SURFACE MINING TECHNOLOGY Contents 1 INTRODUCTION TO SURFACE STRIP COAL MINING FUNDAMENTAL CONCEPTS AND DEFINITIONS SURFACE COAL MINING PRODUCTION COST AND STRIPPING RATIO ANALYSIS Stripping Ratio for Multiple Seams BASIC PROFIT FUNCTION ANALYSIS 2 GEOLOGYAND EXPLORATIONS GEOLOGY OF SOUTH AFRICAN COAL RESOURCES Coal Formation Stages in the Formation of Coal Principal Coal Seams of South Africa WITBANK COALFIELD FREE STATE COALFIELD WATERBERG COALFIELD Coal Quality Coal Production and Markets ENERALISED APPROACH TO ORE RESOURCE TO RESERVE DELINEATION EXPLORATION AND THE MINE PLANNING PROCESS Conceptual mine plan Pre-feasibility mine plan Cost ranking and feasibility mine plan LAND ACQUISITION REQUIREMENTS 3 SURFACE COAL MININGMETHODS SURFACE MINING METHOD SELECTION UNIT OPERATIONS FOR SURFACE MINING METHODS Preparing the Surface Drilling and Blasting Overburden Removal Loading and Haulage of the Deposit Rehabilitation Strip Mine Layout Strip Mining Over Mined-out Areas TERRACE MINING OVERBURDEN AND WASTE DUMPING Design and Construction of Dumps Design and Construction of Embankments SURFACE MINE SERVICE INFRASTRUCTURE Electrical Reticulation Systems Water Reticulation Systems 4 ROTARY DRILLING MACHINES MECHANICAL EXCAVATIONOR DRILL AND BLAST DRILLING METHODS Percussion Drilling Drifter Percussion Drills Down-The-Hole Drills (DTH) Percussion Drills Rotary Drilling SELECTIONMETHODS Selection of Hole Diameter Required Production Rates and Cost of Drilling ROTARY BLASTHOLE DRILLING Tricone Rotary Drill Main Components Rotary Drill Penetration Rate Tricone Rotary Drill Bits Selectionand Air Requirements 5 SURFACE STRIP COAL MINE BLAST DESIGN INTRODUCTION TO EXPLOSIVES AND BLASTING Blasting Theory Explosives Properties and Types EMULSIONS ANFOHEAVY ANFO INITIATION SYSTEMS DETONATORS SHOCK TUBE SYSTEMS DETONATING CORD Explosive Strength and Performance THE BLAST DESIGN PROCESS The Influence of Blasting Practices on Production CONCEPTUAL BLAST DESIGN Powder Factor (PDF) Size of Blasthole Parameter Empirical Relationships Determining Design Burden BLASTHOLE LAYOUT AND INITIATION OPTIMISING A CONCEPTUAL BLAST DESIGN Fragmentation Analysis and Optimisation Measuring Fragmentation Blast Monitoring CAUTIOUS BLASTING Control of Flyrock Airblast Ground Vibrations Highwall control CAST BLASTING 6 LOADING AND HAULING SYSTEMS INTRODUCTION AND EQUIPMENT OPTIONS LOADING EQUIPMENT - CYCLIC Transport Distance and Production Volume Effects Selection Criteria– Cyclic Loaders Front-end Loaders Hydraulic Shovels Electric Rope Shovel CYCLIC SHOVEL MINING METHODS Loading Floor Area and Minimum Loading Bench Widths Loading Methods TRANSPORT EQUIPMENT – CYCLIC Selection of Tyres Mine Haul Roads FACTORS EFFECTING CYCLICSYSTEMS PRODUCTIVITY Basic System Productivity Calculation Factors Effecting System Productivity LOADING EQUIPMENT –CONTINUOUS Selection of BWE BWE Productivity Estimation Continuous Mi TRANSPORT EQUIPMENT – CONTINUOUS Types of Conveyor Systems Crushing Waste Handling ContinuousSystem Costing 7THE SELECTION AND APPLICATION OF DRAGLINES INTRODUCTION TO DRAGLINES Basic Machine Operation Machine Operational Parameters Bucket Dumping Options DRAGLINE SELECTION Geotechnical Investigations for Dragline Mining General Dimensional Relationships for Dragline Mining FACTORS INFLUENCING GENERAL DIMENSIONAL RELATIONSHIPS Selection of Dragline Bucket Capacity Dragline Selection Methodology DRAGLINE OPERATING METHODS Box-cut Simple Side Casting Advanced Bench Chopdown Bench Extension OPTIMISING DRAGLINE PRODUCTIVITY Dragline Utility and Operational Efficiency Dragline Productivity in Deep Overburden DRAGLINE RELOCATION Transportation Options Considerations for Walking a Dragline 8 EQUIPMENT COST ESTIMATIONTECHNIQUES INTRODUCTION TO COST ESTIMATION EQUIPMENT REPLACEMENT DECISIONS ESTIMATING CAPITAL AND OPERATING COSTS Estimating Cost of Ownership Estimating Cost of Operation 9 MINING ENVIRONMENT, REHABILITATION AND CLOSURE ENVIRONMENTAL PROTECTION INTEGRATED ENVIRONMENTAL MANAGEMENT INTEGRATED WATER MANAGEMENT REHABILITATION PLANNING AND COSTING Approaches to Rehabilitating Mined Land Costing the Rehabilitation of Mined Land MINE CLOSURE Closure Planning Process URFACE STRIP CO AL MINE PLANNING AND SCHEDULING INTRODUCTION TO PLANNING AND SCHEDULING MINE DEVELOPMENT PHASES STEPS AND PHASES INVOLVED INA MINE PLANNING STUDY MINE SCHEDULING
SURFACE MINING TECHNOLOGY
Contents
1
INTRODUCTION TO SURFACE STRIP COAL
MINING
FUNDAMENTAL CONCEPTS AND DEFINITIONS
SURFACE COAL MINING
PRODUCTION COST AND STRIPPING RATIO
ANALYSIS
Stripping Ratio for Multiple Seams
BASIC PROFIT FUNCTION ANALYSIS
2 GEOLOGYAND EXPLORATIONS
GEOLOGY OF SOUTH AFRICAN COAL RESOURCES
Coal Formation
Stages in the Formation of Coal
Principal Coal Seams of South Africa
WITBANK COALFIELD
FREE STATE COALFIELD
WATERBERG COALFIELD
Coal Quality
Coal Production and Markets
ENERALISED APPROACH TO ORE RESOURCE TO RESERVE DELINEATION
EXPLORATION AND THE MINE PLANNING PROCESS
Conceptual mine plan
Pre-feasibility mine plan
Cost ranking and feasibility mine plan
LAND ACQUISITION REQUIREMENTS
3 SURFACE COAL MININGMETHODS
SURFACE MINING METHOD SELECTION
UNIT OPERATIONS FOR SURFACE MINING METHODS
Preparing the Surface
Drilling and Blasting
Overburden Removal
Loading and Haulage of the Deposit
Rehabilitation
Strip Mine Layout
Strip Mining Over Mined-out Areas
TERRACE MINING
OVERBURDEN AND WASTE DUMPING
Design and Construction of Dumps
Design and Construction of Embankments
SURFACE MINE SERVICE INFRASTRUCTURE
Electrical Reticulation Systems
Water Reticulation Systems
4 ROTARY DRILLING MACHINES
MECHANICAL EXCAVATIONOR DRILL AND BLAST
DRILLING METHODS
Percussion Drilling
Drifter Percussion Drills
Down-The-Hole Drills (DTH) Percussion Drills
Rotary Drilling
SELECTIONMETHODS
Selection of Hole Diameter
Required Production Rates and Cost of Drilling
ROTARY BLASTHOLE DRILLING
Tricone Rotary Drill Main Components
Rotary Drill Penetration Rate
Tricone Rotary Drill Bits Selectionand Air Requirements
5 SURFACE STRIP COAL MINE BLAST DESIGN
INTRODUCTION TO EXPLOSIVES AND BLASTING
Blasting Theory
Explosives Properties and Types
EMULSIONS
ANFOHEAVY ANFO
INITIATION SYSTEMS
DETONATORS
SHOCK TUBE SYSTEMS
DETONATING CORD
Explosive Strength and Performance
THE BLAST DESIGN PROCESS
The Influence of Blasting Practices on Production
CONCEPTUAL BLAST DESIGN
Powder Factor (PDF)
Size of Blasthole
Parameter Empirical Relationships
Determining Design Burden
BLASTHOLE LAYOUT AND INITIATION
OPTIMISING A CONCEPTUAL BLAST DESIGN
Fragmentation Analysis and Optimisation
Measuring Fragmentation
Blast Monitoring
CAUTIOUS BLASTING
Control of Flyrock
Airblast
Ground Vibrations
Highwall control
CAST BLASTING
6 LOADING AND HAULING SYSTEMS
INTRODUCTION AND EQUIPMENT OPTIONS
LOADING EQUIPMENT - CYCLIC
Transport Distance and Production Volume Effects
Selection Criteria– Cyclic Loaders
Front-end Loaders
Hydraulic Shovels
Electric Rope Shovel
CYCLIC SHOVEL MINING METHODS
Loading Floor Area and Minimum Loading Bench Widths
Loading Methods
TRANSPORT EQUIPMENT – CYCLIC
Selection of Tyres
Mine Haul Roads
FACTORS EFFECTING CYCLICSYSTEMS PRODUCTIVITY
Basic System Productivity Calculation
Factors Effecting System Productivity
LOADING EQUIPMENT –CONTINUOUS
Selection of BWE
BWE Productivity Estimation
Continuous Mi
TRANSPORT EQUIPMENT – CONTINUOUS
Types of Conveyor Systems
Crushing
Waste Handling
ContinuousSystem Costing
7THE SELECTION AND APPLICATION OF DRAGLINES
INTRODUCTION TO DRAGLINES
Basic Machine Operation
Machine Operational Parameters
Bucket Dumping Options
DRAGLINE SELECTION
Geotechnical Investigations for Dragline Mining
General Dimensional Relationships for Dragline Mining
FACTORS INFLUENCING GENERAL DIMENSIONAL RELATIONSHIPS
Selection of Dragline Bucket Capacity
Dragline Selection Methodology
DRAGLINE OPERATING METHODS
Box-cut
Simple Side Casting
Advanced Bench Chopdown
Bench Extension
OPTIMISING DRAGLINE PRODUCTIVITY
Dragline Utility and Operational Efficiency
Dragline Productivity in Deep Overburden
DRAGLINE RELOCATION
Transportation Options
Considerations for Walking a Dragline
8 EQUIPMENT COST ESTIMATIONTECHNIQUES
INTRODUCTION TO COST ESTIMATION
EQUIPMENT REPLACEMENT DECISIONS
ESTIMATING CAPITAL AND OPERATING COSTS
Estimating Cost of Ownership
Estimating Cost of Operation
9 MINING ENVIRONMENT, REHABILITATION AND CLOSURE
ENVIRONMENTAL PROTECTION
INTEGRATED ENVIRONMENTAL MANAGEMENT
INTEGRATED WATER MANAGEMENT
REHABILITATION PLANNING AND COSTING
Approaches to Rehabilitating Mined Land
Costing the Rehabilitation of Mined Land
MINE CLOSURE
Closure Planning Process
URFACE STRIP CO
AL MINE PLANNING AND SCHEDULING
INTRODUCTION TO PLANNING AND SCHEDULING
MINE DEVELOPMENT PHASES
STEPS AND PHASES INVOLVED INA MINE PLANNING STUDY
MINE SCHEDULING
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