UNIVERSITY OF MORATUWA

Faculty of Engineering

DESIGN REPORT
MODULE ER4122: DESIGN PROJECT

DASSANAYAKE D.M.S.M. (100855B)

PUSHPAKUMARA K.B.N. (100850F)

SAMPATH R.P.S. (100836T)

PRABHANGA U.B. (100830U)

Department of Earth Resources Engineering

Date of Submission 02-12-2014

 Design Project 2015

PREFACE
The major goal of designing a mine utilizing the optimum strategies is the gaining of economic
stability when the hour of need arrives. No mine in the known world can be designed for 100%
safety and overwhelming profits. Where there is a mine there is a threat for the people who are
working in there, there is a threat of major economic draw backs and there is a threat for the
natural habitat and the environment.

The ultimate objective of a mining engineer or the group of design engineers is the minimization
of threats and weaknesses and maximization of the strengths and opportunities, the desired mine
will be facing in the future, past and most importantly in the present. This is the purpose of this
whole design project. This particular design of the mine is the ultimate design we came up as a
group for our final year design project.

In the first chapter, an introduction is given regarding the location of the mine and the available
details for the designing. In this context, the method which we used to determine the dip and strike
of the ore body and the three dimensional visualization of the area geology are presented briefly.

In the second chapter exploration program is discussed. Under that, the exploration done using
the diamond drilling program and the selection of the locations for drilling are discussed. We
strictly followed the continuity of the report, at the same time answering the desired questions
which were attached with the initial design project materials.

In the third chapter, the mining method and the operational and strategic utilization of the
engineering knowledge in designing the mine are expressed. The design regarding the
underground mineral transport system is also elaborated with general details.

Final chapter is allocated for the costing and economical evaluation of the mine. With the
available information we could build up a systematic approach to justify the accountability of the
whole design project.

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Table of Contents
PREFACE .......................................................................................................................................................... 2
1. CHAPTER I ................................................................................................................................................ 6
1.1 Introduction ..................................................................................................................................... 6
1.2 Calculating the strike and dip of the veins ...................................................................................... 7
1.3 Surface distribution of the veins ............................................................................................................ 8
1.3 Exploration ...................................................................................................................................... 9
2.1.1 Diamond Drilling Programme ........................................................................................................ 9
2.1.2 Developing access roads...............................................................................................................14
1.4 Mine opening.................................................................................................................................16
2. CHAPTER III ............................................................................................................................................18
3.1 Addit ....................................................................................................................................................18
3.1.2 Drilling pattern of the Addit .............................................................................................................18
3.2 Blind Shaft...........................................................................................................................................20
3.2.3 The auxiliary shaft of the mine .....................................................................................................21
3.2.4 Blind shaft & auxiliary shaft sinking .............................................................................................22
3.3 Shaft lining ...........................................................................................................................................24
3.5 Mining method ....................................................................................................................................28
3.5.1 Overhand cut and fill method .......................................................................................................28
3.6 Mine Layout ........................................................................................................................................31
3.7 Underground transportation system ....................................................................................................32
3.8 The conveyor belt system ....................................................................................................................34
3.8 Ventilation methods ............................................................................................................................36
3.8.1 Stope ventilation methods ............................................................................................................36
3.9 All the costing has attached to appendixes

3. REFERENCES ..........................................................................................................................................38

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List of figures
Figure 1.1 The contour map of the area .................................................................................................................. 6
Figure 1.2 The projected strike lines of the veins ................................................................................................... 7
Figure 1.3 The graphical representation of the dip and strike ................................................................................. 7
Figure 1.4 The expected surface distribution of the veins ....................................................................................... 8
Figure 1.5 The 3D visualization of the vein ............................................................................................................ 8
Figure 2.1 The hypothetical pattern of the exposed point distribution .................................................................. 10
Figure 2.2 The horizontal depth to 500 m depth of the ore ................................................................................... 10
Figure 2.3 The 3D visualization of Drilling lines from the drilling point ............................................................. 11
Figure 2.4 The drilling locations ........................................................................................................................... 12
Figure 2.5 The map of the access roads ................................................................................................................ 14
Figure 2.6 Adit opening......................................................................................................................................... 16
Figure 3.1 The proposed addit with its dimensions ............................................................................................... 18
Figure 3.2 Drilling pattern and the blasting sequence of the addit ........................................................................ 19
Figure 3.3 The location of the blind shaft ............................................................................................................. 20
Figure 3.4 Blind Shaft features and dimensions .................................................................................................... 21
Figure 3.5 Auxiliary shaft Dimensions ................................................................................................................. 22
Figure 3.6 Main shaft & Auxiliary shaft blasting pattern ..................................................................................... 23
Figure 3.7 The winch and the steel structure ......................................................................................................... 24
Figure 3.8 The cross cut with dimensions ............................................................................................................. 25
Figure 3.9 The blasting pattern of the cross cut .................................................................................................... 27
Figure 3.10 The ore blocks created to be mined ................................................................................................... 28
Figure 3.11 The layout of the mine with cross cuts, winzes and shafts ................................................................ 29
Figure 3.12 The extraction procedure ................................................................................................................... 30
Figure 3.13 3D view of the mine lay out ............................................................................................................... 31
Figure 3.14 The dimensions of the rail cross section ............................................................................................ 32
Figure 3.15 The mine car with dimensions ........................................................................................................... 33
Figure 3.16 The deflection of the pulley ............................................................................................................... 34
Figure 3.17 Pulley width ....................................................................................... Error! Bookmark not defined.

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List of tables
Table 1-1 The Dip and Strike of the veins .............................................................................................................. 8
Table 2-1 Distances to the drilling position .......................................................................................................... 11
Table 2-2 The drilling length from the drilling locations ...................................................................................... 13
Table 3-1 The location of the blind shaft .............................................................................................................. 20
Table 3-2 Factor of safety for the rails .................................................................................................................. 33
Table 3-3 Pulley width recommendations ............................................................................................................. 35

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1. CHAPTER I

1.1 Introduction
This report is comprised of the mine design done by the group members of the final year design
project group. The mine described here is a hypothetical mine. According to the given information
the area geology suggests a steeply dipping graphite mineralization. The contour map including
the mineralization of the area was given. The contour map is shown in figure 1.1

Figure 1.1 The contour map of the area

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1.2 Calculating the strike and dip of the veins

Figure 1.2 The projected strike lines of the veins

The contour interval was given as 70m. Therefore we can generate the lines of strike of different
levels as shown in figure 1.4.

𝜭 ≈ 59o

Figure 1.3 The graphical representation of the dip and strike

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Vein Dip Strike

C 59o 9o 29’ 24’’
D 63o 181o 51’

Table 1-1 The Dip and Strike of the veins

1.3 Surface distribution of the veins

Surface distribution pattern of the veins considering the vein thickness as 40cm and the marked
points are in the center of the vein.

Figure 1.4 The expected surface distribution of the veins

Figure 1.5 The 3D visualization of the vein

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CHAPTER II

1.3 Exploration

2.1.1 Diamond Drilling Programme

The need of the diamond drilling arises when the sub surface distribution of the ore body has to be
identified. It deviates from the earlier exploration methods as it allows the removal of solid
cylinders of rock or often what referred to as “core” from deep within the earth. The materials
present in the desired depth levels are visually inspected and later detailed investigations are run
on them to identify what actually exists in the given depths.

There are basically two ways in which the diamond drilling programme can be conducted.

1. Inclined core drilling

 The main advantage in this method is that the drilling machine can be kept at one
location. The drilling can be done at various directions. Since the angle of drilling
increases the length between the drilling position and the desired ore body identified,
the drilling length is usually high. It, the inclined core drilling method, has to be
selected with great caution. When the estimated mobility cost of the drill machine is
higher than the estimated drilling cost, application of this method is cheaper.

2. Vertical core drilling

 The drilling can be done in various locations but the only condition is that the drilling
should be done vertically penetrating the subsurface strata. The drilling length is always
the vertical length and no any alteration regarding the length can be achieved other than
changing the drilling location. When the estimated mobility cost of the drill machine is
higher than the estimated drilling cost, application of this method is costlier.

In this particular design-exploration programme, the depth at which the exploration ends is
defined as 500m. Since the area geology is asked to be assumed closer to the one that in Bogala
area (i.e. rock type; Metamorphic garnet biotite gneiss), with the dip of the mountain (higher cost
for mobilization and stabilization of the drilling machine), the best way to do the diamond drilling
is inclined core drilling.

The requirement of the diamond drilling program in this context is to explore the underlying
geology. Therefore out of the two methods of rotary drilling and wireline drilling, wireline
drilling method is chosen. In wireline drilling method, it allows the inner tube of the core barrel
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to be raised to the surface and empty the barrel to be pumped back into place without removing
the drill string or diamond tools from the hole. Because of that there are long distances to be
drilled this method is more suited.

Figure 1.6 The hypothetical pattern of the exposed point distribution

Let the distance between two parallel lines going parallel to the strike is “X”, the number of times
which “X” has to be multiplied in order to find a location on the surface which meets the vein at
500 m depth on the line going perpendicular to the strike is “c”. The dip angle is “𝜭”.

cxX
𝜭
c x X tan𝜭 = 500 m

500m

Figure 1.7 The horizontal depth to 500 m

depth of the ore

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Inclined ore body

Angled drill holes

Figure 1.8 The 3D visualization of Drilling lines from the

drilling point

The distances are calculated to the point where the ore body will be lying 500 m below.

X 𝜭 c Horizontal Distance
to the Location
Vein C 36 m Vein C 59o Vein C ≈8 Vein C 288 m
Vein D 41.99 m Vein D 63o Vein D ≈6 Vein D 249 m
Table 1-2 Distances to the drilling position

But based on the above calculations the drilling points will be located way beyond the perimeter
of the given map. Assuming the map is the only reference we can have and there may be other
constructions beyond the perimeter another method has to be developed.

Let’s find the point located at equal distances to the exposed vein-c points on the plane of the ore
body.

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Figure 1.9 The drilling locations

The drilling locations are selected so that the distances from the drilling point to the respective
exposed points are equal. An exception had to be made for the c-vein exposed points due to the
presence of the river. There, drilling point and two exposed points are selected to measure the
distance in each two cases avoiding the buffer zone of the river. That is the reason for the presence
of two C-drill points named, C-drill point1 and C-drill point.

AQ (Hole diameter: 48mm) (refer appendix i) drill bit is selected to be used for the drilling
since, drilling lengths exceeding 1000 m can be achieved by it with minimum failures. Its core
diameter is less and the torque needed to rotate the bit is less and fuel consumption is also less
than other types. The drilling rig that fits the requirements is the “hechang-HQY-500” drilling
rig (refer appendix ii).

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Surface drill point location Drilling details

Bearing angle to the Drilling length
horizontal
axis
D-drill point 1 Directly 90o 150 m
downwards
048o 65o 200 m
131o 65o 200 m
C-drill point 1 Directly 90o 150 m
downwards
284o 600 200 m
206o 80o 200 m
C-drill point 2 Directly 90o 150 m
downwards
325o 65o 150 m
o o
260 60 150 m
Table 1-3 The drilling length from the drilling locations

Apart from the initial exploration programme, continuous exploration programmes have to be
conducted while the mine is under operation. The following figure shows the expected locations
and drilling patterns when each level of the mine is under operation.

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2.1.2 Developing access roads

Based on the given area map, two access roads are developed as branches of the main roads
specified in the map. R1 road will be the access road for the vein D addit entrance and R2 will be
the access road for the vein C addit entrance.

In the second stage when the mine is under operation, principle level roads are driven to the
deposit. These roads are rail tracks for the ore transportation purposes. Since the lower levels are
to be accessed, a blind shaft is sunk from the addit and the lower level rail tracks are connected to
this blind shaft. This is the case for both the addits. Hence there are two blind shafts. These two
will be eventually connected to all the cross cuts and auxiliary shaft.

Figure 1.10 The map of the access roads

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2.1.3 Ore grade calculation

When the exploration drilling is over, the shape and the distribution of the ore body can be
visualized. But that doesn’t give a clear indication whether the initiation of the mining project is
economically feasible. To find out whether mining is profitable more detailed survey has to be
conducted. The drill core samples can be analysed to find the ore grade. Using statistical methods
the total ore grade of the mine as well as the areas where higher grade deposits present can be
mapped out. If the cut-off grade value is low the parts of the mine where the grade is low can be
mined out quickly, if the cut-off grade is higher some parts of the mine will have to be abandoned.

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1.4 Mine opening

The two veins are located directly opposite to each other. With the river flowing on top of the vein
c it would be difficult as well as costly to use addits to open the ore body. Therefore a better
option would be sinking a shaft at the center of gravity of the two main veins in order to extract
the maximum out of them.

But the circumstance is such that the shaft has to be sunk on the top of the mountain. But that
would require a huge investment. Since the extraction of the ore will not be possible until the
drives are also developed, sinking a main shaft at the beginning would not be a good strategy.

Therefore using one addit to enter into the ore body from the opposite side of the river while an
auxiliary shaft is being sunk from the top of the mountain would be more economically viable
since the revenues will be generated at the initial stage also with the production from the driven
addit. The location of the addit is selected opposite to the river to avoid possible costly operations
such as pumping water from the addit that is being excavated. The first move is merely for
covering up as much as possible for the expenses incurred during the initial mine development
operations.

Figure 1.11 Adit opening

It is expected that the auxiliary shaft will be finished up to the depth of the second level of the
vein D, when the first few levels of the vein D are extracted. Then level by level the vein D can be
extracted using cut and fill method.

When adequate revenues are generated, the extraction can be started from the vein C using the
second addit. The advancing of the addit will open up the first level of the vein C. with that being
developed a cross cut is also developed to meet the auxiliary shaft. So the whole mine lay out
comes in to operation with time.
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When the mine becomes enlarged with the connection of the cross cut from the vein C to the
auxiliary shaft, natural ventilation will not be adequate enough. Therefore an exhaust fan has to be
implanted on the auxiliary shaft.

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2. CHAPTER III

3.1 Addit
The mine is expected to be operated at the beginning using addits. The major reason behind that is
the economic factor. The locations of the ore bodies are such that the safety also will be high if the
initial opening was developed as an addit.

Figure 2.1 The proposed addit with its dimensions

3.1.2 Drilling pattern of the Addit

In this particular blasting pattern, a burn cut at the centre is used to create the space for the burden
of rocks to fall into. The specified blasting sequence helps the fragmented material to pile
systematically without disturbing the flow of the blast. Closer spacing of the drill holes in the
bottom emphasizes the fact that the load is predominant in the bottom part compared to the upper
part of the perimeter.

The following information are assumed in this design.

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 Addit area = 4.6 m2

 Bit size of the drilling machine =38 mm
 Advance of the shaft per round = 1m
 Number of holes per round = 53
 Powder factor for the blast = 2.7kg /m3

Dimension in ft

Cut Hole (64mm)

Drill hole (38mm)

Figure 2.2 Drilling pattern and the blasting sequence of the addit

 Romanic Numbers – half second delay

 Arabic numbers – m second delay

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3.2 Blind Shaft

The entry to the mine is achieved thorough an addit. Therefore to extract the underlying ore body
in the subsurface of the mountain, a blind shaft has to be developed. This shaft is the main
development shaft used to connect the cross cuts which are connected to the ore body from the
other end. Since the shaft is not visible to the outside this is called a blind shaft. To hoist the
materials being extracted from the underground there is a winch located at the top.

Addit

Blind Shaft

Figure 2.3 The location of the blind shaft

The location of the shaft is selected considering two reasons.

1. The closeness of the shaft opening to the river (i.e. the buffer zone of the river)
2. The distances at the subsurface level to the two ore bodies from the shaft (this should be as
minimum as possible fulfilling the condition 1)

Considering all these conditions the most favorable area boundary for the shaft sinking was
identified and the location of the shaft can be given as follows.

location (380, 630)

Elevation (assumed from M.S.L.) ≈ 480 to 500 m
Slope ≈ 27o
Table 2-1 The location of the blind shaft

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3.2.2 Blind shaft Dimensions & Features

Although this is a blind shaft this may well be acting as a primary shaft in this design as the
mining operations progress. This is the main transport passage into the underground from the
main addit entrance. The 2x7 ft rectangle cross sectional area indicated in the below figure acts as
the passageway for facilitating electricity, compressed air and other necessary supplies which are
continuously needed when the mine is in operation. The skip is used to hoist material as well as
men working underground. To hoist this cage the winch specified earlier is used with wire ropes.

Services facilitating area Blind shaft

Guide vain
Skip or Cage

Dimension in ft
Figure 2.4 Blind Shaft features and dimensions

3.2.3 The auxiliary shaft of the mine

The need of an auxiliary shaft occurs mainly due to two factors.

1. For the emergency exit purposes as a secondary entry path

2. For effective ventilation across the mine.

The dimensioning of the auxiliary shaft is given in the below figure. The shaft is sunk with the
rectangular shape neglecting the resistance created by the shapefactor to the ventilating air flow
considering the fact that the natural ventilation caused by it is high. Since the top most point of the
shaft is located towards the top of the mountain, there exists a natural stream flow development
through the main addit entry towards the upper opening of the auxiliary shaft due the differences
in wind speeds in the respective hights. Thus the natural ventilation is pretty high and the

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ventillation by fans will be only needed after the first levels of the workings have advanced to a
significant distance .

Dimension in ft

Figure 2.5 Auxiliary shaft Dimensions

3.2.4 Blind shaft & auxiliary shaft sinking

The whole operation can be emphasized as the following sequence of points.

• Preparation for blasting (Cleaning and marking of the blast face)

• Drilling

• Charging and Blasting

• Washing & scaling

• Mucking

• Supporting

This is a cyclic process. Once the sequence has reached to supporting stage again another blasting has to be
undertaken. It is evident that the presence of the river will cause the water table to rise. When the water
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table is closer to the surface, dewatering process becomes a need. Not only that the blasting agents and the
explosives also must be selected based on their ability to withstand wet conditions. Therefore water
resistant explosives should be used.

The following information are assumed in this design.

 Shaft area = 5.2m2

 Bit size of the drilling machine =38 mm
 Advance of the shaft per round = 1m
 Number of holes per round = 60
 Powder factor for the blast = 3.1 kg /m3

Dimension in ft

 Romanic Numbers – half second delay

 Arabic numbers – m second delay

Figure 2.6 Main shaft & Auxiliary shaft blasting pattern

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Due to the presence of the river the water table might well be very close to the surface of the area.
Therefore the mine shaft conditions are ought to be wet. It is important to use gelatineous water-
resistant explosives. After drilling the holes must be blown out with compressed air. The premier
cartridge must be inserted first into the hole, the detonator pointing to the main charge. The final
trimmer holes should be drilled with a slightly smaller burden and loaded relatively lightly.

3.3 Shaft lining

Since the area geology is to be assumed that of a strong self-supporting type we can use concrete
lining for the shaft. There is no seepage assumed because the shaft sinking location was selected
avoiding the buffer zone of the river. The shaft collar is developed to the bed rock and at the shaft
location it is assumed to be reaching the bed rock at a depth of 30 m. therefore the length of the
drill collar is considered as 30 m and the thickness of the concrete wall of the collar is set in three
different phases.

 For the first 15 m from the surface the thickness of the shaft collar is set as 1 m
 For the next 10 m it is set as 0.7 m.
 From 25 m to 30 m the thickness is set as 0.5 m.
The winch is located at the same level where the top of the blind shaft lies, on top of the drill
collar, using a steel structure as shown in the figure below. A very accurate survey has to be done
to position the winch.

Figure 2.7 The winch and the steel structure

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3.4 Cross cut

In this particular design the cross cuts are designed to be arched shape and are to be driven with a dip of
0.005 towards the mouth. No extensive timbering is to be use. The cross cuts are designed to be of the
shortest length from the main addits to the ore bodies, so that the cost would be minimum.

The cross cuts are the developments used to reach the working areas of the mine. Therefore the
ventilation and the electricity supplies have to be transported through these. As shown in the
figure below the ventilation duct and the electricity lines are placed on to the left top corner of the
cross cut cross section. There should be a spacing in between those and the mine cars as well as
the men who are travelling in the cross cut. That is the reason why spacing is provided as shown
in the figure.

Ventilation
Cross cut

Electrical Line
Ore Transportation

Dimension in ft

Figure 2.8 The cross cut with dimensions

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The following figure exhibits the drilling pattern as well as the blasting sequence at the same time.
To come to the conclusion regarding the number of drill holes and the advance of the shaft per
one cycle of the process a small calculation has been done as follows.

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 Cross cut area = 4.1m2

 Bit size of the drilling machine =38 mm
 Advance of the shaft per round = 1m
 Number of holes per round = 37
 Powder factor for the blast = 2.5 kg /m3

9 9
8

6 6 6

7 vi vi vi 7

iv iv
ii

0
ii 0
ii
4 Iv 4
iv 0
0
4 ii 4
iv Iv

5 3 3 3 5

Dimension in ft

Cut Hole (64 mm)

Drill Hole (32 mm)

Figure 2.9 The blasting pattern of the cross cut

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3.5 Mining method

3.5.1 Overhand cut and fill method

Overhand cut and fill mining is a highly selective open-stope mining method considered ideal for
steeply dipping high grade deposits found in weak host rock. Many variations of the general cut
and fill technique exist. Overhand cut and fill evolved from square set stull stoping to provide
stronger support. In this method, mining begins at the bottom of the ore body or block and
progresses upward.

During the mining sequence, the back of the excavation is to be temporarily supported using rock
bolts before the stope is back filled to form the floor of the next level of development. Backfill is
designed to provide mild excavation support as well as to provide a strong working floor for
personnel and equipment. Backfill selection is dependent on the quality of the host rock and the
size of equipment operating on top of the backfill.

Figure 2.10 The ore blocks created to be mined

In this particular design the height difference between the two levels is set to be about 40m. This
undercut will form the transport drift from which ore will be removed by rail cars. The winzes
were sunk from top level to bottom level in order to connect drives vertically. As we proceeds
upwards, first one or two benches are to be kept vacant and the backfilling from the next bench is
started. The reason for doing this is that we need that space to construct the haulage way and to
install machinery, such as winches, pumps, etc.

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Ore body
Addit
Drift

Winzes

Cross Cut

Auxiliary shaft

Figure 2.11 The layout of the mine with cross cuts, winzes and shafts

Advantages and Disadvantages of this Mining Method

Advantages

• High selectivity and low dilution ma achieved

• Minimal development is required; low capital cost

• Versatile for mining method; can follow irregular ore bodies

• Flexible; mining method can be easily modified

• Low equipment investment relative to other methods

• Minimizes ground movement

Disadvantages

• Cyclical ore production

• Labour and skill intensive

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• Dangerous working conditions; work conducted on a top of freshly blasted rock

• High degree of ground control required

• Expensive and costly ventilation system

• Need for backfill infrastructure (piping and paste plant)

• Not suitable for low grade ore due to high mining cost

The extraction operation is done in the traditional way, i.e. drilling and blasting. The drift is to be
developed along the vein. The figure below illustrates the blasting sequence and the pattern.

Figure 2.12 The extraction procedure

The portion of the vein in a given cross sectional area is to be initially drilled, charged and
blasted. After that “mucking” has to be taken place. When that is finished the remaining portion of
the drift’s cross section is drilled, charged and blasted to trim the edges in order to retain the shape
of the drift. After the execution of the whole operation of drilling, charging and blasting a total of
a 1 m advance is expected. At maximum of a two days’ duration the whole cycle is expected to be
finished. Hence the rate of advancement of a drift is 1 m per two days.

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3.6 Mine Layout

The below figure shows the whole layout of the mine discussed so far. The two blind shafts
connect to the auxiliary shaft through cross cuts. The auxiliary shaft is located at a position where
the optimum use of the natural ventilation flow can be utilized and the distances to the ore bodies
are minimized. Winzes and the drives are going along the ore body in different directions.

Figure 2.13 3D view of the mine lay out

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3.7 Underground transportation system

In this particular mine, rail tracks and locomotives are used as the underground transportation
system. The length of rails used in mines varies from 3 m to 7 m. The size chosen at a
particular mine often depends on the limitations imposed by the shaft and
transport arrangements. The aim should be to select the longest length of rail,
which reduces the number of joints needed when it is installed. This will also result
in a reduction in supply and maintenance costs. In this mine 7 m long rails are to be used.

The minimum weight of rail recommended for any new installation

underground in mines is 17.36 kg/m (35 lb/yd). Based on the expected production at the initial
stages of the mine these minimum weighted rails are to be used.

Figure 2.14 The dimensions of the rail cross section

In this particular design of the mine, the use of locomotives is omitted since the cut and fill mining
operation for such a narrow vein might not incur such a need.

The next most important part of the rail track is the use of sleepers. Sleeper spacing is the distance
between the centres of adjacent sleepers.
The following sleeper spacings have proven acceptable in practice and should not be exceeded

o locomotive track – 840 mm;

o man riding rope-haulage track – 840 mm;
o non-man riding rope-haulage track – 1000 mmsince this design is for non-
manriding rope-haulage track, the spacing should be taken as 1000 mm.

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Mass of rail Maximum axle Distance between Factor of

(kg/m) load (tonnes) sleepers (mm) Safety
30.54 7.5 840 4.1
24.8 7.5 840 3.1
17.36 4 1000 2.5
Table 2-2 Factor of safety for the rails

The factor of safety for 17.36 kg/m rail is relatively low, and the maximum axle
loading of 4 tonnes is considered to be an abnormal load, which is carried only infrequently,
and not the regularly carried load. Fixed mine cars are used in this transport system. Their gauge
width is approximately 2 feet.

Considering the requirements MGC 1.7-6 mine cars can be recommended as more suitable for the
mineral transport operation (appendix iii).

Figure 2.15 The mine car with dimensions

The broken ore is directly transported to the mineral processing plant located at the point
specified. When the processing plant is to be located lot of factors have to be considered. The
accessibility of the location is the major point in a project like this which is situated in a hilly
terrain. Considering that and also the distance to be travelled from both the main addits, a location
for the processing plant is identified.

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3.8 The conveyor belt system

The ore has to be transported from the mine to the processing plant. In this design, there is a
conveyor belt system between the mine and the processing plant. This enables the continuous
operation of the mine. The guidelines for the design of the conveyor system are as follows.

Power system

Standardized three-phase squirrel-cage motors with star-delta start are preferable. The starting is
usually smooth. The belt speed is often controlled through an electronic frequency inverter.

Driving pulley

Here cylindrical conical shape driving pulleys are used since they will also produce a self-centring
effect on the running behavior of the belt. Clean, oil- and grease-free steel pulleys with a smooth,
almost polished surface (corresponding to a roughness Ra = 1.6 μm) are in most cases sufficient to
ensure slip-free power transmission.

Pulley design

Since, conical cylindrical pulleys are used in the design, the following condition for the
admissible deflection y caused by the tension can be emphasized.

For Cylindrical-conical pulleys:

y ≤ (0.001 · d) + 0.07 *mm+

Figure 2.16 The deflection of the pulley

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Pulley width

Pulleys and rollers should be wide enough so that the belt would make full contact with them over
its entire width, even when it is not positioned on the exact centre of the pulley.

Figure 3.17 Pulley width

Belt width bo Pulley width b

bo ≤ 100 mm b = bo + 20 mm
bo > 100 mm b = (1.08 ∙ bo) +
12 mm
Table 2-3 Pulley width recommendations

Multiple rollers are expected to be fixed on the path of the conveyor belt.

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3.8 Ventilation methods

3.8.1 Stope ventilation methods

The objective of any ventilation system is stage. First, the primary ventilation must course air
through the main airways to the immediate working area out by the working faces, thus making
fresh air available for face ventilation, and then return the contaminated air through return
(exhaust) airways to the surface. Second, the face ventilation system must be designed to
effectively utilize the available air in the immediate working area to sweep the working face, to
capture and remove dust, and to dilute and carry away gas, if any, emitted during mining
activities.

Without a properly designed ventilation system, an efficient production cycle would not be
possible. The system should provide the required air volumes and quality at reasonable pressure
losses, perform with minimum interference and cost to production, and do so in the most cost-
effective way possible. Furthermore, the primary ventilation system may be well designed, but if
the available air brought to the working area is not properly utilized for ventilating the faces
where most workers are located, the total system has failed.

Stope Ventilation

Separate ventilation shaft(in this design the auxiliary shaft) is used to the mine layout to throw the
air out from mine. Air is sucked from the mine main shaft down to lower level and air circulate
through all the working areas and used unclean air goes up through the winzes developed at the
ore body into ventilation shaft. Two or three Centrifugal fans can be installed on the surface at the
entrances of the two addits. Because of the fact that if one fan fails a specific amount of the total
air volume can be provide from rest. It is possible for the fan to be located directly on the top of
the auxiliary shaft. But usually air is turn through the right angle at the shaft collar and reach the
fan through an inlet drift and set of self-closing door. For Specification for centrifugal fan refer
appendix iii.

All stopes are ventilated by the fresh air flowing up from the lower level of the stope. There are
two raises constructed at each end of the stope. Air enters the raises at the bottom level and flows
up the raise and then enters the stope and exits through the other raise, depending on the pressure
difference. When stopes are mined out, the raises are closed, thus the movement of airflow was
affected. Similarly, when new raises are constructed for stoping, airflow is also affected.
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Therefore, there is a need to continuously monitor the movement of air especially in the stope
where miners are working. This study is conducted to assess the movement of air in the stope.

A mine ventilation booster fan is a primary fan that is in series with another primary fan. Without
the booster fan operaton, the total mine airflow will fall significantly. Booster fans are typically
installed as mine develops and primary fan no longer has the pressure or flow capability to service
increased resistance of operation. In this sense, booster fan operates as an integral and “symbiotic”
unit with original primary fan to provide sufficient total airflow for mine.

Air output

Air input

Figure 2.16 Stop ventilation plan

Mine booster fans are technically main fans which are installed underground to maintain required
airflow by overcoming the mine resistance. Booster mine ventilation fans can reduce pressure of
main fan and decrease system leakage and total required air power.

A mines booster fan is an underground ventilation device installed in the main airstream (intake or
return) to handle quantity of air circulated by one or more working districts. It is installed to
operate in series with a main fan and boost air pressure of ventilation air passing through it.
Specifications for the booster fans are given in appendix iv.

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3. REFERENCES
 http://www.slideshare.net/hzharraz/lecture-1-9998430
o Accessed on 24-11-2014
 Evaluation of Overhand Cut and Fill Mining Method used in Bogala Graphite Mines,
SriLanka; P G R Dharmaratne, P V A Hemalal and M C Hettiwatte
o Accessed on 22-11-2014

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