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Introduction
As the rock pressure increases at the bottom of the block, the ore is
crushed while travelling downwards, to a fragmentation that allows
removal through draw points or any other type of arrangement.
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Applications
Developments
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4) Another set of finger raises is developed at the production
level.
5) A full undercut is made at the base of the block.
The number of these roadways and finger raises under the block
can be very high and all excavations are subject to high rock
pressures. Therefore cross-sections are kept to a minimum and
often heavy reinforcements with perhaps concrete are required.
Production
Once the undercut is completed the ore should start falling down
itself into the finger raises and continue to do so as the mineral is
removed at the haulage drift level.
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Mineral Transport
Conclusions
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b) Although there are numerous remedial actions available to the
mining operational engineer but still both fragmentation and
caving are operations that cannot always be predicted or
controlled. In other word, cavability, as a natural process, is
potentially unpredictable and uncontrollable. This may create
certain hazards that make the method risky. Unexpected hang-ups
of large boulders can cause serious problems that cannot be solved
easily, specially in the surrounding material that is already broken
or at least fractured. Recent developments in the application of the
method, such as new equipment and design practices, have
however decreased the level of these risks drastically.
Introduction
Areas of sufficient size are undercut so that the ore will cave
naturally. Drawing the ore from the bottom causes further caving
to occur, until all the ore in the block is broken into suitable sizes.
If applicable and when properly applied, block caving results in
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lowest cost per ton of extracted ore, than any other underground
method.
2) Panel caving- Divide the horizontal area into panels and then
ore is drawn from the bottom of the panels in a retreating
manner and so that the top of the ore in each panel is kept
inclined (diagonal).
3) Mass caving- The ore body is not divided at all. The whole
deposit is attacked at the same time. Developments are made
for all the reserve and when retreating, undercutting and
hence loading is carried out. The caved area therefore
proceeds upwards simultaneous with the undercut. Ore
removal is carried out in a way that an inclined plane is kept
at the top of the ore body (diagonal).
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Suitable Ore Bodies
a) Ore characteristics
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6) The overburden must be of a type that breaks and caves
when the underlying ore is removed. The weight of the
overburden on the ore is necessary to break it into
manageable pieces when travelling downwards.
7) The most favourable overburden is the one that breaks
into coarse pieces that resist attrition.
8) A soft overburden that breaks into fine particles is
undesirable since the waste rock particles can seriously
dilute the ore. Such fine particles can reach the draw
points before the larger size ore particles. This may be
enough reason to decide against the adoption of block
caving.
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is perhaps more irrelevant to block caving than any other
underground mining method. It is sometimes thought that the draw
points providing low- grade ore can be closed earlier. This is not
advisable since an important consideration in block caving the
progress of the cave upwards. This can only be achieved by
drawing ore from the bottom of the block.
c) Cavability
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Since initial caving of an ore body is almost always obtained by
the action of gravity on the planes of weakness, it is doubtful that
caving will occur without these planes of weakness unless the
material is as un-cohesive and runny as perhaps sand.
The more closely spaced the fractures, the more readily the ore will
cave. In the ideal ore body, all the fragments will break into small
enough pieces, to pass through the draw holes.
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As drawing the ore down continues, stress on the block increases
and attrition helps to give a better fragmentation.
If the ore body is massive and fairly suitable (soft), having a fairly
widely spaced fracture pattern, then mass caving should be
considered. In this type of work it may be necessary to undercut a
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large horizontal area before caving starts, hence a type of boundary
cut-off (pillar) is recommended.
Experience in similar ore bodies should help but the final plan in
such cases should be decided upon after experimenting in local
conditions.
Technical Matters
The mineral caves from the bottom and progresses upwards. For
different minerals there are different rates of caving which depends
on the structure of the mineral.
Arching
If the ore is drawn faster than it caves, a void may be created over
the caved material, which would create a dangerous situation. The
non-caved portion or a large part of it may suddenly drop into the
voids causing a destructive air blast through the openings.
These arches may also become stable if the rock has sufficient
strength, in which case caving below the arch produces voids and
above the arch, the ore compacts.
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In these cases it may be difficult to promote caving to restart. The
main way to do this is usually to enlarge the block perhaps on
both sides. It is not uncommon that a rectangular block enlarged on
one side does not cave for a long time.
Rate of draw
Ore caves by the virtue of its own weight and that of the
overburden, preferably to suitable sizes. If oversize pieces occur,
they must be blasted to go through the openings.
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Dilution control
The amount of ore loss and dilution are again the most important
determinants of the application of the method. There is really no
reliable solution to the problem of predicting the end result. Values
in other mines are good indicative.
Height of blocks
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- Characteristics of the ore and the capping.
But, on the other hand, when the cross section area is large, the
speed with which the ore lowers in the caved area is low and hence
undesirable. The cost of roadway maintenance is also an important
factor here.
The more finely the ore breaks, the closer the draw points should
be. However, draw points are also used to gain access to the
undercut to blast any large blocks. Therefore their number should
be sufficient. Spacing perhaps should not exceed 15mx15m.
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Weight problems
Developments
Also, if the ore is relatively hard and the ground is generally hard,
then less number of draw points is required. If the ore is expected
to break into small pieces, then draw points should be more closely
spaced. This will necessitate more roadways, which will lead to a
higher initial investment level.
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Undercut level- The undercut level is directly and with some
distance above the production level.
As the blasted ore is removed and dumped into the draw points, the
ore above starts to fall by the action of gravity.
But eventually it becomes larger than this area and the surface
within the plains of some 45 degrees in all four sides of the block
is mostly affected. No permanent structures or shafts should be
within this area.
Block weakening
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Block weakening essentially consists of either: increasing the
magnitude of the forces in the block by enlarging the block cross
sectional area or directing the forces available due to the weight of
the overlaying strata to the volume inside the block.
These stopes can extend horizontally in two directions i.e each one
stope covers two sides of the block.
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If LHDs are used, they should be 4 or 6 m^3 capacity, although
they are not used very often at all. On the haulage level, high
capacity trains should be used, perhaps 9 tons mine cars and 20-30
mine car trains. Loading onto these mine cars should be multiple
points or if possible continuous.
General Considerations
With year 2000 prices, for development costs, the value of $5-$8
per ton of ore recovered is typical. It is very sensitive to the height
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of the block. The total operating costs (production costs) can be
$10-$14 per ton.
Advantages include:
1) Mining is inexpensive compared to other methods, since little
drilling and blasting and small amount of development cost
per ton of ore extracted is involved. It is the only method in
which cost per ton of mined ore can easily be compared to
that of surface mining.
Disadvantages include:
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1) Development costs are higher than any other method before
production starts. Block caving, especially the mass caving
system, has requires the highest possible amount of initial
investment amongst all underground mining methods, in the
form of drivage and support installation of many long
roadways. This amount of initial capital may net always be
available.
2) Maintaining the drifts in the draw area can be costly and can
interfere with production. Maintenance of grizzly and
transport roadways may also be difficult and expensive.
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the method, which is by far the most important advantage of
block caving.
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