Minimum supportDisadvantagesofOpenPitMining Limited depth Stripping ratio Need of huge deposit and largescale equipment to achieve high productivity Affected by bad weather conditions Waste disposal area & extensive reclamation requirement(MinE 202Surface Mining Lecture Notes; KARPUZ, C.; 2005; M.E.T.U.)

5.DevelopmentDesign

5.1.MineLayoutDesign

5.1.1.DumpsiteSelection

First of all, in order to select an appropriate dump site, suitable area must be found with thecapacity to fulfill the waste rock volume throughout the life of the mine. The criterion for dump siteselection covers in determining the topography, waste rock volume, pit size and location.The main trouble with the dump site location is that as the mining area must be as close as possibleto reduce transportation cost. It was eventually decided to place the dump site at the emptied areathat will be smooth area by using compactor and some part of the overburden will be spilled intovalley. Dump site is located in southsouthwest part of pit. Stream passes through the overburdenspilled area so tunneling practice will be done into stream.The total overburden volume is calculated to be 241,799,298m3. Considering the swell factorwhich is 1.5, the area needed for the dump site is determined to be 362,698,947m3. The angle of


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repose is designated to be 30. The area chosen as the dump site will provide capacity up to439,124,174m3.

Figure28 Micromine image; Dumpsite place

Figure29 Micromine image; pipe line for changing the bed of riverSince the creek that passes through the dump site and mine site, bed of the river is changed to thevalley at the eastern side of the area. The length of the required pipe line is 2.5 km.


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5.1.2GeneralLayout

Figure30 Micromine image; General Layout

6.ProductonSchedulng

The ore has an outcrop feature at the northeast side of the mine. The main plan for the minedevelopment is planning to done both stripping and ore production in the same time. To achievethat aim, the mining operation are planning to be started from northeast of the ore body.


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Figure31 Micromine image; outcrop features at northeast side of the ore body.For first five year of the mine life, 22,367,180 tons of ore will be excavated by stripping 55,408,192m3 overburden material.


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Figure32 Micromine image; Pit design at the end of 5th year.


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Figure33 Micromine image; the ore body which is extracted at the end of 5th year.


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Figure34 Micromine image; the overburden volume which is stripped after 5 years.In the second five year period, 22,324,521 tons of ore will be extracted by stripping 35,596,334 m3of overburden volume. Therefore, at the end of the 10th year, a total of 44,691,701 tons of ore isexcavated by stripping 91,004,526 m3 of overburden.


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Figure35 Micromine image; Pit design at the end of 10th year.

Figure 36 Micromine image; the ore body which is extracted at the end of 10th year.


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Figure37 Micromine image; the overburden volume which is stripped after 10 years.In the third five year period, 23,126,076 tons of ore will be extracted by stripping 80,463,595 m3 ofoverburden volume. Therefore, at the end of the 15 th year, a total of 67,817,777 tons of ore isexcavated by stripping 171,468,121 m3 of overburden.


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Figure38 Micromine image;: Pit design at the end of 15th year.

Figure39 Micromine image; the ore body which is extracted at the end of 15th year.


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Figure40 Micromine image; the overburden volume which is stripped after 15 years.For last 4 year period, 17,229,784 tons of ore will be extracted by stripping 70,331,177 m3 of

overburden. Therefore, at the end of 19th

year, which is also the end of the mine life, the total of85,047,561 tons of ore is extracted and 241,799,298 m3 of overburden will be stripped.


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Figure41 Micromine image; Final Pit Design

Figure42Micromine image; The ore body which is extracted at the end of 19th year.


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Figure43 Micromine image; the overburden volume which is stripped after 19 years.

7.Stability

The design concept applied to the overall pit slope is to ensure that for the majority of the mine life,the walls will have a factor of safety against large scale instability of at least 1.52.0. Considerationsmust be given as to what governs the stability of an open pit slope. Stacey (1968) provided thoseimportant factors:

Geological Structure Rock Stresses and Groundwater conditions Strength of discontinuities and intact rock Pit geometry including both slope angles and slope curvature Vibration of blasting and seismic events Climatic conditions Time

The above list probably not complete: however it serves to show the difficulty in assessing rockslope stability. These factors also determine the mode of failure of a pit slope. It is only logical thatdesign of pit slopes should be based on the failure modes expected to occur and the governing thefailure mechanism.


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PhysicalProperty Limestone Ore Sandstone

Compressive Strength (Mpa) 60 70 120Tensile strength (Mpa) 8 9 14Shear Strength (Mpa) 18 20 30Hardness 3 3 5Cohesion (Mpa) 6 7 10Internal Friction Angle 32 36 40

Specific gravity (t/m3

) 2.65 3 2.65RMR 60 30 70Table19 Physical Properties of the Rock Types (source: Given Project Data)

Safety in Design For a portion of a structure critical to safety, structural failure must be avoided. In order for failure to be avoided, possible failure modes must be identified. Failure criteria must be established for each failure mode. These failure criteria are then used in designing the part. A factor of safety also is applied to reduce the chance of failure in a structure, thereby

minimizing the risk of injury to those in contact with the structure.(http://www.mech.utah.edu/ergo/pages/Educational/safety_modules/Safey_Factor/safety_factor_ns.pdf)

Table20Rock mass classes determined from total ratings and meaningRMR Ratings 81 100 61 80 41 60 21 40 < 20Rock massclass

A B C D EDescription very good

rockgood rock fair rock poor rock very poor

rock

(http://lmrwww.epfl.ch/en/ensei/Rock_Mechanics/ENS_080312_EN_JZ_Notes_Chapter_6.pdf)


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According to the rock mass rating values Limestone is in the range of fair rock, sandstone good rock.Importance must be given the physical properties of existed rock types such as, RMR, specific

gravity, cohesion to design overall slope angles and failure risk. When factors of safety are appliedappropriately, the chance of failure is significantly reduced while maintaining system capability.According to discontinuity investigation, mine site have two discontinuities: 135/50, 090/30. Basedon these discontinuities, planar and wedge failure analysis is done and showed in following pages.

7.1.FailureTypes

7.1.1PlaneFailure

Plane failure occurs due to sliding along a single discontinuity. The conditions for sliding are that: The strikes of both the sliding plane and the slope face lie parallel (20) to each other. The failure plane "daylights" on the slope face. The dip of the sliding plane is greater than friction. The sliding mass is bound by release surfaces of negligible resistance.

Possible plane failure is suggested by a stereonet plot, if a pole concentration lies close to the pole ofthe slope surface, in the critical area corresponding to the above rules.

Figure44 Typical Plane Failure

(http://environment.uwe.ac.uk/geocal/SLOPES/SLOPSLID.HTM)

At southeast benches of pit, there is failure risk in southeast part of pit, therefore there exist overallpit slope angles different from 55 that is due to safety concepts at southeast part of pit, and overallpit slope reduces 51. Overall pit slope angle gave 1.7 safety factor that is acceptable for safetyconsiderations.


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Figure45 Friction circle and pole point of two discontinuities

Figure46 3D Input parameters Roc Plane image, 51pit slope angle with bench slope angle is 180m,failure plane angle is 50 and % 20 water pressures by using peakpressure midheight.


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Figure47 2D Factor of safety determinations and overall slope height dimensions

Figure48: Slope angle =51 vs. Factor of Safety values

0,6

0,8

1

1,2

1,4

1,6

1,8

51 52 53 54 55 56 57

FactorofSafety

SlopeAngle(deg)

SlopeAngle(deg)vs.FactorofSafety


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Figure49Slope Height=180 m vs. Factor of Safety values

SlopeHeight

(m)

Factorof

Safety:

174.96 1.75468175.68 1.74852176.4 1.7424

177.12 1.73634177.84 1.73032178.56 1.72435179.28 1.71843

180 1.71256

180.72 1.70673

181.44 1.70095182.16 1.69522182.88 1.68953183.6 1.68388

Table21 Slope Height vs. Factor Safety Table RocPlane Software

Also at west part of the pit there is discontinuity dipping 30 to east. Besides there are 3 benches,each of height is 12meters. So 36 meter overall pit slope is 55 as similar the other overall pit slopes.

1,5

1,55

1,6

1,65

1,7

1,75

1,8

1,85

1,9

1,95

2

165 170 175 180 185 190 195 200

FactorofSafety

SlopeHeight(m)

SlopeHeight(m)vs.FactorofSafety


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Figure50Micromine Open Pit Image demonstrating direction

7.1.2.Wedge

Wedge failure occurs due to sliding along a combination of discontinuities. The conditions forsliding require that f is overcome, and that the intersection of the discontinuities "daylights" on theslope surface. On the stereonet plot these conditions are indicated by the intersection of twodiscontinuity great circles within the shaded crescent formed by the friction angle and the slope'sgreat circle. Note that this intersection can also be located by finding the pole P12 of the great circlewhich passes through the pole concentrations P1 and P2.

Figure51Typical Wedge Failure(http://environment.uwe.ac.uk/geocal/SLOPES/SLOPSLID.HTM)


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Figure52Great Circle represents discontinuities, friction angle, intersection pointTwo discontinuities exist in mine site; these great circles represent the discontinuities in mine site.Friction circle represents 35 friction angle.Wedge Sliding may occur if the mean joint set orientation Intersections fall within the zone definedby friction cone and the pit slope. Since no plane intersections fall within this region, wedge slidingfailure should not be a concern.

1 1.2 1.4 1.6 1.8 2.0CivilEngineeringApplication

SoilEarthworksSlopesDams

MiningApplicationsMine RockSlopes

Table22Examples of acceptable FoS values (Priest & Brown 1983)


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Table23Bench Face Angle design process for moderate to strong rocks (Guidelines for Open PitSlope Design, Read J. , Stacey P., )

8.MaterialsHandlingandEquipmentSelection

Equipment selection is a critical activity for mining operations. The selection affects the efficiency ofproduction and the economy of the mine. Hence it is crucial to select the best fit equipment to therequired operations. In the mine, Shovel & Truck system will be used for production. Shovels will beused to extract the blasted overburden and ore. And trucks will be used for material haulage. Mainadvantages and disadvantages of shovel & truck are given as below (Surface Mining Lecture notes,Prof.Dr. Karpuz, 2007)

Advantages and disadvantages of shovel and truck:Advantagesofshovel;

Lowercapital

cost

of

bucket

capacity

Digspoorblastsandtoughermaterialsbetter

Canhandlepartingswell

Disadvantagesofshovel;

Susceptibleto

spoil

slides

and

pit

flooding

Cannoteasilyhandlespoilhavingpoorstability

Cannotdigdeepboxcutseasily

Difficulttomove

Reducedcoverdepth capabilitycomparedwith

adraglineofcomparablecost

Statistical Analysis Based on available structural data (stereographic projections)

Definition of Sets By orientation and typeMajor structures= faults, beddingFabric= joints or shears

Sectorization By wall orientation and defined sets

Kinematic Analysis Based on defined

Bench face angle Analysis by wall orientationPlanar/Wedge/TopplingBench Height ,Bench WidthBENCHCONFIGURATION


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Advantagesoftruck;

Flexibleandmaneuverable

Handlescoarse,blockyrock

Moderategradeability

Disadvantagesoftruck;

Requiresgoodhaulroads

Slowedbybadweather

Highoperatingcost

8.1.OreProduction

8.1.1.ShovelSelection

Hourly capacity for production is calculated previously 828.9 tons/hr which has a volume of276.3m3. 3600

Q Hourly Ore Production = 276.3 m3ts Cycle Time of Shovel = 30 secE Efficiency = 0.73FFill Factor = 0.85D Digging Factor = 1AAngle of Swing Correction Factor = 1S Swell Factor = 1.5 276.3 m

30 1.53600 0.85 1 1 0.73 5.6

The loose density of ore is . 2 . The capacity of the selected shovel is 5.70 m3 forloose density lower than or equal to 2.2 .Liebherr R974 Litronic backhoe attachment with Gooseneck Boom 7.20 m SME and Heavy DutyCounterweight. Bench height 12 m.


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Figure53 Liebherr Crawler Shovel (source: Liebherr R974 Catalogue)


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Figure54Digging Envelope of Backhoe Attachment with Gooseneck Boom 7.20 m (source: LiebherrR974 Catalogue)

8.1.2TruckSelection

Dipper capacity for shovel 5 , 73 ,, 9,7 According to shovel dipper capacity we selected CAT 770 offhighway truckNumber of dippers for one truck is. 4 dippersRoad used for ore production is constructed between pit and processing plant.

Features of ore production road are: Total length of the road is 1748m. 916 m part of road has 10% grade. Second part of which is 476 m and it has1% grade.

Then we calculated the truck speeds and loaded and empty travelling time of trucks. We divide oreproduction road two section as road1 and road2. Then we calculated the truck speeds and loaded

and empty travelling time of trucks.According to features of CAT 770 offhighway truck speeds of truck are determined and calculationsare shown below.ROADIDOWNHILLLOADED

Total Resistance= Grade Resistance Rolling ResistanceRolling Resistance (RR) = 2 %Grade Resistance (GR) = 10 %


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Total Resistance = 8 %

Traction Coefficient = 0.3 = Gross Vehicle Weight (GVW) = Payload + Empty = 157000 lbLoad Axle = 0.34 157000 = 53380 lb1 Use Rimpull = Load Axle = 53380 0.3 = 16014 lb2 Required Rimpull = GVW Total Resistance = 157000 = 12560 lb1>2 Truck can go uphill when loaded

Speed of Truck = 22 km/hrHaulage Time = , = 208 sec

ROADIUPHILLEMPTY

GVW= 71816 lb

= 0.3Total Resistance= GR RR = 10+ 2 = 12 %Load Axle = 0.48 71816 = 34472 lb1 Use Rimpull = Load Axle = 34472 0.3 = 10342 lb2 Required Rimpull = GVW Total Resistance = 71816 = 8618 lb1>2 Truck can go downhill when empty

Speed of Truck = 36 km/hrHaulage Time = , = 127 secROAD2UPHILLLOADED

Total Resistance= Rolling Resistance + Grade Resistance Rolling Resistance (RR) = 2 %Grade Resistance (GR) = 1 %


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Total Resistance = 3 %

= 0.3Gross Vehicle Weight (GVW) = 157000 lbLoad Axle = 0.34 157000 = 53380 lb1 Use Rimpull = Load Axle = 53380 0.3 = 16014 lb2 Required Rimpull = GVW Total Resistance = 157000 = 4710 lb

1>2 Truck can go uphill when loadedSpeed of Truck = 30km/hrHaulage Time = , = 57 secROAD2DOWNHILLEMPTY

GVW= 71816 lb

= 0.3Total Resistance= RR GR = 2 1 = 1 %Load Axle = 0.48 71816 = 34472 lb1 Use Rimpull = Load Axle = 34472 0.3 = 10342 lb2 Required Rimpull = GVW Total Resistance = 71816 = 718 lb1>2 Truck can go downhill when empty

Speed of Truck = 40 km/hrHaulage Time = , = 43 sec


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Empty LoadedGrade Road 1 10 = 36km\h 10 = 22km\hGrade Road 2 1 = 40km\h 1 = 30km\hTable24 speeds of truck according to grade

Cycle time for ore productionTruck load time = tl = 4 30 120 Spot time at shovel = tsm =20 secHaulage time (Travel loeded time) = th = 208 + 57 =265secManeuvering and dumping time = td =27Return time (Travel empty time) = tr = 127 + 43 = 170secCycle time= tl + th + td + tr + ts

= 120+ 20 + 27 +170 + 265 602 secNumberoftruck:

If truck load time extracted cycle time then it divided truck load time we will find the number oftrucks which are loaded before the first truck complete the cycle time.

4,01 Truck can be loaded first truck arrive loading.4, 01 + 1 = 5, 01 =5 trucks + 1 spare trucks = 6trucks


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Figure55CAT 770 off Highway Truck (source: Cat 770 Catalogue)

8.2.OverburdenRemoval

8.2.1.ShovelSelection

First five years total overburden removal = 55,408,192 55,408,1925 11,081,638 m/year

11,081,638300 36,939m

36,939240.75 2052 m/

2052371.53600 0.85 1 1 0.73 50,98 The loose density of the overburden material is. . 1.8 . The Liebherr R995 shovelattachment with shovel boom 7.60 m using general purpose bucket with Esco S110 teeth is selected.Capacity of the shovel at 1.8 is 28 . Therefore, , 1,8 of the shovel isselected.12 m bench height is suitable.


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Figure56Liebherr R995 Shovel (Liebherr R995 Catalogue)

Figure57Digging Envelope of Liebherr R995 Shovel Attachment with Shovel Boom 7.60(Liebherr

R995 Catalogue)


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8.2.2.TruckSelection

Dipper capacity for shovel, 2,65 ,, 38,3 According to shovel dipper capacity we selected CAT 777F offhighway truckNumber of dippers for one truck is, 2,6 3 dippersWe divided our road 2 parts. One of them inside of the mine and length of the road is 1256m. Itsgrade is 9.6%. Second road is connected dumpsite and pit. Length of second road is 1551m. Gradeof second road is 1%. Then we calculated the truck speeds and loaded and empty travelling time oftrucks.

Figure58 CAT 777F offHighway Truck (Cat 777F Catalogue)ROADIUPHILLLOADED

Total Resistance= Rolling Resistance + Grade Resistance Rolling Resistance (RR) = 2 %

Grade Resistance (GR) = = 9.6 %Total Resistance = 11.6 %Traction Coefficient = 0.3 = Gross Vehicle Weight (GVW) = Payload + Empty = 360000 lbLoad Axle = 0.47 360000 = 169200 lb1 Use Rimpull = Load Axle = 169200 0.3 = 50760 lb


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2 Required Rimpull = GVW Total Resistance = 360000 . = 41760 lb1>2

Truck can go uphill when loadedSpeed of Truck = 10.5 km/hrHaulage Time = .. = 408 sec

ROADIDOWNHILLEMPTY

GVW= 142039 lb

= 0.3Total Resistance= GR RR = 9.6 2 = 7.6 %Load Axle = 66758 lb1 Use Rimpull = Load Axle = 66758 0.3 = 20027 lb2 Required Rimpull = GVW Total Resistance = 142039 . = 10795 lb1>2 Truck can go downhill when empty

Speed of Truck = 28 km/hrHaulage Time = . =153 secROAD2UPHILLLOADED

Total Resistance= Rolling Resistance + Grade Resistance Rolling Resistance (RR) = 2 %Grade Resistance (GR) = 1 %

Total Resistance = 3 % = 0.3Gross Vehicle Weight (GVW) = 360000 lbLoad Axle = 169200 lb1 Use Rimpull = Load Axle = 169200 0.3 = 50760 lb2 Required Rimpull = GVW Total Resistance = 360000 = 10800 lb


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1>2 Truck can go uphill when loaded

Speed of Truck =22 km/hr Haulage Time =.

= 241 secROAD 2 DOWNHILL EMPTYGVW= 142039 lb = 0.3Total Resistance= RR GR = 2 1 = 1 %Load Axle = 66758 lb

1 Use Rimpull = Load Axle = 66758 0.3 = 20027 lb2 Required Rimpull = GVW Total Resistance = 142039 = 1420 lb1>2 Truck can go downhill when emptySpeed of Truck =34 km/hrHaulage Time = . = 156 sec

Empty Loaded

Grade Road 1 9.6 = 28km\h 9.6 = 10,5km\hGrade Road 2 1 = 34km\h 1 = 22km\hCycle time for overburdenTruck load time = tl = 3 37 111 Spot time at shovel = tsm =20 secHaulage time (Travel loaded time) = th = 408 + 241 = 649sec

Maneuvering and dumping time =td =20secReturn time (Travel empty time) = tr = 153 +156 = 309secCycle time= tl + th + td + tr = 111+ 20 + 20 +649 + 309 1109 sec


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Numberoftruck:

If truck load time extracted cycle time then it divided truck load time we will find the number oftrucks which are loaded before the first truck complete the cycle time. 8,99Truck can be loaded first truck arrive loading.

8, 99 + 1 = 9, 99 =10 trucks + 2 spare trucks = 12trucks

8.3WorkingBenchDimensions

8.3.1WorkingBenchDimensionsforOverburdenRemoval

Figure59Working bench dimensions for overburden removal representation (Cat CatalogueTruck777F, Liebherr Catalogue for Shovel R995)Total working bench width is calculated as 31, 1 meter. Due to safety regulations half the width of atruck is left near the trucks. Also half the height of the tires is determined for the height of a safetyberm in the edge.


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8.3.2.WorkingBenchDimensionsforOreProduction

Figure60 Working bench dimensions for ore production representation (Cat Catalogue Truck770,Liebherr Catalogue for Shovel R974 C)Total working bench for ore production width is calculated as 20,6 meters. Due to safety regulationshalf the width of a truck is left near the trucks. Also half the height of the tires is determined for theheight of a safety berm in the edge.

8.4.RoadDesign

8.4.1.Designoftheroadsforoverburdenremoval:

First of all, to make the design of the road we select the type of the truck because according to truckfeatures we find equivalent tire load (used maximum load) and size and dimension of the truck.Then determination of the layers of road and width of the road can make.Type of the truck and features:We select 777F OffHighway Truck. General features of trucks given below.


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Size and dimension of the truck:

Figure61777F OffHighway Truck (Cat Catalogue Truck770)

Table25dimension of 777F OffHighway Truck (Cat 777F Catalogue)


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Figure62 the width of mine roads and trucks

Gross vehicle weight of the truck is 360,000lb (information taken from 777FOffHighway Truck catalog ) then we calculate the equivalent tire load It is 45000lb

Figure63Load distribution (MinE202, Surface Mining Lecture Notes)

Finally using California bearing ratio curve haulage road is constructed and below figures showslayers of road.


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Figure64layers of road for stripping (MinE202, Surface Mining Lecture Notes)

8.4.2.Designoftheroadsfororeproduction:

According to truck we selected made road between pit and process plant. Truck selection andcalculation is shown material settling and equipment selection part. Then using truck featureswhich are equivalent tire load (used maximum load) and size and dimension of the truckdetermination of the layers of road and width of the road is made.Type of the truck and features:We select CAT 770 OffHighway Truck for ore production. General features of trucks given below.


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Size and dimension of the truck:

Figure65770 OffHighway Truck (source: Cat 770 Catalogue)

Table26dimension of 770 OffHighway Truck (source: Cat 770 Catalogue)


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Figure66The width of mine roads and trucks(MinE202, Surface Mining Lecture Notes)Gross vehicle weight of the truck is 157,000lb (information taken from 770OffHighway Truck catalog ) then we calculate the equivalent tire load It is 19625lb

Figure67 load distribution of truck(MinE202, Surface Mining Lecture Notes)Finally using California bearing ratio curve haulage road is constructed and below figures showslayers of road.

Figure68layers of ore production(MinE202, Surface Mining Lecture Notes)


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9.DrillingandBlastingDesign

In this section all the information is taken from MinE 324, Mine Fragmentation lecture notes by

Assoc. Prof. Dr. H. Aydn BLGN unless it is the source of the information stated.Drilling and blasting operation is one of the main aspects of open pit mining. Proper selection ofrequired blasting geometry and selection of blasting agent are important factors to assure asuccessful blasting. If a sufficient blasting geometry is not conducted, then both safety andeconomical problems may be obvious. For example, if the burden distance or stemming length of ablasting design is not selected sufficiently, a flyrock problem may arise which creates damages bothfor workers and equipment. The blasts design geometry parameters to be considered in a blastingdesign operation are;

Bench height Burden distance Spacing Hole diameter Subdrill length Hole inclination Length of bottom and column charge Length of stemming

The explosive selection is also is a very important aspect of blasting design. The cost of blastingoperation needs to be optimized between the blasting cost and fragmentation. It is important toreduce the cost of the blasting operation but also it is important to get adequate fragmentation anddisplacement of the rock. The factors to be considered in the selection of explosives are;

Explosive cost Charge diameter Cost of drilling Fragmentation difficulties

Water conditions Explosive atmosphere Storage and sensitivity considerations


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The main purpose of a blasting operation is to get a sufficient fragmentation for mining purpose.The fragmentation of a blasting operation is influenced by several factors which are;

The geology of the rock Specific drilling Drilling pattern Firing pattern Hole inclination Hole deviation Size of the round

9.1.OverburdenRemovalBlastingDesign

Burdendistance

12 2 6 Holediameter

13.3 133 (200 mm al)

1200 20 60; 60 Subdrill

0.3 0.3 6 1.8 Holeinclinationandlength

; 1 90 1121.8 13.8 DrillingFault

0.05 0.03 0.05 0.03 13.8 0.5Burden

6 0.5 5.5


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Spacing

1.25 1.25 5.5 6.9 Unitlengthvolumeofthehole

4 1 0.2004 1 0.0314 31.4 Nobelex 6000 is a water resistant noncap sensitive blasting agent. It is a primer sensitive blastingagent which is a mixture of ANFO and emulsions. It creates a great amount of gases after theexplosion and by this high amount of gas volume, it produce a high rate of force of rock body. Sinceit is denser than water, it submerges in the drill hole. Therefore, it is very useful in saturated drillholes. In drill holes with a little amount of water, it gives a chance to use ANFO after the bottomcharge. It is safe to use and not affected by temperature changes. (Nitro Mak)(http://www.aslanogullari.com.tr/gma/urun_detay_nobelex_6000_7000.php)

Density(gr/cm3) 1.25 1.28Energy(mj/kg) 3.08GasVolume(lt/kg) 1015ExplosionTemperature(K) 2322WaterResistance goodTable27Properties of Nobelex 6000 explosive

CartridgeDiameter(mm) 60 75 90 125 140CartridgeLength(mm) 510520 510520 500510 540550 500510CartridgeMass(kg) 1.82 2.86 4 8 10CartridgeNumberperBox 11 7 5 2 2BoxMass(kg) 20 20 20 17 20

Table28Available size of Nobelex 6000 explosive

For 200 mm drill hole diameter, 140 mm cartridge diameter is selected.


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BottomChargeConcentration(Qb)

1.26 31.4 39.6

1.3 1.3 6 7.8 7.8 39.6 309 Number of cartridge used for bottom charge is 31 Stemming

, , 5.5 ColumnCharge(Qp) 13.8 7.8 5.5 0.5 Normally 40% %50 , but it is practical to use for short length of 0.5 m. So, 39.6 0.5 39.6 19.8

Number of cartridge used for column charge is.

2 TotalCharge

309 19.8 328.8


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Figure69The geometry of drill holes in overburden removal operation.SpecificCharge

5.5 6.9 12 455.4

328.8 455.4 0.72

SpecificDrilling

13.8

455.4 0.03 241,799,298

42,420.9

0.72 42,420.9 30,543.1 0.03 42,420.9

1,272.6 30,543.1 328.8 92.9 93 /


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