Lesson 7 Unit Operations in Mining *The Stripping ratio or the Overburden is the deciding

factor whether you’ll proceed to open pit or underground

Unit Operations is divided into Production and mining operation.
Auxiliary Operations.

Production is directly involved with the operation, steps

contributing directly to mineral extraction. Divided into The basic production cycle consists of these unit
Excavation(breakage) and Handling (materials operations:
handling).
Production cycle = drill + blast + load + haul
The auxiliary steps that support the production cycle are
termed Auxiliary Operations. They are activities that The production cycle employs unit operations that are
guide the Production Operation. normally grouped into rock breakage and materials
handling.
In surface mining, the primary auxiliary operations
include:  Breakage generally consists of drilling and
blasting.
- those providing slope stability,  Materials handling encompasses loading or
-pumping, excavation and haulage (horizontal transport) and
-power supply, sometimes hoisting (vertical or inclined transport).
-maintenance,
-waste disposal or Dewatering, Drilling-
-and supply of material to the production
centers. Rock
-surveying Penetration
-Dust management Rock Breakage
-road maintenance Rock
Fragmentation
*Selection of Equipment for Operations is a major
consideration for selecting operation activity. Rock Penetration- drilling of holes for the placement of
explosives when consolidated rock must be removed.
* Purchase/select equipment necessary for specific The pre-operation for the fragmentation of Rocks (Rock
Operation. Avoid selecting equipment with only fragmentation).
temporary usage for operation.
Rock Fragmentation- blasting or breakage of rocks to
Overburden Removal- major activity to remove the manageable sizes which is now part of blasting activity.
overburden to have an access to the ore body deposit.
Two types of Drilling:
Overburden- the waste material and not a mineral, it
lies above or around the ore body that is needed to 1. Rotary drilling- is used to form a deep observation
remove to have an access to ore deposit. borehole or for obtaining representative samples of rock.

Maximum Slope- needed/basis for designing the open -The drilling method involves a

pit. powered rotary cutting head on the end of a shaft,
driven into the ground as it rotates. The system requires
Pit Slope- Measured from the bottom bench toe to the lubrication (air, water or drilling mud) to keep the cutting
top bench crest. It is the angle at which the wall of an head cool.
open pit stands and it is determined by rock strength,
geologic structures and water conditions. 2. Percussion drilling- is a manual drilling technique in
which a heavy cutting or hammering bit attached to a
Stripping Ratio- can be calculated by dividing rope or cable is lowered in the open hole or inside a
overburden thickness by ore thickness. For example, temporary casing.
an overburden thickness of 100 meters and an ore
thickness of 50 meters would yield a strip ratio of 2:1. - is employed when auger or wash
boring is not possible in very stiff soil or rock. It also can
Overburdenthickness be used in most soil types.
SR=
Ore thickness
or

waste
SR=
recovered
 -used to reduce the overburden or ore to a size
range suitable for excavation depending on the
requirement of ROM(Run-of-mine)

Run of Mine- means the raw unprocessed or uncrushed

Mechanical Drilling- material in its natural state obtained after blasting or
digging, from the mineralized zone of a lease area.
Method Machine
Percussion Blasting equipment:
DTH Churn or cable-tool drill
Hammer Rock Drill Boosters

Rotary, Drag Bit Detonating Chord- chemical, electrical, mechanical

Blade Auger or rotary drill, boring
Stone-set Diamond Drill Dynamite-
Sawing Wine-rope, chain or rotary saw
Rotary, roller-bit Rolling-cutting drill, boring LE HE BA
Black Dynamite Gelatin Water
Rotary percussion Powder s Dynamit Gels,
Hammer Rock Drill e slurries ANFO
Rotary Rolling- Cutting Straight Straight Semi- Binary blends
Dynamite Gelatin gelatins Emulsions
Ammonia Ammoni
Dynamite a Gelatin
Rock Type
Drilling SOFT Medium- Hard Very Hard A Shotfirer in the minerals industry assembles,
Method (Shale, hard (Granite (Taconite, positions and detonates explosives at mining sites to
weath (limestone, , Chert) Quartzite)
ered, weathered,
dislodge rock or soil.
Limest sandstone)
one,
Coal)
Materials Handling
Hydraulic / /
Jet  Loading/ Excavation
Rotary, / /
 The removal of rock Material whether
drag-bit overburden or ore.
Rotary, / / /  Hauling
roller-bit  The transport of rock material
Rotary / /
 Dumping
Percussion
Percussion / / /  the placement of rock material into storage
areas
Thermal / /
Jet Loaders/Excavators
piercing
 Hydraulic backhoe excavator
 Shovel
Percussion Drilling- considered with highest
penetration rate.  Rope Shovel
 Hydraulic Shovel
Hydraulic Jet- high environmental degradation.  Dragline
 Front-end Loader
 Bucket wheel excavator
Blasting  Surface Miner
 Scraper
Rock
Penetration
Rock Breakage Loading Equipment Selection
Rock
Fragmentation  Cost
 Operating cost
Blasting is the activity in which in-situ rock is broken in  Capital Cost
both development and stopping and in surface mining by  Rock Hardness and Abrasiveness
drilling holes in the rock, charging them with explosives
 Surface competence
and detonating the holes in a planned sequence.
 Mining Method
 Deposit Size  can be used as hauling equipment
 Productivity Requirements  Disadvantages
 Ore/ overburden interface  high maintenance cost
 Mobility requirements  requires smooth terrain
 Availability  material requires loose and spread out muck
 Due to differing requirements, some mines have profile
multiple loading equipment in order to handle all Two common types:
types of loading tasks  Track Front-end
Loader
 Wheel Front-end
Hydraulic backhoe excavator Loader

-used for digging material below the equipment level Draglines

-clockwise movement -used commonly in open-cast mines, in high productivity

mines with the dumpsite located in-pit
 Advantages
 separation between loading and hauling  Advantages
equipment  high productivity
 good for digging ramps and drop cuts  low operating cost
 high flexibility  doesn’t require hauling equipment (direct
 Disadvantages casting)
 Lower productivity when digging material on the  Disadvantages
same level  High capital cost
 Low mobility  Very low mobility
 Can only be used in limited applications
Types of Loading  Requires bench preparation
 Top Loading-truck and excavator are
on the same level
 Bench Loading- the excavator is on top Bucket Wheel Excavator
while the truck is on lower level
-used in mines with soft rock; doesn’t require drill and
 Double benching-capable of lower and blast; considered to be one of the biggest equipment in
upper benches mining, attached to it is a conveyor that transports
Shovel excavated material directly into the stockpile; commonly
used in coal mines
-for digging material on the same level as the equipment
 Advantages
-counterclockwise movement  high productivity
 low operating cost
 Advantages
 continuous cycle
 High productivity due to lower swing time
 Disadvantages
 Disadvantages
 High capital cost
 Can’t dig deep drop cuts
 Very low mobility
 Low mobility
 Can’t be used in hard rock applications
Two common types:

 Hydraulic Shovel
 Rope shovel

Front-end Loaders

-used in ROM stockpiles, road maintenance, moving

small amounts of material (i.e. stemming), loading
equipment

 Advantages
 high mobility
 flexible
CYCLIC OPERATION for loading and hauling  Flexible
operation  Cyclic in nature and has better compatibility with
L
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qly backhoes and shovels
 Disadvantages
 High maintenance costs
 Require properly maintained roads

Types:

 On-Highway truck
 Articulated
 Rigid Dump Trucks

Articulated Trucks

 Smaller and has a smaller turning radius

Hauling Equipment Selection  Can be used in rugged, cramped terrain and
higher road gradient
 Distance
 Loading equipment compatibility
 Haul road quality Rigid Dump Trucks
 Terrain
 Road gradient  Bigger and higher capacity
 Water drainage  Rigid dump trucks are the backbone of
 Slope stability haulage equipment for the worldwide mining
 Dust concerns industry

Percentage of expenses in surface mining

Haulage- 48%

Overhead-15%

Drill and blast- 13%

Roads and Dumps- 12%

Loading- 12%

*Loading drives production while hauling drives the

cost in surface mine

Types of Loading
Dozers- 0-150m(0-500ft)
 Frontal Cut- Advance direction- right
Load and Carry- 50 to 120m (150 to 400ft) - Excavator is placed 90 degrees
from the surface
Scrapers- 120 to 1200m (400 to 4000ft) - Double spotting for loading trucks
Articulated Trucks- 120 to 1200m (400 to 4000ft) - 110 degrees maximum swing
 Drive-by Operation
Rear-Dump Truck- 120 to 9000m (400 to 29 500ft) - Advance direction- Left
- Similar to parallel loading
Wagon/Hauler- 7000 to 20000m (22900 to 65,600ft)
- Loading equipment is already
parallel to bench face
- Bigger space for penetration
Trucks - Faster spotting mobility, Single
Spotting
 Advantages
 Stop-and-Reverse
 High productivity
 - Combination of both Frontal Cut and Auxiliary Operation
Parallel but is more complicated
- Favorable in constrained area 1. Surveying
- 45.5 degrees maximum swing angle 2. Road Maintenance – Maintenance trimming
and spillage removal
Conveyor Belts - Scarifying soft spots
- Road graders- is a form of heavy
 Continuous hauler equipment with a long blade used to
 Advantages create a flat surface during grading
 Good compatibility to continuous - Road roller- is a compactor-type
mining engineering vehicle used to
 Low operating costs compact soil, gravel, concrete, or
 Doesn’t require too much personnel asphalt in the construction
 Disadvantages of roads and foundations.
 Low flexibility 3. Slope Stability
 Requires permanent structures 4. Dust Management – usually done to reduce
 Huge downtime during maintenance drill dust and dust generated in overburden
removal by mobile excavation equipment.

Loading/Hauling Combinations

 Loading and Hauling Equipment need to match in

order to have better efficiency
 When using trucks, 3-6 passes are the best
 Overloaded trucks can cause higher maintenance
costs due to higher tire wear
 When using continuous mining methods, conveyors
are the most suitable hauling equipment

Surface Miner

 Multipurpose equipment designed to crush, cut and

load soft material
 Advantages:
 Can be used in highly selective applications
(dilution control)
 Reduced amount of equipment and processes
 Disadvantages:
 can’t be used in hard rock applications
 relatively low productivity

Scraper

 used to crush, cut, load and transport soft material

 also considered as part of auxiliary operation
 Advantages:
 Can be used in highly selective applications
(Dilution control)
 Reduced amount of equipment and processes
 Disadvantages:
 Can’t be used in hard rock applications
 Relatively low productivity
 Rugged terrain