1. Senior Design Spring 2011 ©2011 Dr. B. C. Paul Acknowledgement is given to Companies whose design software is referenced by trademark name in this presentation.

2. Class Overview Does not have a specific lecture sequenceDoes not have a specific lecture sequence You will work on a comprehensive mine design project in teamsYou will work on a comprehensive mine design project in teams –Class time will be used for lectures related to topics needed –To group planning mediums –To work and design –To student presentations. Warning – this class is way more work than is implied by 3 credit hoursWarning – this class is way more work than is implied by 3 credit hours –My Rule 3 credits of Sr. Design = 12 credits of regular classes in terms of brute force work time.

3. Grading Criteria No Curve – Fixed Percentage GradingNo Curve – Fixed Percentage Grading –90% A –80% B –70% C –60% D –Less than 60% (you get to try again next year)

4. Break-Down 40% on meeting individual deadlines each week40% on meeting individual deadlines each week –Ie not waiting till the end is enforced 10% midterm project submission10% midterm project submission –5% of team quality –5% individual work 30% final project submission30% final project submission –20% of team quality –10% individual quality 20% final oral presentations20% final oral presentations –10% on team quality –10% on individual quality

5. Organizing Teams Teams will be groups of 2 to 4 individuals who will work on a common projectTeams will be groups of 2 to 4 individuals who will work on a common project Form has been distributed to let those who know what kind of project they want to submitForm has been distributed to let those who know what kind of project they want to submit –As requests come in we will organize teams –You can suggest interest in team members –Exercised if there may be a need to distribute expertise or experience –If operating problems are foreseen –If adjustments need to be made to balance teams

6. Software It is unlikely that you will be able to complete a project without design software.It is unlikely that you will be able to complete a project without design software. SIUC’s official package is MineSightSIUC’s official package is MineSight –Projects have starting files and data loaded into MineSight You are not obligated to use MineSightYou are not obligated to use MineSight –Moving data out of MineSight and into another package is your responsibility –You have to produce projects readable by the instructor –SIUC also has Carlson, but the instructor is not able to offer technical support for software features or problems. –If you choose another package figuring out how to make it available to your team is your responsibility

7. Projects Available Surface CoalSurface Coal Surface MetalSurface Metal Underground CoalUnderground Coal AggregateAggregate

8. Surface Coal Overview You have a large coal reserve in 3 seamsYou have a large coal reserve in 3 seams –You will be looking for a mine life in the 20 to 50 year range –You will be shipping raw coal –You will have constraints to maintain 10,500 BTU + and less than 10% ash Ie you will have to include blending in a scheduleIe you will have to include blending in a schedule –You begin with surface topography and drill holes and property status You will be located near Craig, ColoradoYou will be located near Craig, Colorado

9. Rough Outline of Work You Will Need to Do You will be marketing low to mid sulfur bituminous steam coal – find out what its worthYou will be marketing low to mid sulfur bituminous steam coal – find out what its worth Determine where you might sell the coal and how you would get it thereDetermine where you might sell the coal and how you would get it there –Estimate the cost of transporting the coal to the potential customer Build a model of your “ore deposit”Build a model of your “ore deposit” –Evaluate the reserves and estimate size and life of mine Determine what type of equipment and mining you will be doingDetermine what type of equipment and mining you will be doing –Estimate your sustainable stripping ratio –Re-evaluate your reserves

10. Surface Coal Project Continued Lay out a series of cuts by which you will mine out the depositLay out a series of cuts by which you will mine out the deposit Evaluate your cuts to make sure they meet the production quality constraints.Evaluate your cuts to make sure they meet the production quality constraints. Determine the amount and specific type of equipment you will use to mine the deposit and meet the capacity neededDetermine the amount and specific type of equipment you will use to mine the deposit and meet the capacity needed Draw in a detailed pit plan and drawings for 1 year of the mining operationDraw in a detailed pit plan and drawings for 1 year of the mining operation

11. Surface Coal Continued Evaluate the workforce needs and availability you will haveEvaluate the workforce needs and availability you will have Evaluate infrastructure that you will have to buildEvaluate infrastructure that you will have to build Lay out your economicsLay out your economics –Check the feasibility of your mine plan Prepare a Nice Written and Oral Report.Prepare a Nice Written and Oral Report.

12. Surface Metal Mine You will have a copper/moly porphyry deposit with about 20 to 40 years of reservesYou will have a copper/moly porphyry deposit with about 20 to 40 years of reserves You will assume a location near Ray, ArizonaYou will assume a location near Ray, Arizona You will have a mine and concentrator to planYou will have a mine and concentrator to plan –Smelting and refining will be offsite with shipping of concentrates to the smelter You will start with a surface and a collection of drill holesYou will start with a surface and a collection of drill holes

13. Approximate Things You Will Do Build a Block Model Ore ReserveBuild a Block Model Ore Reserve Estimate Copper and Moly PricesEstimate Copper and Moly Prices –Determine location of smelters and transportation plans and costs Estimate Operating CostsEstimate Operating Costs Make a Draft Open PitMake a Draft Open Pit –Check Reserves and mine life Make Stage PitsMake Stage Pits Pick Equipment – Design your millPick Equipment – Design your mill Use Strategic Planner to set up extraction sequenceUse Strategic Planner to set up extraction sequence

14. More Work Verify your mining costs with actual haulage and equipment selected.Verify your mining costs with actual haulage and equipment selected. Revise if neededRevise if needed Set up project economicsSet up project economics Produce Final Oral and Written ReportProduce Final Oral and Written Report

15. Underground Coal You have coal land, mineral rights, and options for up to 3 seams of coal - #6 steam coal, #5 lower sulfur coal, and #3 met coalYou have coal land, mineral rights, and options for up to 3 seams of coal - #6 steam coal, #5 lower sulfur coal, and #3 met coal Your location is presumed 10 miles north of McCleansboro, Ill.Your location is presumed 10 miles north of McCleansboro, Ill. Your mine will use a preparation plantYour mine will use a preparation plant –Some washability data is available. You will start with a property map –topo, and some drill holesYou will start with a property map –topo, and some drill holes –You will have to identify other drill hole locations –Identify – and justify the coal quality testing you will need. –Build your model and evaluate the need for additional drill holes

16. Work You’ll need to evaluate the market for coal pricesYou’ll need to evaluate the market for coal prices –You’ll need to see where you might market the coal and how much it will cost to get it there. –You’ll have to decide what parameters you need to analyze for in your coal for economic and design reasons. You’ll need to determine your mining methodYou’ll need to determine your mining method LayoutLayout SequenceSequence –Catch if your sequence bumps into geologic surprises you will be told and have to consider the cost of having to retrofit

17. Work You’ll design your coal prep facilitiesYou’ll design your coal prep facilities Set up equipment, ventilation, materials handlingSet up equipment, ventilation, materials handling You’ll have to explain you rock mechanics control plansYou’ll have to explain you rock mechanics control plans You’ll work out your economicsYou’ll work out your economics Complete Final Oral and Written Reports.Complete Final Oral and Written Reports.

18. Aggregate You will have an aggregate property and mineral rights on surrounding land in an area being engulfed by suburban sprawl around a Midwestern CityYou will have an aggregate property and mineral rights on surrounding land in an area being engulfed by suburban sprawl around a Midwestern City You will start with a model of your ore deposit, the surface, and ownership mapYou will start with a model of your ore deposit, the surface, and ownership map You have a large market for aggregate, significant markets of high calcium limestone for cement and scrubbers, available sales for brickmaking shale, and markets for underground warehousing, manufacturing, and waste disposal.You have a large market for aggregate, significant markets of high calcium limestone for cement and scrubbers, available sales for brickmaking shale, and markets for underground warehousing, manufacturing, and waste disposal.

19. Task List First Big Task is deciding what you will doFirst Big Task is deciding what you will do –Get Pricing for Aggregate Products You will have about 40 miles of trucking cost advantage over any competitionYou will have about 40 miles of trucking cost advantage over any competition –Evaluate post mining opportunities Underground warehousing 8 cents/ft2 per month with development cost of 50 cents per square footUnderground warehousing 8 cents/ft2 per month with development cost of 50 cents per square foot Underground Manufacturing Space 12 cents/ft2 with development cost of 80 cents per square footUnderground Manufacturing Space 12 cents/ft2 with development cost of 80 cents per square foot Underground Office Space 20 cents/ft2 with development cost of $2.50/ft2Underground Office Space 20 cents/ft2 with development cost of $2.50/ft2 Underground Mall 25 cents/ft2 with development of $1.75/fts but only about 60% actual shop space utilizationUnderground Mall 25 cents/ft2 with development of $1.75/fts but only about 60% actual shop space utilization –May be nice public relations stunt Underground Ash and Scrubber byproduct disposalUnderground Ash and Scrubber byproduct disposal –$7/ton but can only put above the water table –Can get cement quality ash free if you are making cement and concrete