Arch. Min. Sci., Vol. 53 (2008), No 2, p. 257–270

Arch. Min. Sci., Vol. 53 (2008), No 2, p. 257–270

Arch. Min. Sci., Vol. 53 (2008), No 2, p. 257–270
257
ZBIGNIEW KASZTELEWICZ*, MACIEJ ZAJĄCZKOWSKI*, ZBIGNIEW JAGODZIŃSKI**
TECHNOLOGY OF EXPOSING LIGNITE DEPOSIT WITH APPLICATION OF THE TEMPORARY DUMP
ON THE PRE-FIELD OF EXPLOITATION FRONT BASED ON EXAMPLE OF OPEN PIT “DRZEWCE”
IN KONIN LIGNITE MINE
TECHNOLOGIA UDOSTĘPNIENIA ZŁOŻA WĘGLA BRUNATNEGO Z ZASTOSOWANIEM ZWAŁOWISKA TYMCZASOWEGO NA PRZEDPOLU FRONTU EKSPLOATACYJNEGO NA PRZYKŁADZIE
ODKRYWKI „DRZEWCE” W KOPALNI WĘGLA BRUNATNEGO „KONIN” S.A.
Article presents a first example of adapting in Poland the new dumping technology from opening cut
which is located on a temporary dump on the pre-field of the exploitation front. There is also described
a technology of a further dump liquidation. Farthest part of the article shows possibilities of usage of
a brand new IT tools together with a description of foreground dump designing method.
Applying that described method allows to make number of analysis regarding to the most profitable
location of lignite deposit exposure as well as localization of dump on the pre-field. What’s more it also
allows to achieve the simulation of exploitation front progress. Using that exploitation design method
together with IT tools permits to make in short time several options of exposure and exploitation and
next allows to select the most suitable of analyzed scenarios concerning both economical issues and mine
extractive possibilities especially during the period of foreground dump liquidation.
Keywords: lignite mining, dumping, exploitation, dump on the pre-field of exploitation front, mining
IT tools, method of exposing lignite deposit
W artykule przedstawiono zastosowanie nowej technologii zwałowania nadkładu z wkopu udostępniającego na zwałowisku tymczasowym na przedpolu frontu eksploatacyjnego. Zastosowano ją po raz
pierwszy w Polsce w odkrywce „Drzewce” w wieloodkrywkowej Kopalni Węgla Brunatnego „Konin”
S.A. Opisano także technologię przyszłej likwidacji tego zwałowiska. W dalszej części artykułu zaprezentowano możliwości wykorzystania nowoczesnych narzędzi informatycznych wraz z opisem metody
projektowania zwałowiska na przedpolu frontu eksploatacyjnego.
Zastosowanie prezentowanej metody pozwala na dokonywanie szeregu analiz dotyczących najkorzystniejszego miejsca udostępnienia pokładu węgla, lokalizacji zwałowiska na przedpolu, a także dokonania
*
**
AGH UNIVERSITY OF SCIENCE AND TECHNOLOGY, DEPARTMENT OF OPENCAST MINING, AL. MICKIEWICZA 30,
30-059 KRAKOW, POLAND
KWK KONIN, KONIN LIGNITE MINE, 600-LECIA 9, 62-540 KLECZEW, POLAND
258
symulacji postępów frontów eksploatacyjnych. Wykorzystanie metody projektowania eksploatacji przy
użyciu opisanych narzędzi informatycznych pozwala na wykonanie w krótkim czasie kilku wariantów
udostępnienia i eksploatacji, a następnie wybór najkorzystniejszego z analizowanych wariantów pod
względem ekonomicznym oraz możliwości wydobywczych kopalni, szczególnie w okresie likwidacji
zwałowiska na przedpolu. Może ona być także stosowana zarówno przy eksploatacji węgla brunatnego
jak i innych kopalin.
Słowa kluczowe: górnictwo węgla brunatnego, zwałowanie, eksploatacja, zwałowisko na przedpolu
frontu eksploatacyjnego, górnicze programy komputerowe, metoda udostępnienia
złoża
1. Introduction
Open cast mining is always connected with deposit exposing necessity throughout
upper-lying overburden removal. Until the moment of changing into the internal dumps,
overburden is usually dumping out of both opening cut and future exploitation boarders
creating the external dump. Choosing the proper dump localization makes necessity for
accurate re-analyzing all possible site buildings together with economical and technical
cost-analysis of each option.
During exposing the lignite deposits, overburden from opening-cut can be localized
in three basic ways: very near to the opening-cut – creating the external dump, on the
pre-field of exploitation front and in the another open pit (Steinmetz & Eckard, 1994).
Overburden site localizations are presented at Figure 1.
a)
b)
c)
dump on the pre-field
of exploitation front
external dump
dump located in other
open pit
openning cut
openning cut
openning cut
residual pit
Fig. 1. Places of opening cut overburden localization; a) – external dump, b) – dump located
on the pre-field of exploitation front, c) – dump located in other open pit
Rys. 1. Miejsca lokalizacji nadkładu z wkopu udostępniającego; a) – zwałowisko zewnętrzne,
b) – zwałowisko na przedpolu frontu eksploatacyjnego, c) – zwałowisko w innym wyrobisku
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Solution that is mostly applied in open pit mines goes for external dump building.
In case of multi open pit mines, where distances between the pits stand for a few up to
several kilometers, overburden is located in already exploited residual pits. Those overburden dumping technologies are extensively described in literature (Wiśniewski, 1971;
Sulima Samujłło, 1977; Strzodka et al., 1983; Hartman et al., 1992; Tatiya, 2005).
However overburden dumping technology together with building temporary dump
on the pre-field of exploitation front so far have been used in ore-open cast mining
(Pжeьcкoг, 1971). But in this case discontinuous exploitation system is not in use and
amount of dumping overburden is incomparable smaller than amounts in lignite open pit
mining. In view of overburden amounts and overburden to lignite ratio at lignite mines
there is used a continuous exploitation system: BWE – belt conveyor – spreader.
Choosing different dumping technologies in view of dump localization there is a need
to compare benefits from given variants. Each of them consist of different technological
parameters e.g. dump volume, shape, time of changing into internal dumping, changes
in the way of mine dewatering, post-mining reclamation. External dump building makes
a necessity of cost bearing combined to grounds acquisition, paying charges and taxes
due to land use, as well as future reclamation cost. Cash flow structure in this option is
unfavorable in view of considerable cost sustaining (ground acquisition) at the moment
of deposit exposing which until the moment of exploitation account for “inter – period
cost billing” and there are accounted systematically during entire exploitation process.
After accomplishing the exploitation there is formed greater post-mining pit than in other
options, which reclamation and management costs that mining contractor has to pay.
In case of building temporary dump on the pre-field of exploitation front it is avoided
a necessary ground acquisition apart from those which future exploitation will be hold
as well as additional costs connected to external dump. Additionally, after accomplishing
the exploitation there is smaller residual pit thanks to use of overburden for decrease its
volume which causes less reclamation cost, land use cost and taxes paying time reduction. However, sometimes cost, connected to repeated exploitation of temporary dump,
can be much higher than benefits gathered form its application. In the third option of
dump localization, in the case of another post-mining pit existence, overburden can be
used for faster reclamation and management thanks to it, cost of its reclamation and
time of paying taxes decreases (Uberman, 1996). In this case there is no acquisition cost
(excepting lands where are transportation routes from one to another pit) as well as external dump reclamation. Also, there are no costs of repeated exploitation of temporary
dump. The greatest costs are costs of building the overburden transportation routes as
well as overburden transportation costs in much longer distance in case of external or
temporary dump (Zajączkowski, 2006).
Open pit „Drzewce” in Konin Lignite Mine is an example of application the innovative overburden dumping technology during the period of lignite deposit exposure,
which is based on building a temporary dump on the pre-field of exploitation front.
That temporary dump located on the foreground had been applied for the first time.
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After numerous technical and economical analyzes concerning the location and way of
exposing, as well as profitable analyze of building external dump, had decided that the
most optimal option would be building the dump on a foreground. That venture was
based on key factors such as lack of proper area around the mine that could have been
used as a place to storage to overburden. Another factor that determined building the
temporary dump on the foreground was the low bearing capacity of the ground intended
for that venture.
2. Construction of the temporary dump on the pre-field of exploitation front
On November 2005 had started exposing works at the one of three exploitation fields
–Bilczew field at open pit Drzewce. After analyzing the overburden to lignite ratio, as
the one of the primary criterion in construction of the exposing pit, there was chosen
west part of the Bliczew field with overburden to lignite ratio of about 4:1. During
preparation works, before construction of the opening cut on the foreground of the mine
there was exploited superficially lied sand lens which parameters consistent with the
PN-EN 13139:2003 standards. That sand was classified as proper material that could
be used in building industry and road works. Lens occurred in the overburden between
projected exploiting ramp and area of planned foreground dump. Volume of the sand lens
amounted to 850 000 cubic meters. Moreover, in order to leveling the area of the sand
storage yard which was to be located just next to the opening cut border, 450 000 cubic
meters of overburden located directly above the sand lens were exploited (Kasztelewicz
et al., 2006a).
Possessing sand, before initiating opening cut construction and putting it aside on the
storage yard outside southern border of the mine, allowed to decrease total amount of
overburden volume necessary for taking off 1.3 million cubic meters during the exposing and at the same time reduced the volume of foreground dump. Similarly there was
a decrease of the volume of overburden which was necessary for the second exploitation
during foreground dump liquidation.
While further project works it was stated that there was possibility to reduce size
of the opening cut through the correction of its shape and decrease of the overburden
as well, what caused dump volume reduction up to 4.45 mln cubic meter and took up
58.9 ha of the area surface (Figure 2).
Preliminary variants of foreground dump construction, timing when the sand lens
wasn’t taken into consideration for exploitation, considered projecting the volume of
the dump up to 7 mln cubic meters (Kasztelewicz et al., 2006b). Re-designing the shape
of the decreased dump body and possibility to perform correction of its height allowed
to increase velocity progress of the overburden front in order to lignite front during its
liquidation. Thereby occurred possibility of achieving better exploiting capability during
the period of dump liquidation. Due to those changes the liquidation technology was
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+98
A2 R s
B 500
+90
0M
+98
+98
+98
+98
sand lens
(capacity
1,32 mln m 3)
+98
+98
00
0
s9
40
hR
Rs
Sc
+90
+98
dump on the pre-field of
exploitation front
(area 58,9 ha,
capacity 4,45 mln m 3)
lign
ite c
onv
eyo
r be
lt
+106
e
+85
+85
rag
sto
nd rd
sa ya
+106
Fig. 2. Overburden dump located on the pre-field of the exploitation front in open pit Drzewce,
Bilczew field (status after finished exposing and switching to the internal dumping)
Rys. 2. Zwałowisko nadkładu na przedpolu frontu eksploatacyjnego w odkrywce „Drzewce” w polu
„Bilczew” (stan w momencie zakończenia udostępnienia i przejścia na zwałowanie wewnętrzne)
simplified by opportunity of exploiting overburden and lignite layers from the same
work level using one excavator. If the dump was higher, there would be necessity of
circular movement of the overburden excavator onto additional work flour designed at
the temporary dump and periodical disuse of exposing the lignite (exploiting successively
dump on the foreground and than exploiting 2nd overburden flour together with exposing
lignite deposit). During the first phase of the dump liquidation it was predicted work of
only one overburden excavator SchRs 900. That kind of situation could take place until
the time of bringing in another overburden excavator KWK 800M1 brought from the
nearby open pit Lubstów and establish second phase of the dump liquidation.
After applying next KWK 800M had increased possibility of exploiting overburden
and accelerated dump liquidation (Jagodziński et al., 2007).
3. Forming the temporary dump on the pre-field during exposing
SchRs 900 was exploiting 1st overburden flour 17 m height together with 5 m height
bottom substage. Rs 400 was assigned to lignite deposit exploitation. Overburden was
transported by conveyor draft to A2RsB 5000M located on the pre-field of the exposing
mine working. A2RsB 5000M had accomplished temporary dump construction on the
1
KWK 800M – BWE after modernization.
262
pre-field situated into exploitation borders of the 1st overburden flour (figure 3). After
finished forming the dump and reconstruction shame of conveyors (reversing the overburden transport direction) spreader began the internal dumping.
Fig. 3. Spreader during dump forming on the pre-field of open pit Drzewce
Rys. 3. Zwałowarka A2RsB 5000 M podczas formowania zwałowiska
na przedpolu odkrywki „Drzewce”
4. Dump liquidation located on the pre-field of exploitation front
As it was mentioned before, liquidation process was divided into to phases. Phase 1
liquidation of the part of dump and exploitation in use of one excavator SchRs 900.
Phase 2 applying excavator KWK 800M for liquidation the rest of the dump. Both
phases were realized after initiating internal dumping. During carrying out the 1st phase
of liquidation, planning temporary dump top located on ordinate +98 above mean sea
level allowed to exploit, using one overburden flour, both the overburden and the dump
situated at the foreground (figure 4).
A2RsB 5000M
SchRs 900
+98
Rs 400
Temporary dump
+85
Overburden flour
Lignite
+81
+76
Internal dump
Fig. 4. Technological shame of placing primary machines in open pit Drzewce,
Bliczew field (Phase 1 – foreground dump liquidation)
Rys. 4. Schemat technologiczny ustawienia maszyn podstawowych w odkrywce „Drzewce”
w polu „Bilczew” (pierwszy etap likwidacji zwałowiska na przedpolu)
+110
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Such construction and selection of the optimal exploitation flour height allowed to
use maximal excavator’s exploitation height and faster advance of the overburden front
regarding to lignite front as well.
In phase 2 of the dump liquidation there was brought in a second excavator KWK
800M which finished its work at open pit Lubstów 17 km from open pit Drzewce. In
view of possibility to use both excavators to overburden removal there was change of
exploitation flour layout in mine working. Technological shame of placing primary
machines during the 2nd phase is presented at figure 5 and 7.
A2RsB 5000M
+110
KWK 800M
+98
Temporary dump
Overburden flour
SchRs 900
Rs 400
+85
+76
Internal dump
Lignite
Fig. 5. Technological shame of placing primary machines in open pit Drzewce,
Bilczew field (Phase 2 – foreground dump liquidation after applying KWK 800M excavator)
Rys. 5. Schemat technologiczny ustawienia maszyn podstawowych w odkrywce „Drzewce” w polu
„Bilczew” (drugi etap likwidacji zwałowiska na przedpolu po wprowadzeniu koparki KWK 800 M)
After dividing into two exploitation flours SchRs 900 excavator began to exploit 2nd
overburden flour moving on the side of the lignite. At the same time KWK 800M excavator began the liquidation of the remaining part of the temporary dump (approximately
65% of its total volume) starting from ordinate related to surrounding area. Condition
of exploitation fronts as well as exploitation flours at the time of starting the phase 2 is
presented on figure 6. Regarding to heavy KWK 800M excavator’s unit pressure exploitation level was designed in order to exploit both temporary dump layer and layer
of undisturbed ground located under the dump with thickness of about 2÷2,5 m. Also,
due to necessity of draining rain waters, operating level was designed with acceptable
inclination in the range of +85 to +94 above mean sea level. That allowed safer work of
the excavator at the time of dump liquidation.
KWK 800M operating level location, which was above initial ground level, could
have caused that excavator would move on already heaped overburden used for creating
temporary dump of lower unit pressure durability than the ground not disturbed because
of the exploitation. It could have led to possibility of losing excavator’s stability especially at the time of bad weather conditions.
After liquidation of remaining part of temporary dump, KWK 800M will be used
for taking off overburden from reaming exploitation fields of open pit Drzewce, namely
at field A and B where the proportion of overburden to lignite is much higher than at
Bliczew field. Bringing in additional excavator at the period of dump liquidation will
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allowed to increase lignite extraction from initially planned level of 2,2 million Mg up
to 2,8 million Mg.
Fig. 6. Excavator KWK 800 during work at 1st exploitation flour after beginning Phase 2
Rys. 6. Koparka KWK 800 M podczas pracy na I piętrze eksploatacyjnym
po rozpoczęciu II etapu likwidacji zwałowiska na przedpolu
KWK 80
+98
0M
Rs 400
A2
Rs
B5
+110
SchRs 900
+90
00
dump
o
pre-fie n the
ld
exploita of +98
tion
front
0M
+98
+110
+90
lign
+108
ite c
onv
eyo
r be
lt
+108
+106
+85
+85
e
rag
sto
nd rd
sa ya
+106
Fig. 7. Dump located on the pre-field of exploitation front at open pit Drzewce, Bilczew field
(status at the time of brining in KWK 800M excavator)
Rys. 7. Zwałowisko na przedpolu frontu eksploatacyjnego w odkrywce „Drzewce” w polu „Bilczew”
(stan w momencie wprowadzenia koparki KWK 800M)
265
5. Method of designing the opening cut and temporary dump with use of IT tools
on the example of open pit Drzewce
During designing works concerning construction of opening cut and temporary dump
there were used brand new IT tools which were supporting the design of the mining
exploitation technology in the form of MICROSTATION® together with additional compatible softwares, such as MODELLER®, used for making digital 3D surfaces. Konin
Lignite Mine is successfully using this software for designing as well as for geological
and technological servicing at all its mines (Kasztelewicz at al., 2006c).
Bellow there is briefly presented the method of designing the opening cut as well as
the dump on the pre-field of the mine with usage of mentioned software (Jagodziński
et al., 2007).
Designing process was divided into two general phases:
1st Phase – creating necessary input data for excavation pit model design. It is based
on making digital models of both ceiling and bottom of lignite deposit with precedent
input to software data gathered from geological documentation (exploratory borehole
– X,Y,Z coordinates) and calculating total amount of resources in the lignite deposit.
Next step is to take geodesy measurement of the ground surface situated over the deposit.
Digital model of ground surface is being created as well. Hereinafter designing process
is based on projecting models of entire mine up to ceiling and bottom of the deposit
together with slopes what allows to estimate total volume of overburden from entire
excavation pit. After creating target excavation pit models it is possible to estimate total
amount of industrial lignite resources designed for exploitation during entire period of
projected mine existence.
2nd Phase – analysis of the most proper extraction pit location, foreground dump
layout and performance of the exploiting fronts progress simulation.
Analysis is based on:
− finding the most proper overburden to lignite ratio for both excavation pit and
temporary dump localization,
− defining the distance between temporary dump and excavation pit,
− performing simulation of exploiting front progress especially in the period of temporary dump liquidation and defining exploitation capability of designing mine as
well as timing of dump liquidation.
Designing method description.
After choosing the localization of excavation pit and temporary dump it is necessary to make digital model of excavation pit and estimate the volume of overburden
required for taking off during ramp profiling for primary machines. Next, after making
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the exploiting and overburden fronts progress simulation there is defined the exploitation fronts’ status during the moment of changing into internal dumping. On this stage
of designing process it is possible to calculate total volume of overburden required at
temporary dump.
Hereinafter it is necessary to build first model of temporary dump solid together
with defining its volume, area and height. Designing the solid of dump has to take into
consideration parameters of primary machines which will be intended for liquidation
the dump.
It is suggested (unless terrain conditions allow to do this) to design dump solid in the
way that during liquidation make as little as technological operations, e.g. moving belt
conveyors or primary machines onto additional operating levels constructed at temporary dump. Every kind of those operations cause limitation of taking off overburden at
a given period of time, and in the same way cause slowdown of the exploitation front
progress, what in consequence decrease quantity of exploited lignite during the time of
liquidation (Kasztelewicz, 2006a, 2006b).
After creating the first model of dump solid it is necessary to make simulation of
exploitation fronts progress at the time of dump liquidation. It would allow to verify
mine excavation abilities at this period with reference to required lignite excavation
quantities. If received results are unsatisfied, it is performed a change of excavation pit
shape or dump, and eventually even change of their localization. After accepting those
corrections it is necessary to make once again exploitation fronts simulation with defining excavation possibilities after already made correction.
This way of proceeding allows in short time to find the localization of excavation pit
or foreground dump with defining their shape which enable to receive maximal excavation ability and allow to minimize dump liquidation works.
Entire process with description of particular phases is presented on figure 8 and 9.
During proceeding with the simulation, it should be carried out until finishing exposing the pit. It gives an answer, whether in latter time of exploitation, right after
accomplishing exposing the deposit and after temporary dump liquidation, there would
be no excessive approach of lignite exploitation fronts to the bottom edge of the internal
dump (occurrence of lignite and heap front overlapping). Carrying out simulations of
the fronts’ progress in the pit gives an opportunity to demonstrate in what kind of fronts
condition those occurrences can happen and moreover it allows to re-design ordinates of
both excavators and spreaders operating levels in the way of avoiding those situations.
In case of appearing disturbances in operating fronts movement it is possible to control
the progress of the fronts due to changing the shape of the temporary dump, changing
the shape of internal dump.
Briefly presented designing process allows also to define the size of residual pit after
accomplished lignite exploitation together with defining volume and area of the future
reservoir what will allow to estimate the time of filling it up. These dimensions can directly
be used to estimate future costs in connection with reclamation of the residual pit.
267
Geological data from exploratory
boreholes
Geodesy measurement of terrain surface
in the area of the deposit
INTERGRAPH-MICROSTATION digital data input
Creating digital model of lignite deposit and terrain surface in the area
of the deposit using Modeller software
Digital model of the ceiling
deposit surface
Digital model of the bottom
deposit surface
Digital model of the deposit
thickness surface
Calculating deposit resources regarding to generated models
Designing borders of deposit exploitation and opening cut slopes taking into
consideration the requirements obtained from the different software calculations
Mine working shape modeling process up
to the ceiling of the deposit
Mine working shape modeling process up
to the bottom of the deposit
Defining the industrial resources in the mine working model, overburden total volume,
an average overburden to lignite ratio for the entire mine working
Required amounts of both exploited lignite and taken off overburden in each year
Defining mine machinery and dividing mine working into exploitation flours
Modeling process of each exploitation flour for overburden and lignite
Fig. 8. 1st Phase of designing – defining input data and creating general pit models
Rys. 8. Etap I projektowania – określenie danych wejściowych i tworzenie
modeli docelowych wyrobiska
Modeling the solid of dump and exposing pit according to already described method
allowed to significant decrease both the volume of exposing pit and temporary dump at
open pit Drzewce during exposing that lignite deposit.
268
Analysis of the factors related to opening cut localization and selection
of the exposing site together with usage of graphic software
(method of analyzing deposit sections)
Simulation of the both overburden and lignite fronts during the phase of the deposit
exposing – initial defining of the overburden assigned for pre-field dumping
Analysis of the factors related to temporary dump localization and defining the area
required for this dump
Designing the temporary dump solid – making the first computable model
Simulation of the overburden and lignite fronts progress during the temporary dump
liquidation and target exploitation – defining exploitation capabilities and status of
supplies both in the time of dump liquidation and in the further period of exploitation
until the time of accomplishing lignite excavation.
YES
Fulfilling the conditions
of exploitation capability
NO
Negative result = need to re-model dump
solid in the way of changing the shape
(height decrease and either area increase
or location change)
Positive result = accomplishing the
designing process
Dump solid modeling after applying
shape changes
Fig. 9. 2nd Phase of designing – modeling both excavation pit and foreground dump solid
Rys. 9. Etap II projektowania – modelowanie bryły wkopu udostępniającego
i zwałowiska na przedpolu
6. Summary
Designing and creating the exposure of the lignite deposit together with building dump
on the pre-field of exploitation front is an issue more complicated than exposing and
building a typical external dump. There is a lack of both experience and literature from
that kind of dumps. It requires number of calculations and simulations of the exploit-
269
ing fronts’ progress which include both period of exposing the deposits and foreground
liquidation until finishing the process of lignite excavation.
In every of designed and considerated options of exploitation there is a need to
check whether it would be preserved a safe distance between the edge of the lignite
deposit bottom and the edge of the internal dump during entire time of the exploitation.
Furthermore it is necessary to develop technology of dump liquidation and to optimize
the shape and volume of the temporary dump solid in order to minimize the limitation
of lignite exploitation.
In the example of open pit Drzewce, thanks to the proper design of the temporary
dump shape approximately 45% of its volume will be excavated by SchRs 900 wheel
excavator from only one operating level. The rest of the dump will be intended to excavate
by the second overburden wheel excavator KWK 800M, which had been transported
from the nearby open pit Lubstów.
Nowadays, thanks to adapting IT tools it is possible to make number of calculations
and simulations as well as precisely estimating lignite exploitation capabilities during periods of repeated excavation and overburden dumping which is localized on the
temporary dump.It allows to compare many options of the exploitation and select the
most suitable solution. Practical achievements as well as design and research analysis,
due to putting into the practice that kind of deposit exposing, can establish the basis for
designing and exposing further lignite mines and other open-cast mines as well.
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Received: 21 November 2007