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The K2-LV Experiment: Mining the Future
Project Report
Engineering Design 100: Section 004
Team: K2-LV
Submitted to: Wallace Catanach
Date: April 30, 2017
Logan Bayer: [email protected] Keith Griffith: [email protected]
Jiajie Chen: [email protected]
Kainian Chen: [email protected]
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Index Title Page
Executive Summary ………………………………………………………………… 4
Introduction …………………………………………………………………………. 5
Patent Research
Underground Mine Ventilation System…………………………………………. 6
Underground Mine Surveillance System ……………………………………….. 6
Vehicle for Underground Mine Shafts ………………………………………….. 6
Block Caving Mining Method ……………………………………………………… 7
Customer Requirements …………………………………………………………….. 7
Global Marketplace …………………………………………………………………. 8
Concept Generation
Super Elevator …………………………………………………………………... 9
Funnel Elevator …………………………………………………………………. 10
Track and Elevator System …………………………………………………….... 10
Conveyor Belt System …………………………………………………………... 10
Guys with Shovels ………………………………………………………………. 10
Concept Selection …………………………………………………………………… 11
Embodiment of Design ……………………………………………………………… 12
Final Design Description ……………………………………………………………. 16
Geothermal Energy ………………………………………………………………….. 17
After the Mining …………………………………………………………………….. 19
Conclusions ………………………………………………………………………...... 19
References …………………………………………………………………………… 20
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Executive Summary Team K2-LV was one of the many teams designated to develop a new method of extraction for
rare earth elements in the Pocono Mountains. Client General Electric specifically cited block-
caving as the primary method of removal. Block caving requires a weak host rock as the entire
premise of this method relies on the rock fracturing in certain areas. The host rock in the Pocono
Mountains consists of fine to medium grained sandstone, siltstone and conglomerate rock. This
means that the rock is relatively stable and is able to self-support roughly 90% of the mine; this
requires support systems for the remaining 10% of the mine. Although the primary investment
for this method of mining is very high, the payoff in the end is worth it. K2-LV’s goal was to
design and prototype an innovative take on block caving that would solve 8 main problems,
including: airborne contamination, environmental management, stewardship of the ore,
occupational health and workplace safety, operating costs and productivity, local community
engagement, waste management and disposal, and mine closure and rehabilitation.
Before detailing a design for GE’s rare earth element mine, some preliminary research had to
take place. Through GE’s given parameters a few things were clarified. To begin with the mine
has already been setup as a block cave operation with a ramp from the surface to the production
level intended for primary transportation of ore. The ramp is 15.3 km long at a constant 20%
grade. In addition, the ore maintains a uniform concentration throughout. This leads to each
extracted ton being worth approximately $10,000. Each of the 100 draw points throughout the
mine provides a continuous flow of ore as well. This simplified scenario allows the design team
to construct a proper cost model for the mine. The mined ore only travels 300 meters on average
from draw point to haul zone locations. Taking of all the background clarifications and customer
needs into account, K2-LV began brainstorming. These brainstorming sessions led to the
development of a fully automated mine.
There were a number of problems encountered throughout the design process. Initially, worker
safety was a major issue. The best solution we found to this problem was to entirely remove
them from the equation. By automating the whole process we were able to complete the project
without compromising safety. Another major issue we found was a way to supply power to our
mine. The ability for our mine to run all day would allow for max profit in the long run. Since
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geothermal energy is a renewable energy source that is able to create energy at a fairly constant
rate, this was chosen as a power source. Finally, we needed to find a way to access the
automated equipment for repairs. There are multiple ways that this can be done. Robotic
vehicles would be able to do this after development, however, ventilation and access shafts were
put in place. This would allow for miners to access the conveyor belts for repair. The final
prototype and design is scheduled to be delivered to client GE on April 26, 2017.
Introduction
In the Pocono Mountains (pictured) in Northwestern Pennsylvania, the company General
Electric has the foundation laid to set
up a mine. The mission is to extract
many Rare Earth Elements (REE)
from the site. These elements include
Neodymium (Nd), Europium (Eu),
Terbium (Tb), Dysprosium (Dy), and
Yttrium (Y).
Without having a plan in place
to harvest these resources, and not having an idea for a mine design, GE called on K2-LV for the
solution. The team had just completed Wally’s Catanach’s Zero Energy Home needs. K2-LV
had many problems to overcome, and they were all very important aspects to cover.
These problems all spout from the depth. At around 3,000 meters below surface level,
the first problem we encounter is a higher everything. Higher temperatures, higher humidity,
higher natural gas emissions: all problems for human beings. They can’t even flee into the safety
of their diesel vehicles, as the depths cause challenges operating these vehicles as well. Team
K2-LV was ready to take on all of these challenges.
Patent Research
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Underground Mine Ventilation System
US 20120309283 A1
This patent is for a simple underground mine ventilation system,
as suggested above. This patent calls for fans by non-pressurized
ventilation shafts, and it calls for a natural free-flow of air.
Underground mine surveillance system
US 3949353 A
This patent, as suggested by the title above, it is for a
surveillance system. Instead of using video cameras or recording
devices, it rather monitors energy usage. Seismic energy is
processed and classified into meaningful data, and can monitor work and productivity.
Vehicle for underground mine shafts
US 5909780 A
This patent is for a mine shaft vehicle that can transport human bodies into mine shafts. This
vehicle has many safety features similar to regular cars, such as emergency brakes, and a door
security monitor that only allows it to work if the door is shut and the circuit is complete.
Block Caving Mining Method
The method that General Electric wants used is called the block caving mining method. It can be
a very intricate process, but it can be simplified into 5 simple steps.
1) An extraction layer is dug below the rock that is to be
fragmented. (Right)
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2) Using explosives, charges are set off at draw points. Through this
explosion and natural rock decay, fragments break off. (Right)
3) The fragments are collected via special underground mining
trucks. These trucks are called LHDs (Load-Haul-Dump), and
require human drivers to operate them. (Right)
4) The LHDs carry the collected fragments through the
series of tunnels to the crusher. (Left)
5) The crushed fragments are taken to the surface via
conveyor belt. (Right)
Customer requirements
Customer statements Needs statements
We want to reduce the cost. The mining system will use an Automated
System to reduce the labor costs and to
transport waste material at a low cost.
Dangerous gas, humidity and high
temperature in the mine can cause serious
accidents.
A cooling system will be used while mining to
ensure the dangerous gas does not react and to
reduce the temperature. A ventilation system
will reduce the amount of dangerous gas in
the mining area and decrease the amount of
total heat affecting the equipment.
Hazardous environment will be an issue for
our workers.
As long as we use automated system, we will
not require workers work in those conditions.
Our mine should be environmentally friendly. Tailings will be recycled in order to maintain
the overall flora and fauna of the area.
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Our main customer, GE, is mine owner who owns land that contains Rare Earth Element (REE)
ore in the Pocono Mountains. GE listed the following requirements: environmental
consciousness, as both long term and short term hazardous environment effects should be
minimized, safety and health of our workers, all while reducing costs. It is necessary to keep the
cost low in order to receive the maximum amount of profit.
Global Marketplace
Mines have been an important part of US
and World history. The Rare Earth Elements we
are seeking have many uses. The graph
demonstrates some of the uses, and the
breakdowns of them.
Uses that are personal to the everyday
man, and more commonly known include
computer memories, DVDs, rechargeable
batteries, fluorescent lights, and much more.
The demand has gone up a lot over the past
several decades.
China by far has the largest market for these, followed by the US, and then many other
nations. A few examples of block caving mining can be seen throughout the world. To begin
with, Northparkes (Australia) began using block caving mining in 1996. The mining base is 600
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meters under the ground. The main extraction materials are gold and copper. In addition, Auto
Load-haul dumpers (LHD) give 20% more output than the manual LHD. It has reduced the
working times for all workers. Workers no longer need to work 12 hours in order to produce the
same amount of product.
The Henderson molybdenum mine, a mine located in Clear Creek County, Colorado, is North
America’s largest producer of molybdenum. The Henderson mine was the successor to the Urad
mine and was discovered in 1964. Climax Molybdenum Co. was the company associated with
the discovery of the deep orebody. Production began in 1976 and still continues today. Roughly
500 million pounds are estimated to be left. With roughly 40 million pounds of production each
year, the mine brings in roughly $1.1 billion yearly. Soon after production began, the mine
broke through to the surface. This mine utilizes a 15 mile long conveyor belt that travels below
the mine. Prior to the use of a conveyor system, a train was used to transport the mineral.
However, this was only possible when the ore was above the track.
Concept Generation
The brainstorming phase of the process led us to a handful of ideas. K2-LV had to
narrow down the ideas to be scored and then selected. Before we get to the scoring and
selection, here are the ideas we put up against
each other.
The Super Elevator
This idea consisted of collecting the rock
fragments by a series of underground trucks, and
then being transported to a massive elevator.
This “super elevator” would carry the fragments to the surface where it would be unloaded. The
elevator shaft takes up a lot of square footage, and makes any plan for afterwards very difficult
and problematic to implement.
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The Funnel Elevator
The idea of the funnel elevator is one that is very similar to the super
elevator above. The main adjustment here is that when the fragments are
placed on the elevator and taken to the surface, they pass through a funnel at
the top of the elevator shaft. This funnel focuses the fragments into one point
and allows for easier collection. Like the elevator above, due to its massive size, any plan for
use of the site afterwards would be very difficult.
The Track and Elevator System
The idea of a track and elevator system was by far the most
complicated idea thought up. This system was a series of conveyor
belts and elevators that carry the fragments to the surface, after being
collected by underground mining trucks. A downside of this concept
is the lack of a plan for afterwards.
The Conveyor Belt System
This idea uses nothing but conveyor belts to
transport the resources to the surface. After
going through a funnel and then a grinder, a
horizontal conveyor belt carries the grinded up
fragments to another diagonal conveyor belt,
which takes it to the surface. The plan for afterwards is to turn the mine into a ski resort.
Guys with Shovels
This idea was never meant to be
taken seriously, nor did it have a chance to be
selected. Purely for comedy, this idea of
getting thousands of men with shovels to go
down into the mine and take out the resources. It may have been via buckets, or they all may
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have made a chain to transport it out. It wasn’t thought the whole way through. No real plan for
the use of the mine after its time has run out.
Concept Selection
When it came time to select one of our ideas to further develop, we used a simple
plus/minus scoring system using the customer needs we derived from earlier.
The idea of guys with shovels came in last, as to be expected. Slightly above that idea
was the track and elevator system. This concept failed due to the fact that it was too complex
and had unnecessary components. Tied for second were the super elevator and funnel elevator
system. Both provided safety, lacked a plan for post-mine use, and were very similar in the end.
The concept that took the cake was the automated conveyor belt system. It was a positive
on all of the customer requirements, putting it far above the rest. It’s automated system took
workers out of the equation, making it the safest environment possible for them. Not to mention
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the planned ski resort afterward, a great use of any waste and a way to get the local people of the
Poconos involved.
In addition to the selection of our concept versus other concepts, an AHP chart was
created. This chart shows the importance of significant factors in comparison to others.
A few concepts were highly rated including the cooling system, automated system, worker safety
and use for waste. Ventilation system, however, was the least important metric showcased in this
diagram.
Embodiment of Design
The above image showcases the complete underground system of the mine. Further details will
be explained in the following images.
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The image here shows the conveyor belt required to lift material out of the mine. The ore is
transferred onto the lift by another conveyor belt. The ore is then carried directly upwards
towards the processing plant. The plant is located directly over the exit area of the mine. This
ensures efficiency for processing.
The above image showcases the grinders that are located directly below the orebody. The
grinders ensure that the ore is of manageable size for the conveyor belts.
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The above image shows the exit of the material from the mine.
This image is of the transfer conveyor belt. This is located directly below the orebody, funnel,
and grinder. This conveyor belt transfers the material from the grinder to the exit conveyor.
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This is representative of the orebody.
This solidworks model shows an example of an auger/grinder that is able to crush the material to
a manageable size as was represented in the above images.
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This is the conveyor belt that would transport the material to the surface. The horizontal belt
above the surface provide convenience for fixing trucks.
This conveyor is present directly below the orebody and is responsible for moving the material
from grinder to the upward conveyor.
Final Design Description
The final design is rather simple. Unlike the traditional block caving mining method,
The grinder is placed directly below the draw point. This removes the need for trucks and for
people in those trucks. The fragments are funneled into the grinder, where they grinded
fragments fall onto a horizontal conveyor belt. This belt runs to a diagonal belt that carries the
resources out to the surface, where it can be hauled away and used in production.
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Geothermal Energy
Geothermal energy, as was previously listed, was chosen as the primary energy producer for this
mine. Geothermal energy works by using steam to turn a turbine. This turbine then generates
electricity. As hot water is drawn up through the earth, flash steam is created. The hot water that
is not turned into steam then runs through a vaporizer, allowing for double draw from the power
source. The steam and excess water are then passed through a condenser and pumped into the
ground. As long as the amount of water being drawn is less than or equal to the rate it is being
pumped back in, the geothermal power plant will continue to run. Our model showcased a
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simplified version of a geothermal power plant.
The image in this case utilizes different colored balloons and straws to represent different parts
of a geothermal unit. The red balloons represent the hot water areas. The red straws are
indicative of steam pipes. The green straws represent the cooler, but still hot water. The green
balloon is a vaporizer, allowing for another draw of energy. The yellow straw is a condenser that
wraps around the blue, cooled steam straws. The cooled water is then pumped back into the
ground, showed by the smaller blue balloon. The green bottle represents the generator that
would then power the mine.
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After the Mining
Ski facility can be built up on the giant pit after the mining. It will not only increase the
economic effect in the mining areas but also protect the environment.
Conclusions
In conclusion, K2-LV was effectively able to design and prototype a mine system that fulfills all
of the needs of GE project. This was also completed on a strict deadline with a plethora of
customer needs. The project could be considered by many a success, despite temporary
ineffectiveness within the team. The difficulties were solved and the project came together to
produce a quality product. For many, these difficulties would have caused a shutdown, but for
K2-LV nothing is impossible.
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Links
https://www.google.com/patents/US20120309283
https://www.google.com/patents/US3949353
https://www.youtube.com/watch?v=MVDAw56s5dU
GE Mining Presentation
http://www.heavyequipment.com/heavy-equipment/earthmoving-mining
Bing Images (Through PowerPoint)
http://www.greenegroup.co.za/foundations-for-surface-mine-ventilation-fans/
http://www.concordpianoservice.com/what-exactly-is-humidity/
http://www.rnaautomation.com/products/automation-solutions/
http://followgreenliving.com/geothermal-energy/
http://www.trendhunter.com/trends/mitsubishi-electric-elevators
http://digitalmarketingphilippines.com/lead-generation-funnel-what-is-it-and-how-does-it-work/
https://www.amazon.com/Accessory-Elevator-Attachments-Playsets-Flipo/dp/B01LQT3WR6
http://www.mafdel-belts.com/product/positive-drive-conveyor-belt/positivebelt-conveyor-belt/
http://www.outsidethebeltway.com/otb-caption-contest-125/
http://www.open.edu/openlearn/science-maths-technology/science/environmental-
science/energy-resources-geothermal-energy/content-section-8
https://www.youtube.com/watch?v=gI6BhEy7yXo
http://geo-energy.org/Basics.aspx
http://english.visitkorea.or.kr/enu/ATR/SI_EN_3_6.jsp?cid=1976359
http://geology.com/articles/rare-earth-elements/