Method of mining ore

Abstract

A method of open cut mining comprising carrying out mining operations in an area of an open cut mine with manned resources and unmanned resources and providing separate access for these resources to the mine area at selected locations. Alternatively, or in addition, the method comprises carrying out mining operations in the mine area with manned resources and unmanned resources operating in selected, separate unmanned and manned zones, respectively within the mine area.

Claims

1. A method of open cut mining an ore in a mine with manned resources and unmanned resources, the open cut mine including an area to be mined bounded by a perimeter, the area to be mined having separate unmanned and manned zones within the perimeter, the perimeter including a first manned resource access location including a roadway, the perimeter also including a separate second unmanned resource access location including a roadway, the method including: providing access to the unmanned zone for unmanned resources at the first unmanned resource access location in the perimeter, providing separate access to the manned zone for manned resources at the second manned resource access location in the perimeter, carrying out mining operations with manned resources and unmanned resources operating in the separate unmanned and manned zones within the perimeter, and changing the manned and unmanned zones as mining operations progress within the perimeter in response to requirements of the mining operations.

2. The method defined in claim 1, comprising carrying out mining operations within the perimeter with unmanned haulage trucks operating in the unmanned zones within the perimeter.

3. The method defined in claim 2, comprising providing identifiable access roadways for manned and unmanned haulage trucks within the perimeter.

4. The method defined in claim 1, comprising, after a new section of the perimeter is drilled and blasted or otherwise made ready for excavation, increasing the size of the unmanned zone that is proximate the new section to allow unmanned resources in the form of unmanned haulage trucks to move into the new section and be loaded with ore.

5. The method defined in claim 1, comprising carrying out different mining operations in different sections of the manned zone as mining operations progress within the perimeter.

6. The method defined in claim 1, comprising carrying out different mining operations in different sections of the unmanned zone as mining operations progress within the perimeter.

7. The method defined in claim 1, comprising precluding access of unmanned resources into the manned zone or precluding access of manned resources into the unmanned zone.

8. The method defined in 1, wherein the operations in the manned zone comprise any one or more of grading the zone, taking samples of ore in the zone for analysis, and drilling blast holes, charging explosives into the blast holes, and blasting at least a part of the zone to release ore for removal from the mine.

9. The method defined in claim 1, comprising providing at least three resource access locations for manned resources in the form of manned haulage trucks and unmanned resources in the form of unmanned haulage trucks.

10. The method defined in claim 1, comprising establishing new resource access locations to the perimeter as mining operations progress within the perimeter so as to maintain separation of unmanned and manned mining operations within the perimeter.

11. The method defined in defined in claim 1, comprising: changing the resource access locations in the perimeter as mining operations progress within the perimeter to allow access of manned and unmanned resources to new manned zones and unmanned zones, respectively, to allow efficient mining operations to continue within the perimeter.

12. The method defined in defined in claim 1, comprising changing the size of an unmanned zone for the haulage of ore out of the perimeter in response to changes in the location of loading of ore for haulage out of the perimeter.

13. The method defined in defined in claim 1, comprising changing the size of an unmanned zone for the haulage of ore out of the mine area perimeter and retaining the same resource access location or locations in the perimeter to the unmanned zone.

14. The method defined in defined in claim 1, comprising minimizing the amount of disruption to the unmanned resources within the unmanned zone for the haulage of ore during any adjustment in the zones in response to a change in location of loading of ore for haulage out of the mine by changing the amount of use of each resource access location by manned and unmanned resources.

15. The method defined in claim 1, comprising increasing the proportion of the unmanned zone as the mining operations progress within the perimeter until, ultimately, the whole of the perimeter has been mined and is substantially an unmanned zone within the perimeter.

16. The method defined in claim 1, comprising establishing new resource access locations in the perimeter as mining operations progress within the perimeter to allow access of manned resources and unmanned resources to new manned and unmanned zones, respectively, within the perimeter.

17. The method defined in claim 3, comprising retaining existing resource access locations in the mine area perimeter as mining operations progress within the perimeter and allowing access of manned resources and unmanned resources to new manned and unmanned zones, respectively, within the perimeter via the existing resource access locations.

18. The method defined in claim 1, comprising retaining existing resource access locations in the perimeter as mining operations progress within the perimeter and changing the function of the existing access locations so that an access location allows access of manned resources for one time period and access of unmanned resources at another time period.

Description

(1) The present invention is described further with reference to the accompanying drawings, of which:

(2) FIGS. 1 to 9 are a series of perspective views that show the steps involved in mining an area of an underground mine in one embodiment of a method of mining iron ore in accordance with the present invention.

(3) It is noted that the area to be mined may comprise the whole of a mine or a part of the mine. In the latter case, it can be appreciated that the mine may comprise a number of different areas that are mined using the same or different methods, as a consequence of the geology and other relevant mining factors.

(4) Each of the perspective views in the Figures is described in the context of mining iron ore by blasting blocks, for example a 60,000 tonne blocks, of iron ore from a bench, picking up the ore from a pit floor by manned earth moving equipment in the form of excavators such as electric rope shovels, diesel hydraulic excavators, or front end loaders, placing the ore into unmanned haulage equipment in the form of unmanned haulage trucks, and transporting the ore to downstream processing plants (not shown) to produce marketable products to customer specifications.

(5) In addition, each of the perspective views in the Figures is described in the context of using manned resources to carry out a range of mining operations in the mine area. The manned mining operations include grading a section of a bench of the mine area to be subsequently drilled and blasted, drilling blast holes, obtaining samples of ore from the blast holes for analysis, and charging the blast holes with explosives.

(6) In addition, each of the perspective views in the Figures is described in the context of a method of open cut mining that comprises carrying out mining operations in the mine with manned resources and unmanned resources by selectively dividing an area of the mine into (a) one or more than one zone for operation of unmanned resources to the exclusion of manned resources and operating the unmanned resources in that unmanned zone or zones and (b) one or more than one zone for operation of manned resources to the exclusion of unmanned resources and operating the manned resources in that manned zone or zones.

(7) In addition, each of the perspective views in the Figures is described in the context of providing separate access locations for unmanned resources and manned resources. The locations of the access locations are selected to maximise productivity of mining operations in the mine.

(8) With reference to FIG. 1, the area enclosed by the perimeter X is the area to be mined in an open cut mining operation. As described above, the mine area is an area that is to be mined using a combination of manned and unmanned resources.

(9) In this embodiment, the manned resources comprise equipment in the form of earth moving vehicles (in the form of front end loaders), dozers, graders, drill rigs, water trucks, hole charging, survey trucks, explosives trucks and the unmanned resources comprise equipment in the form of unmanned haulage trucks. The following description refers to manned resources as “manned vehicles” and unmanned resources as “unmanned vehicles” and, particularly as “unmanned haulage vehicles”. It is noted that focusing the description on “manned vehicles” and “unmanned haulage trucks” is for the purpose of simplifying the description. Equally, the present invention includes embodiments in which the manned equipment includes other types of excavators such as rope shovels and hydraulic excavators and is not limited to “vehicles” and the unmanned equipment includes any one or more of the equipment mentioned above as being manned equipment, such as drill rigs.

(10) In this embodiment, having regard to a series of factors, the mine operator decided that the area would be mined from the south west end of the area in an easterly direction, noting that north is identified by the arrow marked “North” in the Figures. As a consequence of this decision, in order to facilitate safe access of manned vehicles and unmanned vehicles to the mine area, the operator selected three access locations 3, 5, 6 in the perimeter X. The access location 3, which is in the south west end of the mine area, was selected to provide access for unmanned haulage vehicles only. The access locations 5, 6, which are approximately one third of the way along the respective south and north borders of the area, were selected to provide access to manned vehicles only. The selection was driven by the need to minimise the risk of collision of unmanned haulage vehicles and manned vehicles and to maximise mine productivity and to minimise operating costs.

(11) In addition to the above, having regard to a series of mining-related factors, the mine operator selected a zone 7, described as the “AHS Fleet Island” and the “Unmanned Area” in FIG. 1, that is immediately adjacent the access location 3 to be a zone for operation of the unmanned haulage vehicles. The remainder of the area was selected to be a zone 9 for operation of manned vehicles to the exclusion of unmanned haulage vehicles. This zone 9 is described as the “Manned Area” in FIG. 1. The common boundary of these zones 7, 9 is identified by the numerals 11, 13 in FIG. 1.

(12) The unmanned zone 7 is a region in which manually-operated front end loaders pick up and load blasted ore onto autonomously-operated haulage trucks that transport the ore from the mine via the access location 3. The unmanned zone 7 in FIG. 1 is typically formed as a drop cut. It is noted that, strictly speaking, the unmanned zone 7 is effectively two types of zones, with the first and more substantial type of zone being a zone in which the autonomously-operated haulage trucks operate and the other type of zone being a manned zone in which the manually-operated front end loaders operate. The two types of zones are described as an unmanned zone 7 in order to simplify the description.

(13) As work continues in the unmanned zone 7, one or more than one new section of the manned zone 9 is prepared for drilling and blasting. This work involves movement of equipment described above onto and from the unmanned zone 9 via the access locations 5, 6.

(14) With further reference to FIG. 1, the next section of the manned zone 9 to be blasted is a section that is immediately east of the unmanned zone 7 shown in the Figure. This section is identified by the cross-hatching in FIG. 1.

(15) With reference to FIG. 2, after blasting this new section becomes part of the unmanned zone 7 and is described as an “AFS Fleet Island” and identified generally by the numeral 13 in the Figure. This section has boundaries with the manned zone 9 that are identified by the numerals 15, 17. Front end loaders operate in the new “AFS Fleet Island” 13 and pick-up and load blasted ore onto autonomously-operated haulage trucks that transport the ore from the mined area via a roadway 19 and the access location 3.

(16) With further reference to FIG. 2, the next stage in the extension of mining operations in the mine area involves blasting the section of the manned zone 9 that is immediately south of the AFS Fleet Island 13 shown in the Figure. This section is identified by cross-hatching in FIG. 2.

(17) As a consequence, after blasting a new AFS Fleet Island 21 is formed, as shown in FIG. 3. In addition, a new access location 25, adjacent the access location 3, is constructed to allow access to the AFS Fleet Island 21. Front end loaders operate in the AFS Fleet Island 21 and pick-up and load blasted ore onto autonomously-operated haulage trucks that transport the ore from the mined area via the access location 25.

(18) The AFS Fleet Island 13 remains part of the overall unmanned zone 7 of the mined area and becomes what is described in FIG. 3 as an “Alternate AFS Fleet Island” 13. Autonomous mining operations, if required, continue in this zone as required, with access into and out of the zone via the access location 3. Typically, mining will be complete in this zone by this stage. Moreover, if required for subsequent mining operations, manned vehicle access to this zone is possible via the access location 3.

(19) The new AFS Fleet Island 21 and the Alternate AFS Fleet Island 13 have boundaries with the manned zone 9 that are identified by the numeral 15 in FIG. 3.

(20) With further reference to FIG. 3, the next stage in the extension of mining operations in the mine area involves blasting the section of the manned zone 9 that is immediately east of the Alternate AFS Fleet Island 13 shown in the Figure. This section is identified by cross-hatching in FIG. 3.

(21) As a consequence, with reference to FIG. 4, after blasting, a new AFS Fleet Island 31 is formed. In effect, this is an extension of the existing island 13. Access to the new AFS Fleet Island 31 is via the access location 3 and the roadway 19. Front end loaders operate in the AFS Fleet Island 31 and pick-up and load blasted ore onto autonomously-operated haulage trucks that transport the ore from the mined area via the access location 3.

(22) The previously-described AFS Fleet Island 21 remains part of the overall unmanned zone 7 of the mined area and becomes what is described in FIG. 4 as an “Alternate AFS Fleet Island” 21. Autonomous mining operations continue in this zone as required, with access into and out of the zone via the access location 25. Typically, mining will be complete in this zone by this stage. Moreover, if required for subsequent mining operations, manned vehicle access to this zone is possible via the access location 25.

(23) With further reference to FIG. 4, the next stage in the extension of mining operations in the mine area involves blasting the section of the manned zone 9 that is immediately east of each of the Alternate AFS Fleet Island 21 and the AFS Fleet Island 31 shown in the Figure. This section is identified by cross-hatching in FIG. 4.

(24) As a consequence, with reference to FIG. 5, a new AFS Fleet Island 31 is formed. In effect, this is an extension of the existing island. Access to the new AFS Fleet Island 31 continues to be via the access location 3 and the roadway 19 within the unmanned zone 7. Front end loaders operate in the AFS Fleet Island 31 and pick-up and load blasted ore onto autonomously-operated haulage trucks that transport the ore from the mined area via the access location 3.

(25) In addition to extending the AFS Fleet Island 31 shown in FIG. 4, this further mining operation also extends the Alternate AFS Fleet Island 21 shown in that Figure. Autonomous mining operations continue in this zone as required, with access into and out of the zone continuing to be via the access location 25. However, typically, mining will be complete in this zone by this stage. Moreover, if required for subsequent mining operations, manned vehicle access to this zone is possible via the access location 25.

(26) The expansion of the unmanned zone 7 makes it necessary to extend the access road at the access location 5. In particular, it is necessary to form a ramp 35 that allows vehicles to drive onto the manned zone 9.

(27) After autonomous mining in the new AFS Fleet Island 31 is completed, the autonomous mining fleet operating in this area is swung across to mine the new Alternate AFS Fleet Island 21. This switch in operations is shown in FIG. 6. Mined material is removed from this zone 21—which in effect becomes a new AFS Fleet Island—via the access location 25.

(28) With further reference to FIG. 6, the next stage in the extension of mining operations in the mine area involves blasting the section of the manned zone 9 that is immediately east of each of the Alternate AFS Fleet Island 31 and the AFS Fleet Island 21 shown in the Figure. This section is identified by cross-hatching in FIG. 6.

(29) As a consequence, with reference to FIG. 7, a new AFS Fleet Island 21 is formed. In effect, this is an extension of the existing island. Access to the new AFS Fleet Island 21 continues to be via the access location 25 and a roadway 37 within the unmanned zone 7. Front end loaders operate in the AFS Fleet Island 21 and pick-up and load blasted ore onto autonomously-operated haulage trucks that transport the ore from the mined area via the access location 25.

(30) In addition to extending the AFS Fleet Island 21 shown in FIG. 6, this mining operation also extends the Alternate AFS Fleet Island 31 shown in that Figure. Autonomous mining operations continue in this zone as required, with access into and out of the zone via the access location 6. Typically, mining will be complete in this zone by this stage. Moreover, if required for subsequent mining operations, manned vehicle access to this zone is possible via the access location 6.

(31) The expansion of the unmanned zone 7 makes it necessary to further extend the access road at the access location 5. In particular, it is necessary to construct a roadway 41 as an extension of the ramp 35.

(32) After autonomous mining in the new AFS Fleet Island 21 is completed, the autonomous mining fleet can be swung across to mine the Alternate AFS Fleet Island 31. This switch in operations is shown in FIG. 8. Mined material is removed from this zone 31—which in effect becomes a new AFS Fleet Island—via the access location 25.

(33) With further reference to FIG. 8, the next and final stage in the extension of mining operations in the mine area involves blasting the section of the manned zone 9 that is immediately east of the Alternate AFS Fleet Island 31 and the AFS Fleet Island 21 shown in the Figure. This section is identified by cross-hatching in FIG. 8.

(34) As a consequence, with reference to FIG. 9, a new AFS Fleet Island 31 is formed. In effect, this is an extension of the existing Alternate AFS Fleet Island 21 and the AFS Fleet Island 31. Access to the new AFS Fleet Island 31 is via the access location 25 and the roadway 37 within the unmanned zone 7. Front end loaders operate in the AFS Fleet Island 31 and pick-up and load blasted ore onto autonomously-operated haulage trucks that transport the ore from the mined area via the access location 25.

(35) The expansion of the unmanned zone 7 makes it necessary to further extend the access road at the access location 5. In particular, it is necessary to extend the roadway 41 on the manned zone 9.

(36) After autonomous mining in the new AFS Fleet Island 31 is completed, the part remaining of the manned zone 9 can be mined.

(37) The above sequence of stages that is illustrated in FIGS. 1 to 9 mines ore to one level in the mine area. The series of stages can be repeated to mine successive levels of ore from the mine area.

(38) Many modifications may be made to the embodiment of the present invention described above in relation to FIGS. 1 to 9 without departing from the spirit and scope of the invention.

(39) By way of example, whilst the above-described embodiment includes the use of haulage vehicles as unmanned vehicles, the present invention is not so limited and other mining equipment that is described above as being operated as manned vehicles may be remotely-controlled or operated autonomously. For example, the present invention extends to the use of unmanned resources such as earth moving vehicles as remote-controlled or autonomously operated excavators.

(40) In addition, whilst the above-described embodiment includes swinging the fleet of unmanned haulage vehicles between AFS Fleet Islands and Alternate AFS Fleet Islands shown in the Figure, the present invention is not so limited and extends to arrangements in which there are multiple fleets of unmanned haulage vehicles (or other unmanned resources) operating in multiple AFS Fleet Islands and Alternate AFS Fleet Islands.

(41) In addition, whilst the above-described embodiment includes the use of access locations for manned vehicles and separate access locations for unmanned haulage vehicles, the present invention is not so limited and extends to arrangements in which the same access locations are used for both types of vehicles and other forms of unmanned and manned resources. For example, an access location may be set up so that there are separate pathways for the different vehicles through the location. By way of further example, there may be timed access for vehicles through the location, in the sense that the unmanned haulage vehicles are able to move through an access location during one time period and manned vehicles are able to move through the access location at another time period.