Topic 4: Underground mining

A short series of lectures prepared for the

Fourth year of Geology, Tanta University

2010- 2011
by
Hassan Z. Harraz

[email protected]

This material is intended for use in lectures, presentations and as

handouts to students, and is provided in Powerpoint format so as to
allow customization for the individual needs of course instructors.
Permission of the author and publisher is required for any other usage.
Please see [email protected] for contact details.

29 November 2011 1
Underground Mining
Terminology
Mine Access
Development Mining vs. Production Mining
Underground Mine Ventilation
Ground Support
Stope and Retreat vs. Stope and Fill
1. Stoping
2. Retreat mining
3. Stope and retreat
4. Stope and fill
Underground Mining Methods
1. Unsupported Mining Methods
a) Room and Pillar mining
b) Shrinkage stoping
2. Supported Mining Methods
a) Cut and fill stoping
b) Square-set stoping
c) Stull stoping
3. Caving (or Bulk) Mining Methods
a) Longwall mining
b) Sublevel Caving Stoping
c) Block Caving Stoping
Ore Removal
Unit Operations of Mining

29 November 2011 We will explore all of the above in Part 4. 2

 UNDERGROUND MINING
 Generally underground mining is adopted when the orebody is too deep and it’s not
economically or technically feasible to use an open-pit:
{Deepest “hard-rock” open pits are over 700 m deep (e.g., Palabora in South Africa and
Chuquicamata in Chile)}.
It is increasingly common to progress from open-pit to underground mining of the same orebody.

TYPES OF UNDERGROUND MINING

Soft rock mining Hard rock mining
Refers to a group of underground mining Refers to various underground mining techniques
techniques used to extract coal, oil shale, tar used to excavate hard minerals, mainly those containing
sands, salt and other minerals or geological metals such as ore containing gold, silver, iron, copper,
materials from sedimentary ("soft") rocks. zinc, nickel and lead, but also involves using the same
Because deposits in sedimentary rocks are techniques for excavating ores of gems such as
commonly layered and relatively less hard, the diamonds.
mining methods used differ from those used to
mine deposits in igneous or metamorphic rocks
(i.e., Underground mining (hard rock)).

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 It is more complex than surface mining methods.
 It requires considerable more planning to take into account access, ground support,
ventilation, the effects of blasting, and haulage of material from the mine to the plant.
 generally high grade deposits.
 more selective than open pit.
 Ore extraction and underground development is achieved by precise drilling and blasting
techniques.
 This is closely controlled and monitored by engineers, geologists, and surveyors.
 All Underground mining methods involve:
drilling a pattern of holes into the rock.
 Charging (filling) the holes with explosive.
 Blasting the rock.
 Bogging (digging) it out.
 Transporting it to the surface.

 Design issues:
 Geometry of underground mining.
 Ground support.
 Shaft location.
 Logistics of underground materials.

29 November 2011 4
Terminology
 Stopes are openings from which ore is mined. They may be backfilled with
cemented waste materials.
 Drifts are horizontal passageways used for access.
 Ore passes are sub-vertical chutes for movement of ore.
 Declines or ramps are spiral or inclined drifts.
 Output: In general for underground mines:
o small output mines have output of < 4,000 tpd. Hauling is done on several
levels, tonnage handled on each level is small, and light equipment is used.
o high output mines have output of > 4,000 tpd. A main haulage level is used
and all ore is dropped to that haulage level via ore passes.
 Levels include all the horizontal workings tributary to a shaft station. Ore
excavated in a level is transported to the shaft to be hoisted to the surface.

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 General anatomy of a deep underground mine
• Both ore-rock and water are allowed
to feed to the bottom of the mine
under the force of gravity, and from
there are transported or pumped to
the surface.

• Note the use of “backfill” in mined-

out areas to provide support for the
overlying rock. Backfill allows ore
recovery to be maximized, because
ore is not left in-place as support
pillars.

• Backfill is generally a mixture of

cement with waste rock, sand or
tailings.
29 November 2011 6
Figure from Spitz and Trudinger, 2009.
 Figure shows underground mine terms.

29 November 2011 7
MINE ACCESS
i) Underground Mine Access.
ii) Ore Access.

Accessing underground ore can be achieved via a decline (ramp),

inclined vertical shaft or adit.

 To make underground mining economically

viable, access must be well planned and
efficient.

 Access to the underground orebody is based

on the understanding of its characteristics
and those of the surrounding rock.

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 Figure 1: A three dimensional model of an underground mine with shaft .

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Development Mining vs. Production Mining
There are two principal phases of underground mining: development mining and production mining.

Development mining is composed of excavation almost entirely in (non-valuable) waste rock in order to gain
access to the orebody.
There are six steps in development mining:
i) Remove previously blasted material (muck out round),
ii) Scaling (removing any unstable slabs of rock hanging from the roof and sidewalls to protect workers
and equipment from damage),
iii) Support excavation,
iv) Drill rock face,
v) Load explosives, and
vi) Blast explosives.

Production mining is further broken down into two methods:

i) Short hole mining is similar to development mining, except that it occurs in ore.
ii) Long hole mining: There are several different methods of long hole mining. Typically long hole
mining requires two excavations within the ore at different elevations below
surface, (15m – 30m apart).

Holes are drilled between the two excavations and loaded with explosives. The holes are blasted and
the ore is removed from the bottom excavation

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Underground Mine Ventilation
One of the most important aspects of underground hard rock mining is
ventilation. Ventilation is required to clear toxic fumes from blasting and removing
exhaust fumes from diesel equipment.
In deep hot mines ventilation is also required for cooling the workplace for
miners. Ventilation raises are excavated to provide ventilation for the workplaces, and
can be modified for use as emergency escape routes. Adequate ventilation throughout
the mine may be ensured by the provision of a separate shaft from the surface. This
has a fan that draws fresh air through the mine.
The primary sources of heat in underground hard rock mines are virgin rock
temperature, machinery, auto compression, and fissure water. Other small
contributing factors are human body heat and blasting.

29 November 2011 MPI Mines 11

Ground Support
Ground support is necessary when voids (empty spaces) are created underground. Some
means of support is required in order to maintain the stability of the openings that are excavated.
The competency of the rock being mined will determine how large a void may be created
and what ground support methods will be necessary to maintain a safe working environment.
This support comes in two forms:
1. Area ground support
Area ground support is used to prevent major ground failure. Holes are drilled into the back
(ceiling) and walls and a long steel rod (or rock bolt) is installed to hold the ground together.
There are three categories of rock bolt, differentiated by how they engage the host rock. They
are:
i) Mechanical bolts
ii) Grouted bolts
iii) Friction bolts
2. Local ground support
Local ground support is used to prevent smaller rocks from falling from the backs and
walls. Not all excavations require local ground support.
Welded Wire Mesh is a metal screen with 10 cm x 10 cm (4 inch) openings. It is held to the
backs using point anchor bolts or resin grouted rebar.
Shotcrete is fiber reinforced spray on concrete which coats the backs and walls preventing
smaller rocks from falling. Shotcrete thickness can be between 50 mm – 100 mm.

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Stoping
Stoping is the removal of the orebody from the surrounding rock. The underground
stoping method used depends on the nature and extent of the orebody. Stoping is used for
mining deposits with the following characteristics:
 steep dip, the footwall inclination must exceed the angle of repose.
 stable rock in both hangingwall and footwall.
 both competent ore and host rock .
 regular ore boundaries.
The development of the infrastructure
for both these stoping methods shown in the
figures above is time-consuming, costly and
complex.

Figure shows stoping a narrow vein mining

orebodies may be only half a meter wide

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Retreat
 Retreat mining is a term used to reference the final phase of an
underground mining technique known as room and pillar mining.
 This involves excavating a room or chamber while leaving behind
pillars of material for support.
 This excavation is carried out in a pattern advancing away from the
entrance of a mine.
 Once a deposit has been exhausted using this method, the pillars
that were left behind initially are removed (or 'pulled‘) retreating
back towards the mine's entrance.
 After the pillars are removed, the roof (or back) is allowed to collapse
behind the mining area.
 Pillar removal must occur in a very precise order in order to reduce
the risks to workers, due to the high stresses placed on the remaining
pillars by the abutment stresses of the caving ground.

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Stope and Retreat vs. Stope and Fill
1. Stope and retreat
Using this method, mining is planned to extract rock from the stopes
without filling the voids; this allows the wall rocks to cave in to the
extracted stope after all the ore has been removed. The stope is then
sealed to prevent access.

2. Stope and fill

Where large bulk ore bodies are to be mined at great depth, or
where leaving pillars of ore is uneconomical, the open stope is filled with
backfill, which can be a cement and rock mixture, a cement and sand
mixture or a cement and tailings mixture.
This method is popular as the refilled stopes provide support for
the adjacent stopes, allowing total extraction of economic resources.

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 Underground Mining Methods
 The mining method used will depend on the characteristics of the orebody, particularly thickness
and dip, and the competency of the surrounding rock.
 Different methods can be used in different parts of a mine (as this plan from the Black Swan nickel
mine exemplifies). This type of planning is done continuously as mining proceeds and more data
are acquired on the orebody configuration through underground drilling.
UNDERGROUND MINING METHODS
Soft rock mining Methods Hard rock mining Methods
a) Longwall mining. 1. Selective Mining Methods:-
b) Room-and-pillar mining (or continuous 1.1. Unsupported Mining Methods:
mining). a)Room (Bord) and Pillar mining (or
c) Blast mining. continuous mining).
d) Shortwall mining. b)Shrinkage stoping.
e) Coal Skimming. 1.2. Supported Mining Methods:
a) Cut and fill mining.
b) Square-set stoping
c) Stull mining.
2. Caving (or Bulk) Mining methods:
a) Longwall mining.
b) Sublevel caving stoping.
c) Block caving stoping.

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Note:-
Blast mining
 An older practice of coal mining that uses explosives such as dynamite to break up the coal
seam, after which the coal is gathered and loaded onto shuttle cars or conveyors for
removal to a central loading area.
 This process consists of a series of operations that begins with "cutting" the coal bed so it
will break easily when blasted with explosives.
 This type of mining accounts for less than 5% of total underground production in the U.S.
today.

Shortwall mining
 A coal mining method that accounts for less than 1% of deep coal production, shortwall
involves the use of a continuous mining machine with moveable roof supports, similar to
longwall.
 The continuous miner shears coal panels 150–200 feet wide and more than a half-mile
long, depending on other things like the strata of the Earth and the transverse waves.

Coal Skimming
While no longer in general use, because of the massive amount of water needed and
environmental damage thereof, in the late 1930s DuPont developed a method that was
much faster and less labour intensive than previous methods to separate the lighter coal
from the mining refuse (e.g. slate) called "coal skimming" or the "sink and float method".

29 November 2011 17
 Underground Mining Methods
 The mining method used will depend on the characteristics of the orebody, particularly thickness
and dip, and the competency of the surrounding rock.
 Different methods can be used in different parts of a mine (as this plan from the Black Swan nickel
mine exemplifies). This type of planning is done continuously as mining proceeds and more data
are acquired on the orebody configuration through underground drilling.
 Underground methods are usually classified in three categories of methods:

1. Selective Mining Methods:-

1.1. Unsupported Mining Methods:
a) Room (Bord) and Pillar mining (or
continuous mining).
b) Shrinkage stoping.  They are differentiated by the
1.2. Supported Mining Methods: type of wall and roof supports
a) Cut and fill mining. used, the configuration and size of
b) Square-set stoping production openings, and the
direction in which mining
c) Stull mining.
operations progress.
2. Caving (or Bulk) Mining methods:  The major distinction between
a) Longwall mining. the different underground mining
b) Sublevel caving stoping. methods is whether the mined
c) Block caving stoping. out areas remain supported after
mining, or if they are allowed to
29 November 2011 collapse. 18
1. Selective Mining Methods:-
i. Unsupported Mining Methods:
 Unsupported methods of mining are used to extract mineral deposits
that are roughly tabular (plus flat or steeply dipping) and are generally
associated with strong ore and surrounding rock.
 These methods are termed unsupported because they do not use any
artificial pillars to assist in the support of the openings.
 However, generous amounts of roof bolting and localized support
measures are often used.
a) Room (Bord) and Pillar mining.
b) Shrinkage Stoping.
 The Room-(Bord)- and –pillar mining methods account for almost all of the
underground mining in horizontal deposits in the United States and a very high
proportion of the underground tonnage as well.

29 November 2011 19
 i) Unsupported underground mining
a) Room (Bord)-and-Pillar mining (or continuous mining) method
 It is the most common unsupported method, designed and used primarily for mining flat-lying
seams or gently dipping bedded ore deposits of limited thickness (like coal, trona, limestone, and
salt).
 It is preferred to apply for sedimentary deposits (such as shales, limestone, dolomite or
sandstone) containing copper, lead, coal seams, phosphate layers, and evaporate (salt and
potash) layers.
 Room and pillar methods are well adapted to mechanization, and are used in tabular orebodies
such as coal, potash, phosphate, salt, oil shale, and bedded uranium ores.
 Pillars are left in place in a regular pattern while the rooms are mined out.
 Support of the roof is provided by natural pillars of the mineral that are left standing in a
systematic pattern.
 The mining cavity is supported (kept open) by the strength of remnants (pillars) of the orebody
that are left un-mined.
 Room-and-pillar mining method has a low recovery rate (a large percentage of ore remains in
place underground).
 In many room and pillar mines, the pillars are taken out starting at the farthest point from the
stope access, allowing the roof to collapse and fill in the stope. This allows for greater recovery as
less ore is left behind in pillars.
 It is an advantageous mining method for shallow orebodies –as a means of preventing surface
subsidence. Historic, ultra-shallow underground coal mines (<30 m) nevertheless are
characterized by surface subsidence in the areas between pillars (e.g., Witbank coal field, South
Africa).
 Pillars are sometimes mined on retreat from a working area, inducing closure and caving of these
29 November 2011 20
working panels, and raising the risk of surface subsidence.
 Room (Bord)-and-Pillar Layout

Figure shows Room and Pillar Mining

Note the control of ventilation,

i.e., the separation of
contaminated (used) and
uncontaminated (fresh) air
using a variety of devices.
Figure from Hartman and Mutmansky, 2002.

29 November 2011 21
Underground mining: room-and-pillar mining of thick seams –“benching”

Figure shows Room and Pillar is designed for mining flat, bedded
deposits of limited thickness.

Different approaches allow either the top or

bottom part of the seam to be mined out first.

Note: the “hangingwall” is above the mining

cavity, and the “footwall” is below it.

Figures from Hartman and Mutmansky, 2002.

29 November 2011 22
 b) Shrinkage Stoping
 It is a short hole mining method which is suitable for steeply dipping orebodies.
 Mining progresses upward, with horizontal slices of ore being blasted along the length
of the stope. A portion of the broken ore is allowed to accumulate in the stope to
provide a working plat form for the miners and is there after withdrawn from the stope
through chutes.
 The method is similar to cut and fill mining with the exception that after being blasted,
broken ore is left in the stope where it is used to support the surrounding rock and as a
platform from which to work.
 Only enough ore is removed from the stope to allow for drilling and blasting the next
slice.
 The stope is emptied when all of the ore has been blasted.
 Although it is very selective and allows for low dilution, since the most of the ore stays
in the stope until mining is completed there is a delayed return on capital
investments.[3]
 It is more suitable than sublevel stoping for stronger ore and weaker wall rock.
 Note: Sublevel stoping differs from shrinkage
stoping by providing sublevels from which vertical
slices are blasted. In this manner, the stope is mined
horizontally from one end to the other.

29 November 2011 23
 Unsupported Underground Mining Methods
Factor Room and Pillar Mining Shrinkage Stoping
Ore strength Weak \ Moderate Strong
Rock strength Moderate \ Strong Strong
Deposit shape Tabular Tabular \ lenticular
Deposit dip Low \ Flat Fairly steep
Deposit size Large \ Thin Thin \ Moderate.
Ore grade Moderate Moderate
Ore uniformity Uniform Uniform
Depth Shallow \ Moderate Moderate

29 November 2011 24
In “unsupported” mining, the mine-workings are supported temporarily
only for as long as needed to keep the active face open to mining.
After mining, the support (e.g. hydraulic props or wood packs) is
removed (or becomes crushed), and the mining cavities close up
under the pressure of the overburden material. The cavity closure is
either partial, for shallow mining, or complete, for deep level
mining.

While unsupported mining is advantageous in that it maximizes ore

recovery (as little ore as possible is left behind) the method comes
with significant problems:
Surface subsidence in the case of shallow mines.
Rockbursts underground, causing injury and death in deep level
mines.

29 November 2011 25
ii. Supported Mining Methods
Supported mining methods are often used in mines with weak rock structure.
a) Cut and fill mining method
 It is one of the more popular methods used for vein deposits and has recently grown in use.
 It is an expensive but selective mining method, with low ore loss and dilution.[3] (i.e., allows selective mining
and avoid mining of waste or low grade ore).
 It is a method of short hole mining used in steeply dipping or irregular ore zones and scattered
mineralization, in particular where the hangingwall limits the use of long hole methods.
 It requires working at face (which is less safe than longhole stoping).
 It is the most common of supported mining methods and is used:-
o in mining steeply dipping orebodies in stable rock masses (primarily in steeply dipping metal
deposits), strata with good to moderate stability, and comparatively high grade mineralization.
o Either fill option may be consolidated with concrete, or left unconsolidated.
o Bottom up mining method: Remove ore in horizontal slices, starting from a bottom undercut and
advancing upward (See Figure).
o Moderate production rates.
o Good resource usage.
o Not stress friendly.
 Ore is drilled, blasted and removed from stope.
 The ore is mined in slices: As each horizontal or slightly inclined slice is taken, the voids (Opens) are
backfilled with a variety of fill types to support the walls. (i.e., the fill can be rock waste, tailings, cemented
tailings, or other suitable materials)
{(note: The fill serves both to support the stope walls and provide a working platform for equipment
when the next slice is mined)}.

29 November 2011 26
 Ore is drilled, blasted and
removed from stope

Remove ore in horizontal slices, starting

from a bottom undercut and advancing
upward.

As each horizontal slice is taken, the

voids (Opens) are filled with a variety of Figure showing cut and fill mining method.
fill types to support the walls. (i.e., the fill
can be rock waste, tailings, cemented
tailings, or other suitable materials).

29 November 2011 27
  Because the method involves moving fill material as well as a significant amount of drilling and
blasting, it is relatively expensive and therefore is done only in high grade mineralization where
there is a need to be selective and avoid mining of waste or low grade ore.
 It is practiced both in the overhand (upward) and in the underhand (downward) directions.
i) Overhand (upward) cut and fill
o is applied to ore lies underneath the working area and the roof is backfill.
o involves a work area of cemented backfill while mining ore from the roof.
ii) Underhand (Downward) cut and fill ore
o is applied to ore lies beneath the working area and the roof is cemented backfill.
o ore overlies the working area and the machines work on backfill.

Note:
Drift and Fill is similar to cut and
fill, except it is used in ore zones which
are wider than the method of drifting will
allow to be mined. In this case the first
drift is developed in the ore, and is
backfilled using consolidated fill. The
second drift is driven adjacent to the first
drift. This carries on until the ore zone is
mined out to its full width, at which time
the second cut is started atop of the first
cut.

29 November 2011 28
 b) Square-set stoping
 The square-set stoping method is used where the ore is weak, and the walls are
not strong enough to support themselves.
 The value of the ore must be relatively high, for square-setting is slow, expensive,
and requires highly skilled miners and supervisors.
 In square-set stoping, one small block of ore is removed and replaced by a "set" or
cubic frame of timber which is immediately set into place.
 The timber sets interlock and are filled with broken waste rock or sand fill, for they
are not strong enough to support the stope walls.
 The waste rock or sand fill is usually added after one tier of sets, or stope cut, is
made.
 Square-set stoping also involves backfilling mine voids; however, it relies mainly on
timber sets to support the walls during mining.
 This mining method is rapidly disappearing in North America because of the high
cost of labor.
 However, it still finds occasional use in mining high-grade ores or in countries
where labor costs are low.

29 November 2011 29
 Figure shows Square-set stoping

29 November 2011 30
 c) Stull stoping

 is a supported mining method using timber or rock bolts in tabular, pitching ore
bodies.
 is one of the methods that can be applied to ore bodies that have dips between
10o and 45o.
 often utilizes artificial pillars of waste to support the roof.

Supported Mining Methods

Factor Cut and Fill Mining Square Set Stoping

Ore strength Moderate \ strong weak

Rock strength Weak weak
Deposit shape Tap \ irregular Any
Deposit dip Fairly steep Any
Deposit size Thin \ Moderate Usually small
Ore grade Fairly high High
Ore uniformity Variable Variable
Depth Moderate \ deep Deep

29 November 2011 31
2. Caving (or Bulk) Mining methods:

 Caving methods are varied and versatile and involve caving the ore and/or the
overlying rock.
 Subsidence of the surface normally occurs afterward.

29 November 2011 32
 a) Longwall stoping
• is a caving method particularly well adapted to relatively flat-lying, thin, planar deposits or horizontal seams,
usually coal, at some depth.
• is suitable for tabular orebodies, with moderate dip (e.g., coal and stratiform hard-rock ores like diamond
deposits).
• Need to divide orebody to "face" or the "working face“. The collection of cuts, cross-cuts, and pillars all together
make up a "panel" and all the equipment that goes together to operate in that panel is a "unit or Longwall units".
• In this method, a face of considerable length (a long face or wall) is maintained, and as the mining progresses, the
overlying strata are caved, thus promoting the breakage of the coal itself.
• Applied to longer (~100 m) and longer diameter blastholes (i.e., thus requiring less drilling than sublevel stoping).
• Greater drilling accuracy is required.
• Need to a longwall machine (It's designed to let the roof fall behind it, and mines out big rooms in which the roof
almost immediately collapses, leaving only a small entryway and the metal barrier that protects the longwall
unit).
• Traditionally high production rates. LONGWALL GENERAL LAYOUT
• Large openings with long open times.
Top Gate
• High ground support cost .
• Bottom up mining method. Longwall mining method
• Non-selective mining. includes drivage of two
• Not stress friendly. Face long roadways in coal
• Many equipment types. and joining them at the
end by a perpendicular
drivage forming a face.
Bottom Gate

29 November 2011 33
Figure shows "Slim-size" machines including drill rigs, jumbos, and 2 m3 bucket LHDs, are available
for working in drifts as narrow as 2 m.

29 November 2011 34
Longwall Mining

29 November 2011 35
SCHEMATIC OF LONGWALL PANEL
(HANGINGWALL STRIPPED AWAY FOR
ILLUSTRATIVE PURPOSES)

Protective screen

In hard-rock minerals mining a

“Permanent” support, often “scraper” is pulled down the length
timber packs, will remain in of the stope face after drilling and
place after mining. With blasting, to collect the fragmented
time, these become ore rock.
deformed or completely
In coal mining, a mechanized
crushed –as part of the Temporary support cutting device is run along the
“controlled” closure of the near the working face: length of the coal face.
panel. often hydraulic props.

29 November 2011 36
Figure from Hartman and Mutmansky, 2002.
Example: Longwall Mining of Coal
 Longwall mining is a highly mechanized underground mining system for mining coal.
 It set of longwall mining equipment consists of a coal shearer mounted on conveyor operating
underneath a series of self-advancing hydraulic roof supports.
 Almost the entire process can be automated.
 Longwall mining machines are typically 150-250 meters in width and 1.5 to 3 meters high.
 Longwall miners extract "panels" - rectangular blocks of coal as wide as the face the
equipment is installed in, and as long as several kilometers.
 A layer of coal is selected and blocked out into an area known as a panel (A typical panel
might be 3000 m long X 250 m wide).
 Passageways would be excavated along the length of the panel http://en.wikipedia.org/wiki/File:SL500_01.jpg
to provide access and to place
a conveying system to transport material out of the mine.
 Entry tunnels would be constructed from the passageways along the width of the panel.
 Extraction is an almost continuous operation involving the use of: self-advancing hydraulic
roof supports sometimes called shields, a shearing machine, and a conveyor which runs
parallel to the face being mined.
 Powerful mechanical coal cutters (Shearers) cut coal from the face, which falls onto an
armoured face conveyor for removal.
 The longwall system would mine between entry tunnels.
 Longwalls can advance into an area of coal, or more commonly, retreat back between
development tunnels (called "Gate roads")
 As a longwall miner retreats back along a panel, the roof behind the supports is allowed to
collapse in a planned and controlled manner.

29 November 2011 37
Longwall Mining Machine
http://upload.wikimedia.org/wikipedia/commons/thumb/
5/5d/Schildausbau.jpg/220px-Schildausbau.jpg

It's designed to let the roof fall behind it, and mines out
big rooms in which the roof almost immediately
collapses, leaving only a small entryway and the metal
barrier that protects the longwall unit.

Figure shows Hydraulic chocks

http://upload.wikimedia.org/wikipedia/commons/thumb/9/91/Longwall_wit
h_hydraulic_chocks%2C_conveyor_and_shearer.jpg/220px-
Longwall_with_hydraulic_chocks%2C_conveyor_and_shearer.jpg

29 NovemberFigure
2011 shows Hydraulic chocks, conveyor and shearer 38
 http://wikimedia.org/wikipedia/common
s/thumb/1/19/SL500_01.jpg/

Figure 12c:Longwall system in place.

Fig 12a: Passageway Figure 12b: A typical panel is 3000 m long by 250 m
wide
Mechanized cutting machineon a
longwall coal-mining face.

Figure shows another continuous miner in an underground coal mine.

29 November 2011 39
 Anatomy of a Coal Mine

Pennsylvania Department of Environmental Protection

Bureau of Deep Mine Safety

29 November 2011 40
 Coal Mine
Then And Now

http://en.wikipedia.org/wiki/File:SL500_01.jpg
Mechanized cutting machine on a longwall coal-mining face:
Pennsylvania Department of Environmental Protection SHEARER WORKING AT LONGWALL FACE.
Bureau of Deep Mine Safety

29 November 2011 41
 Deep level gold mining, South Africa

Stope face with temporary support

Stopes (yellow):
on-reef
excavations
where the reef
(orebody) is
mined.

http://www.bullion.org.za/MiningEducation/Images/images/
CrossSectMine.jpg

29 November 2011 42
 Work Face at South African Gold Mine

29 November 2011 43
 b) Sublevel Caving Stoping
 It is used to mine large orebodies with steep dip tabular or massive deposit and continuation at depth
(Fig.17).
 The ore is extracted via sublevels which are developed in the orebody at regular vertical spacing.
 Each sublevel has a systematic layout of parallel drifts, along or across the orebody.
 Sublevel stoping recovers the ore from open stopes separated by access drifts each connected to a ramp.
 The orebody is divided into sections about 100 m high and further divided laterally into alternating stopes
and pillars.
 A main haulage drive is created in the footwall at the bottom, with cut-outs for draw-points connected to
the stopes above. The bottom is V-shaped to funnel the blasted material into the draw-points.
 Longhole rigs drill the ore section above a drift. The ore in the stope is blasted, collected in the draw-
points, and hauled away.
 Blasting on each sublevel starts at the hangingwall and mining then proceeds toward the footwall.
 Blasting removes support for the hangingwall, which collapses into the drift.
 As mining progresses downward, each new level is caved into the mine openings, with the ore materials
being recovered while the rock remains behind.
 Loading continues until it is decided that waste dilution is too high Work then begins on a
nearby drift heading with a fresh cave.
 As mining removes rock without backfilling, the hangingwall keeps caving into the void. Continued mining
results in subsidence of the surface, causing sink holes to appear. Ultimately, the ground surface on top of
the orebody subsides (Fig.18).
 However, the stopes are normally backfilled with consolidated mill tailings after being mined out (This
allows for recovery of the pillars of unmined ore between the stopes, enabling a very high recovery of the
orebody).

29 November 2011 44
 Figure 7: Sublevel stoping Fig. : longhole stoping and removing ore after blasting

29 November 2011 45
 Figure shows sublevel caving is used to
mine large orebodies with steep dip and
continuation at depth.

Figure shows Continued mining results in

subsidence of the surface, causing sink holes
to appear.
Ultimately, the ground surface on top of the
orebody subsides.

29 November 2011 46
 c) Block Caving stoping
 Block-caving method is employed generally for steeply dipping ores, and thick sub-
horizontal seams of ore. The method has application, for example in sulphide
deposits and underground kimberlite (diamond) mining.
 It is most applicable to :-
o A large-scale or bulk mining method that is highly productive, low in
cost, and used primarily on massive steeply dipping orebodies that must
be mined underground.
o Weak or moderately strong orebodies that readily break up when caved.
o Large, deep (>two km deep), low-grade deposits with high friability
(Fig.19
 It is often done to continue mining after open pit mining becomes uneconomic or
impossible. However, some mines start as block cave operations (e.g., There are
several of these in Chile. Rio Tinto is considering a deep at the Resolution deposit to
the east of Phoenix).
 A grid of tunnels is driven under the orebody The rock mass is then
undercut by blasting.
 Ideally the rock will break under its own weight Broken ore is then taken
from draw points.
 There may be hundreds of draw points in a large block cave operation (Fig.20).

29 November 2011 47
  An undercut with haulage access is driven under the orebody, with "drawbells"
excavated between the top of the haulage level and the bottom of the undercut. The
drawbells serve as a place for caving rock to fall into.
 The orebody is drilled and blasted above the undercut, and the ore is removed via the
haulage access.
 Due to the friability of the orebody the ore above the first blast caves and falls into the
drawbells. As ore is removed from the drawbells the orebody caves in providing a
steady stream of ore[3].
 If caving stops and removal of ore from the drawbells continues, a large void may form,
resulting in the potential for a sudden and massive collapse and potentially catastrophic
windblast throughout the mine.[4]
 Where caving does continue, the ground surface may collapse into a surface depression
such as those at the Climax and Henderson molybdenum mines in Colorado. Such a
configuration is one of several to which miners apply the term "glory hole".
 Orebodies that do not cave readily are sometimes preconditioned by hydraulic
fracturing, blasting, or by a combination of both. Hydraulic fracturing has been applied
to preconditioning strong roof rock over coal longwall panels, and to inducing caving in
both coal and hard rock mines.
 Essentially block caving creates an underground 'inverted open pit'. Surface subsidence
can be a problem….???.

29 November 2011 48
Figure shows application of the
Block caving to large, deep, low-
grade deposits

Figure shows hundreds of draw

points to take broken ore in a
large block cave operation

29 November 2011 www.ivanhoe-mines.com/s/Mongolia_ImageGallery 49

Surface An undercut tunnel is driven under the orebody,
TOP OF OREBODY with "drawbells“ excavated above. Caving rock falls
into the drawbells. The orebody is drilled and
OREBODY
blasted above the undercut to initiate the “caving”
process. As ore is continuously removed from the
drawbells, the orebody continues to cave
spontaneously, providing a steady stream of ore. If
spontaneous caving stops, and removal of ore from
the drawbells continues, a large void may form,
resulting in the potential for a sudden and
massive collapse and a potentially catastrophic
Figure from Hartman and Mutmansky, 2002.
windblast throughout the mine (e.g., the
Northparks Mine disaster, Australia).

29 November 2011 50
Block-cave mining: Mud-rushes –an under-reported hazard
Mud-rushes are sudden inflows of mud from ore drawpoints (or other
underground openings), in block-cave mines that are open to the surface.
Considerable violence, in the form of an airblast, is often associated with
mud-rushes. Mud-rushes are (under-reported) hazardous occurrences that
have occurred frequently in mines in South Africa, as well as in Chile and
Western Australia, and have caused fatalities (Butcher et al., 2005).

Mud is produced by the breakdown

of rock in the near-surface
muckpile in the presence of
rainwater.

Kimberlite rock on diamond mines

is particularly susceptible to
weathering by rainwater.

SCHEMATIC CUT-AWAY VIEW OF SUB-LEVEL BLOCK-CAVE MINE

Figure from Hartman and Mutmansky, 2002.

29 November 2011 51
Effect of Mineral extraction upon displacement of country rock and surface
Workings and voids formed after extraction of mineral gets filled with time by the
caving rock so that the rock over the deposit may deformed and subside.

This phenomenon is called "Displacement of rock". Displacement causes smooth

subsidence of the earth's surface without ruptures, or abrupt subsidence with
considerable movements, caving and collapses.

The rock displacement zone include:- "a

caving zone" within which the displacement
is accompanied by the fault and destruction
of layers and the separation of lumps and
blocks from the solid;
"a cracking zone" which is an area of rock
discontinuity and cracks;
"a smooth-displacement zone" wherein rock
features plastics deformation without
discontinuities.

The earth's surface area which experienced

displacement is called a "trough".

Figure shows Effect of Mineral extraction upon displacement of country rock and
surface as well as rock displacement in mining.

29 November 2011 52
Example for Block Caving Production

Figure shows large fragments of ore are a problem because they cannot be easily transported?.
Usually they have to be broken up by secondary
blasting, which costs money and time.

29 November 2011 53
 Note: Both block caving and longwall mining are widely used because of
their high productivity.

Caving (or Bulk) Mining Methods

Factor Longwall stoping Block caving stoping
Ore strength Any Weak \ Moderate
Rock strength Weak \ Moderate Weak \ Moderate
Deposit shape Tabular Massive \ thick
Deposit dip Low \ flat Fairly steep
Deposit size Thin \wide Very thick
Ore grade Moderate Low
Ore uniformity Uniform Uniform
Depth Moderate \ deep Moderate

29 November 2011 54
Ore Removal
 In mines which use rubber tired equipment for coarse ore removal, the ore (or
"muck") is removed from the stope (referred to as "mucked out" or "bogged")
using center articulated vehicles (referred to as boggers or LHD [i.e., Load, Haul,
Dump]). These pieces of equipment may operate using diesel or electric engines
and resemble a low-profile front end loader.
 In shallower mines , the ore is then dumped into a truck to be hauled to the
surface.
 In deeper mines the ore is dumped down an ore pass (a vertical or near vertical
excavation) where it falls to a collection level. On the collection level, it may
receive primary crushing via jaw or cone crusher. The ore is then moved by
conveyor belts, trucks or occasionally trains to the shaft to be hoisted to the
surface in buckets or skips and emptied into bins beneath the surface headframe
for transport to the mill.
 In some cases the underground primary crusher feeds an inclined
conveyor belt which delivers ore via an incline shaft direct to the
surface. The ore is fed down ore passes, with mining equipment
accessing the ore body via a decline from surface.

29 November 2011 55
 UNIT OPERATIONS OF MINING
Ore extraction and underground development is achieved by precise drilling
and blasting techniques.
 Drilling a pattern of holes into the rock.
 Charging (filling) the holes with explosive.
 Blasting the rocks.
 Bogging (digging) it out.
 Ground support.
 Transporting it to the surface.
During the development and exploitation stages of mining when natural materials
are extracted from the earth, remarkably similar unit operations are normally employed.
The unit operations of mining are the basic steps used to produce mineral from
the deposit, and the auxiliary operations that are used to support them. The steps
contributing directly to mineral extraction are production operations, which constitute
the production cycle of operations.

The production cycle employs unit operations that are normally grouped into rock
breakage and materials handling. Breakage generally consists of drilling and blasting and
materials handling encompasses loading or excavation and haulage (horizontal transport)
and sometimes hoisting (vertical or inclined transport).

29 November 2011 56
The Mining Production Cycle includes the following steps:-
 Drill holes.
 Blast. Production Cycle =
 Mining machinery. Drill + Blast + Load + Haulage
 Load .
 Haulage.
 Repeat until orebody is depleted.

29 November 2011 57
 Mining Process used in Underground Mining methods

ROAD HEADERS
DrillingCONTINUOUS MINERS Coal drill
| |
Supporting
Blasting Permitted explosives
Ventilation
| |
Pumping
Loading Manual/ SDL/ LHD/Scraper
| |
Hauling Manual/ SDL/ LHD/Scraper
SDL/ LHD/Scraper
| |
Transporting Tubs, Conveyors, etc
| |
Processing/Washing Coal washeries

29 November 2011 58
 Reference
1. de la Vergne, Jack (2003). Hard Rock Miner's Handbook. Tempe/North Bay: McIntosh Engineering.
pp.2. ISBN 0-9687006-1-6.
2. Fowler, JCW; Hebblewhite, BK (2003).
"http://www.mining.unsw.edu.au/Publications/publications_staff/Paper_Fowler_AGCM_2003.pdf".
New South Wales.
http://www.mining.unsw.edu.au/Publications/publications_staff/Paper_Fowler_AGCM_2003.pdf
3. "TauTona, Anglo Gold, South Africa". 2009.
4. http://www.mining-technology.com/projects/ tautona_goldmine/
5. Howard Hartman and Jan Mutmansky, 2007. Introductory Mining Engineering, 2nd Edition. John
Wiley & Sons, Inc. 584p.
6. Lottermoser, B. (2007). Mine Wastes: Characterization, Treatment and Environmental Impacts,
2nd Edition. by Springer, Berlin Heidelberg.
7. Puhakka, Tulla (1997). Underground Drilling and Loading Handbook. Finland: Tamrock Corporation.
pp.153–170.
8. Puhakka, Tulla (1997). Underground Drilling and Loading Handbook. Finland: Tamrock Corporation.
pp. 98–130.
9. Spitz, K. and Trudinger,J. (2009). Mining and the Environment: From Ore to Metal. CRC Press,
Leiden.
10. Tatiya, R.R., 2005 Surface and underground excavations: methods, techniques & equipment. A.A.
Bakema, 579p.

29 November 2011 59