Terminal Report

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MINE AND MILL PRACTICE
CHAPTER 1 INTRODUCTION 1.1 Location and Accessibility Philex Mining Corporations mine site is situated at the southern tip of the Central Cordilleras, spanning the municipalities of Tuba and Itogon, Benguet. It is about 17 inflight kilometers south-southeast of Baguio City, and sets at a distance from the ground of 1500 meters above sea level. Access from Baguio City is by means of a 32 kilometer company-maintained provincial well-
paved road, with a travel time of one hour. The total land area applied for MPSA is 14,256.00 hectares. Area covered by Mining Claims (prior to MPSA) is 4,085.00 hectares and area with Mining Lease Contract is 432.85 hectares. Developed areas affected by operations, which and Ore include body the area, areas,
The location of Philex Mining Corporation in the Baguio Mineral District.
Subsidence Tailings
ponds,
Residential
School and Recreation and Industrial areas, covers a total area of 580.00 hectares.
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1.2 Physiography and Climate The locale is very rugged, where the mine site lies at an elevation of 1,500 meters above sea level and depicted by steep and gentle slopes varying in different parts. The climate is cool and bracing with the rains coming mostly between the rainy seasons of June and October. Occasional typhoons occur in the area annually with 500mm average rainfall. Several tributaries of Agno River (Albian Creek), Bued River and Toboy River were drain to the eastern, western, and southern area respectively. Vegetation is mostly pine trees and secondary undergrowth. 1.3 Brief History of the Mine Philex Mining Corporation was incorporated in July 1955 with the Sto. Tomas II deposit in the Province of
Benguet as one of its valued and treasured began properties. Philex
immediate
exploration
activities in the area and by the end of 1956, an initial reserve of 18 million metric tons of 0.90%
copper and 0.977 grams gold per ton was blocked after drilling
Open Pit Mining (March 59)
2,703 meters (9000 ft) of diamond drill holes and driving 463 meters (1,520 ft of cross cuts and drifts).
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MINE AND MILL PRACTICE Development of the mine by open pit and later by underground and construction of mill facilities at 2,000 tons per day ensued. Development works started in 1957; the concentrator commenced in 1958 with an initial tonnage of 800 metric tons per day at 0.795 Cu and 1.030g Au/t.
Block Caving - Slusher System (1963-1996)
The mine was operated for the first two years by small open pit and shifted ever since to block caving method using slushier system and gradually gearing for full LHD operation by 1999. Production started in the middle of 1958 with a small tonnage of 800 tons per day. Today, after more than 50 years of operation, the mill has a rated capacity of 26,000 TPD.
Block Caving - LHD System (1996-Present)
By 1960, mining shifted to block caving using slusher system in extracting the ore and mine cars pulled by locomotives in hauling the ore to the mill. In 1994, the company modernized its mining method by the use of hydraulic jumbo drills and minimatic drills in
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the development phase and slusher winches for production due to the massive characteristics of the ore body. Philex Mining Corporation has been continuously adhered to stringent rules and regulations promulgated by the government. Even before the late President Ferdinand Marcos enacted the Anti-Pollution Law in the late 60s, the company already started the construction of its tailings pond in 1967. Two additional tailings dams were constructed subsequently as operation progressed. In addition to this, the company embarked on reforestation program even before the First Lady get on her program Man and Biosphere Project. The initial reforestation project was spearheaded by the wife of the former Vice-President as one of her community projects. Areas planted were the watershed areas surrounding the Philex Camp and Operation. Its employees and residents in different reforestation areas within the mine site and neighboring areas have already revegetated thousands of hectares. Vegetative erosion controls such as watt ling structures are being done along Philex-Kias road. The company has well established socio-economic programs that cater not only to the needs of the employees and their dependents but also to the residents in the outlying communities. Assistance provided to the neighboring communities is in the form of materials, technical assistance, and medical missions, among others. Various livelihood projects are being initiated and implemented by the company for the employees dependents and residents. Livelihood associations were established to ensure continuity of these projects.
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CHAPTER 2 GEOLOGY 2.1 Regional and District Setting The ore body is situated within the southern portion of Baguio Mineral District. The district is underlain by meta-rocks of the Zigzag-Pugo Formation of Paleogene age and flanked in the east by the Agno Batholith of Early Miocene age and in the west by the Klondyke Formation, a probable Pliocene sedimentary formation consisting mainly of conglomerate and variegated sediments with lenses of limestone.
GEOLOGY OF STO. TOMAS II PORPHYRY COPPER DEPOSIT
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The regional structures that generally trend north south are believed to have controlled the batholithic mass and the later intrusive. Most of the faults within the
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vicinity of Philex, strike N50-70E and dips steeply almost vertical. One of these pronounced faults is the Albian Fault which horsetail and is believed to be the major control in ore deposition. The ore body is believed to be emplaced through four episodes of intrusions and associated mineralization into Zigzag-Pugo Formation along the northeast trending steeply dipping Albian Fault. The first intrusive body was dark diorite; the most altered and mineralized rock followed by the introduction of clear diorite. These two rock types have essentially the same mineral composition except that the dark diorite is finer in texture and dark in color due to the evenly distributed fine-grained magnetite and biotite. The clear diorite is coarser in texture with hornblende as the predominantly mafic mineral and less mineralized than the dark diorite. Potassium Arsenic dating showed dark diorite to be 3.8 million years while the clear diorite was dated to be 2.1 million years through Zircon Fission Track Dating. The third intrusive rock was the andesite porphyry that forms the core of the ore body and represents the barren core due to its low copper but moderately high gold content. It is porphyritic in texture with diagnostic sub rounded plagioclase phenocrysts. The last intrusive rock introduced into the meta-volcanics was the hornblende andesitic porphory that cut across all other rock types. It occurs generally as steeply dipping dikes and spread out forming flat lying bodies on the surface. These intrusions formed a pipe like ore body, which measured 500 meters by 550 meters lateral dimension with a depth of 730 meters pinching out at depth towards the north.
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a. Host Rocks Meta-Andesite and Meta-Sediments b. Intrusives Andesite Porphyry 0.5 Myrs Clear Diorite Dark Diorite Late Pliocene Late Miocene Early Pleistocene
Age Paleogene
1.4 + 0.4 Myrs
1.9
2.1 + 0.5 Myrs 3.8 + 1.1 Myrs Description of Lithology 1. Andesite Porphyry:
Located within the center of the orebody and represents the low grade core. It is porphyritic in texture with diagnostic plagioclase light gray in sub rounded
phenocrysts, color and
weakly mineralized. 2. Clear

Geologic structures that surrounds Sto. Tomas II Deposit.
diorite:
Light
gray in color, fine to medium
grained in texture with quartz, plagioclase as primary minerals. This rock unit is less mineralized as compare to dark diorite.
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3. Dark Diorite: this is the oldest of the intrusive complex and the most mineralized and altered. It is usually dark colored fine grained quartz diorite porphyry. The primary minerals are quartz, plagioclase, hornblende and accessory magnetite. Its dark color is due to its fine texture and to fine magnetite and secondary biotite disseminations. 4. Meta-sediments/volcanic: this is the country rock unit belonging to the ZigzagPugo Formations of the Baguio District. It consists of regionally metamorphosed andesite and tuffaceous rocks with intercalated sediments. The texture is variable ranging from aphanitic to porphyritic and hornfelsic. It is usually dark in color. Mineralization near contact with the diorite intrusive is strong and decreasing outward to a maximum radius of about 200m from the contact. 2.2 Geology of the Ore Body The ore body is pipe liked and almost vertical with lateral dimension of 500 meters and by 550 meters and a vertical column of 730 meters. Top of the deposit had its outcrop at the headwaters of Toboy River and Albian Creek (a tributary of Agno River) with elevation of 1,500 meters above sea level. The complex stocks of quartz diorite porphyries (1-2 million years by Fission Track Dating) intruded into the Zigzag-Pugo Formations along the northeast trending steeply dipping Albian Fault in four episodes of intrusion and associated mineralization. These intrusions are classified from oldest to youngest as the dark diorite, clear diorite, andesite porphyry and hornblende andesite porphyry.
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Primary ore minerals are chalcopyrite and bornite (1-2%) with associated gold and silver and trace of palladium bearing carried by quartz and anhydrite stock works. Native gold occurs mainly with copper sulfides either locked or along grain boundaries and also interstitial to gangue minerals like quartz and anhydrite. Bn/Cp ration in the main ore zone is 1:1 to 1:4 and +- 1:3 in the fringe ore zone.
ORE BODY GEOMETRY Length-550 M Width-500M Height-730 M Shape-Pipe Like Attitude-Vertical, tapers to the north
2.3
Geologic Structures Structures recognized to have control on the ore deposition are the three faults
locally called as the North, Middle, and South Faults that have been westerly directed. These are the horse tail end of the NE trending major structure known as the Albian Fault. This NE fault in regional scale is a conjugate shear of the NW trending Philippine Fault Zone. The ore body is about 16 kilometers north of the Philippine Fault.
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Pyrite is ubiquitous in the fringe ore with ration of pyrite to copper sulfide at 1:2 to 1:3 while in the main ore zone, it ranges from 1:8 to 1:20. Molybdenite is rare, spalerite and galena are associated with post porphy copper mineralization usually accompanied by gypsum, calcite, and pyrite veinlets. Magnetite occurs as discrete disseminated grains in the rock or with ore and also as stringers in the surrounding propylitic zonex. Specularite also present oftentimes associated with high-grade ore accompanying chlorite as an alteration product. Alteration is typical or porphyry copper deposits. Main alteration assemblage associated with copper-sulfide mineralization is quartz-biotite-chlorite. Orthoclase that is characteristic of potassic zone is absent. Sericite is also weak. Actinolite is also noted. The zone consequently makes the ore below very coarse in fragmentation. Phyllic and argillic alteration with pervasive clay, pyrite and silification were mapped only near the surface at the subsidence area. A possible pyrite halo is observed underground at the fringes about 200 meters from the ore boundary. Sto. Tomas II ore can be characterized as having a clean and simple mineralogy with the absence of the common ore types such as pyretic, slimy, acidic, oxidized and chalcocitic materials. DOMINANT ALTERATION MINERALS Ore Zone: Quartz, secondary biotite, anhydrite, sericite, and magnetite Fringer Zone: Quartz, chlorite, epidote, magnetite, and pyrite
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HYPOGENE COPPER MINERALS Chalcopyrite and Bornite SULFIDE MODE OF OCCURRENCE Fracture fillings and stock works, associated with quartz and anhydrite as disseminations. GOLD OCCURRENCE Free gold associated with chalcopyrite and bornite, 80% recovered with Cu concentrate: 20% from gravity concentrate. FLUID INCLUSION Type Polyphase Daughter crystals Sylvite (KCl) Halite (NaCl) Bubble Liquid-rich Vapor-rich Homogenization Temperature Salinity 100-200 450-550 600 330-350 350 4-5%
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2.4
MINERALOGY OF PHILEX ORE
Valuable Minerals (Major) -5-10% volume of Chalcopyrite and Bornite with native gold and silver, and traces of palladium bearing minerals. -<1% Covellite/Chalcocite partly replacing bornite and chalcopyrite along fractures and as thin coatings. Other Sulfides (Minor) -<1% volume of Galena and Sphalerite as discrete grains from the copper sulfides. Associated with post porphyry copper mineralization. -Occasional to rare presence of Molybdenite. -3-5% volume of Pyrite. Ubiquitous in the fringe zone and very low within the high grade zone. Oxides -5-10% occurrence of Magnetite as discrete disseminated grains in the rock or with ore. -1% volume of Specularite as discrete grains associated with high grad ore. Transparent Gangue Minerals -80% volume of Quartz and Silicate -5-10% volume of Biotite and other ferromagnesian minerals.
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-3-5% Anhydrite/gysum -1-2% Calcite.etc.
2.5
Sampling, Prospecting and Exploration Sampling is the process by which portion of an ore body are collected and
analyzed to estimate the average mineral content of the entire body. Sampling also provides information about the bulk composition of the ore for the mineralogical and metallurgical tests that determine the economic ore waste boundaries and geologic trends for exploration. Chip sampling is used here in Philex underground where they collected 5 kg per 3 meters interval and the sample materials are taken with the height of 2 meters or along the waistline side. Sampling is done on the eastern side of northsouth trending drifts/crosscuts and on the northern side of east-west trending drifts/crosscuts. The samples are taken from the different parts of block are sent to the assay laboratory. Fragmentation of samples is done before the reduction of the amount of sample. Previous exploration works conducted over the Padcal area including the immediate peripheries of the ore body showed intersecting areas. The encouraging results as well as their proximity to the operations of Philex make then good target areas for further investigation. Exploration is presently undertaken at the vicinity of Mt. Pukis. Getting soil samples weighing 500-1000g from B-horizon of the hole does geochemical prospecting.
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These samples are dried and sent to the laboratory. From the assay value, interpretation can be made with reference to the geochemical background and threshold. The delineated anomaly that is above the threshold, possible location of mineralization can be inferred. Inference of location is made possible by plotting the contour line, profile and cross-sections. Diamond drill exploration will hold the further observation and if mineralization is proven, further sampling will follow. 2.6 Diamond Drilling and Core Logging Diamond drilling is the standard procedure for consolidated rock, moderate to great depths and conditions requiring an intact core sample (as opposed to chips, sludge, or cuttings) for geologic logging and analytical determinations. A valuable adjunct to core drilling is the information it provides on structural geology and for rock mechanics. The cutting action is rotary and accomplished by many diamonds mounted or impregnated in the tungsten carbide bit matrix. Drilling involves both surface and underground diamond core drilling using LONGYEAR, TONE, AND MINDDRILL drill machines. These drilling machines are from Baguio Gold Mining Company. Drilling method employed then was both old conventional and modern wire line system. For the first 100 meters, the drill hole starts with HQ diameter and subsequently reduced to NQ diameter. In case of difficulty in advancing the diameter is reduced to BQ. A drill hole length varies from 17.68 meters to 1000.21 meters, the average being 226 meters. All drill hole cores are transported to the main core house, which also accommodates drill hole samples from the outsides exploration projects. This is where
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logging of the sample is undertaken. The samples are neatly and orderly arranged for easy retrieval. The objective of diamond drilling is the proper procedures and collection of required samples from drill holes that geologist will propose either for exploration, development, water source and structural stability or foundation test purposes. 2.7 UNDERGROUND MAPPING Expert geologist assistant will map the newly advance opening underground. They are well trained and skilled for a great number of years. A plastic tape is extended throughout the length of the openings that are mapped. These data, though taken at one side only, represent the whole part of the openings. The total number of joints, visible occurrences the major structures such as faults, and joints are being observed and obtained of their strike and dip. Fillings, alteration, roughness and irregularities of the rock are also mapped and rated by estimation. The joint condition rating, total number of joints, rock strength and intervals of previously mapped are recorded and tabulated. The tabulated results are then used for the recommendation of Rock Mass Rating (RMR). 2.8 Engineering Geology The study of the strength of the rock both on surface and underground mine is needed. It is very important to study the possible resistance of the rock mass to mining. It was studied that if the rock is at rest in which mining is not impounded, the stress has a higher resistance and said to be pre-mining stress. When mining is impounded, it is
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said to be the rock stress is redistributed mining stress. Mining Rock Mass Rating (MRMR) is the geomechanics classification system for the rock masses. It is based on mining experiences, and is calibrated for mining requirements. Cavability based on hydraulics radius of the undercut, fragmentation (primary and secondary), support designs and numeric modeling for draw zone spacing, height of the interaction zone, pillar strength, etc: are the practical application of the MRMR in block caving.
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MINE AND MILL PRACTICE RELATED PICTURES
Aerial Location of Sto. Tomas II Deposit
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Plan view of Level 908 showing Sta. Fe Fault
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Lithology of Sto. Tomas II deposit (Top View)
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CHAPTER 3 MINING METHOD 3.1 Operation Philex Mining Corporation is a copper mine presently operating its Sto. Tomas II orebody. The mining method being used is the Block Caving System of mining. At the present, load-haul-dump (LHD) units are used for ore extraction while feeder and conveyor belts are used for ore transport. The method is normally used to extract deep-seated, massive, low-grade deposits where open pit mining is not economical due to high cost stripping to uncover the deposit. In block caving operations, the ore fragmentations from the caving action normally determines the type of ore extraction method required to best extract a certain ore deposit. Block caving was found to be suitable for the geology of the site. The mining method and the ore body are egg-shaped porphyry type. Block caving is a method of mining which thick block of ore is partly cut-off from surrounding blocks by series of drills, as one above the other, or by boundary shrinkage stopes. It is then undercut by removing a slice of ore or a series of slices separated by small pillars underneath the block. The isolated, unsupported portion of the block of ore breaks and caves under its own weight. Gravity forces in the order of millions of tons act on the rock masses, and successive fracturing occurs, affecting the entire block. As the rock pressure increases at the bottom of the block, the ore crushes to a fragmentation that allows removal through draw points.
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Block Caving is used for large and massive ore bodies having the following characteristics: (1) the ore body must exhibit a steep dip. (2) After undercutting, the rock must be capable of caving and breaking into suitable fragments. (3) The surface conditions must allow subsidence of the caved area. These rather specific conditions limit the applications of the block caving method. Common applications are found in the mining of low-grade disseminated ores. The mine was operated for the first two years by small open pit mining and shifted to underground block-caving method using slusher system and eventually shifted to load-haul-dump Two methods of Induced Caving Methods 1. Coyote Blast Chamber Method The method successfully caved a couple of blocks at the 1020 ML but the system was very tedious, time consuming and the ore fragmentation result were boulder. 2. In-the-Hole Method This was done by drilling drifts 60 meters from the undercut back. From this drilling drift 6 diameter blast holes are drilled down to undercut back then loaded with explosives. Because of the longer burden and the required volume of ore to be drawn to take care of the swell, there was not enough time for the ore to break. The result was boulder fragmentation that was not suited for slusher system of extraction.
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Methods of Driving Vertical Headings 1. Conventional Raise Driving This consists of utilizing timber and wooden ladders as platforms for short raise. While in long raising, the chute and man way system of advancing is utilized. 2. Alimak Raise Driving The method is usually used in long and vertical or inclined raising. The Alimak commonly called the raise climber consists of a hoist with a working platform having a rack and pinion drive. It travels along a monorail with pin rack and integrated pipes for air and water, which is bolted to wall of the raise. Mining Extraction Methods 1. High Packing Method This is employed in bringing down hang-up or clogged large ore blocks at the undercut level or within the finger raise column. This method involves providing a series of wooden ladders to reach the clogged fragments. The supported large block of ore are drilled and blasted. This activity is undertaken by highly skilled miners and is closely supervised to implement strictly the Standard Operating Procedures (SOP). 2. Secondary Blasting-Blasting Stick Method The method is used to bring hang-up at the undercut level or above the brow of the draw point. A considerable amount of ANFO in plastic cartridge and dynamite sticks are tied around the end of the stick or pole. It is wedged in between the large blocks or ore. Initiation is done at the line through the detonating cord. The
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strong shock generated by the blast will either bring down or break the large boulders. Ratio of Dynamite (SENATEL MAGNUM) to that of ANFO is 1:9. 3. Pop-Hole Drilling or Bouldering Clogged boulders are drilled with pneumatic drills and the drill holes are charged with explosives. 4. Mud Capping Considerable amount of explosives is plastered over large boulders with mud/clay. This method is also done to break fragments into smaller sizes that can pass down through the grizzly. Load-Haul-Dump (LHD) System of Ore Extraction Due to the increasing hardness of ore at depth and water-related problems that have adversely affected the extraction operation, the PMC has in 1994 embarked on a mine mechanization and modernization program. With this program, state of the art hydraulic jumbo drills for development activities and slusher winches by LHD units for ore extraction replaced the conventional rock drills. This method can draw coarsely fragmented ore at high production rate. The ore is drawn from draw points with wider openings by mechanized equipment such as LHDs either diesel powered or electric powered. The lower levels particularly at 908 ML, 4m X 3.5m openings called Production Lines are laid out in an east-west orientation. These are driven at an interval distance of 30 meters center to center. Connecting the production lines is the northwest and southwest 3.5m X 3m draw crosscuts. Within the draw crosscuts are the trenches where broken ore from the undercut lines are pulled out. The trenches are similar to that
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of the finger raise, only that it measures 4m X 10m at the draw crosscut and belled 10m X 10m at the undercut.
The broken ore is extracted from the draw crosscut by LHDs and dumped into the grizzlies equipped with mechanical breakers. The sized ore travels into long transfer raises and conveyed to the cable belt conveyors through the feeder belts. From the cable belts the ores are delivered into the dump bin for primary crushing. Ore Distirbution Level 975 ML 908 ML 863 ML 773 ML M DMT 5.508 29.869 51.933 38.173 125.483 % Cu 0.245 0.284 0.280 0.290 0.282 g Au/t 0.718 0.593 0.591 0.843 0.674 Metavolcanics Intrusives 75% 65% 60% 75% 25% 35% 30% 35%
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MINE AND MILL PRACTICE Related Pictures
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CHAPTER 4 MINE PLANNING AND DESIGN 4.1 Underground Mine
4.1.1 Engineering The skilled-draftsmen, professional mining and civil engineers who are expert in their respective fields do the layouts, plans, and designs. The people in the Mine Division Department are responsible for the operation and development in the underground. The department acts as one in having a common goal in aiming for a high standard and appropriate and economical design in mining operation. The engineering department achievements include mine design. The department is also responsible for the projection of schedules, cost for development openings as well as the equipment and the explosives to be used, labor cost and other miscellaneous. The mine engineering department passes their prepared design and plan to the mine division manager for approval. After the manager has checked the design and plan, it will be passed over who is in charge for the implementation. Plan- a map showing features such as mine working of geological structures; a way or a system of projecting objective and strategies. Planning- is the method or the science of pre-designing of the different and various detailed work to be undertaken.
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Factors to consider in Planning: 1. Layout or design of a certain project 2. Consider the feasibility study 3. Cost estimate at development stage 4. Project duration/completion at development stage 5. R.O.I. (Return of Investment) at production stage 6. Life span 7. Schedule Importance of Proper/Good Planning 1. To determine if your feasibility study is acceptable 2. To determine if the design is acceptable 3. To determine the development cost and production cost 4. To determine the life span of the project Project Scheduling- is a form of planning strategy; of the method indicating the various detailed work activities and the time frame of a certain project to be undertaken. Two (2) kinds of Project Scheduling 1. Gantt Chart Schedule 2. PERT/CPM- Project Evaluation Review Technique/Critical Path Method Importance of Project Scheduling 1. To determine the manpower to be utilized in the project 2. To determine the duration or date of completion
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Factors/Steps to consider in Project Scheduling 1. Different work activities to be undertaken 2. Resources involved in the project- Manpower involved 3. Availability of materials/equipment needed 4. Arrange the activities in a sequential manner 5. Determine the parameter to consider in each activity 6. Determine the duration/time frame of each work activity 7. Determine the activity/activities that proceeds, succeed or those that can be simultaneously be done 4.1.2 Grade Control In the mine, the boundaries to which a minable deposit can be extended up from the center going outward in every plan of production level, traced and colored by the geologists and their assistants. Problem in grade control arises when one block is 80% - 100% extracted. Possibility of dilution increases because of larger volume of overburden exposed. During this stage of extraction, the Draw Control Department instructs its block samplers to more frequent sampling of the ore being mined every day. Functions of Draw Control 1. Ore Extraction drawing Draw Rate quantity that must be pulled out in a draw point Caving Rate ability of the ore to caved and crushed
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Draw rate is directly proportional to caving rate If slow draw; there will have pack-up and it will build pressure Maximize ore recovery and minimize dilution Dilution every material mix with ore that is not economical to mine Draw Order 2. Ore Accounting account tonnage 3. Sampling sampling is done per draw point Grab Sampling double checking by using channel and chip sampling 4. Draw Points Survey availability and fragmentation survey 5. Subsidence Area Operation Backfilling subsidence at the ration of 1:4 Gradient of -4% - -7% towards the drainage outlet Construction of benches to support wall Maintenance of silt pond Reforestation
4.1.3 Rock Mechanics Section Rock mechanics Section is under the Geology Department. It is responsible for determining the specific value of the Rock Mass Rating (RMR), which is based on the underground mapping data. It will coordinate with the mine division in order to give the right suggestion about the structural condition of the rock underground. The RMR is used to classify the rock mass as highly fractured, fractured and moderately fractured,
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massive and very massive. The equivalent RMR ratings are: very poor (<20), poor (21 40), fair (41 60), good (61 80) and very good (81 100), respectively. Geomechanical issues such as cavability, fragmentation, draw zone spacing, dilution entry, draw control, layout design, undercutting sequence and support requirements can be assesses provided adequate and accurate geotechnical data are gathered and that geological variations are recognized. It is essential that classification data are made available at an early stage, so that the correct decisions are made on mining method, layout and support requirements. Accessibility of the production drifts, ventilation and access drifts and crosscuts and dumping points should be maintained to ensure continuous and efficient extraction operation. The rock mass surrounding the extraction openings is subjected to four stress cycles in all caving situations and a fifth cycle if the retreat is towards an unfavorable geological structure. a. Adjustment of the rock mass to the openings b. Abutment stresses ahead of the undercut, and redistribution of stresses around the caved area c. Uplift after the undercut is complete, with the removal of the vertical stresses d. Vertical loading on the apexes from the point loads and an increasing column of caved material; and e. High toe stresses if wedge failure occurs against a structural fault. With these conditions, it is a must that all openings in the production level should be reinforced and supported to last until the life of the block. The support system should be
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designed and agreed prior to the development stage so that there is interaction between the components of the initial and final stages. The initial support will be installed concurrently with advance to control deformation and will preserve the integrity of the rock mass. The final support will cater the induced stresses and stress changes that will result from mining operations. An integrated support system consists of components that are interactive and the success of the system depends therefore on correct installation and on the use of materials of the right quality. Furthermore, the effectiveness of a support system can be related directly to an appreciation of the rock mass and the stress environment, as well as to correct selection, timing and installation of the support. At Philex, where the mining rock mass rating at the production level falls under 3A and 3B supports at the production drifts and draw crosscuts consists of rock bolts, wire mesh, cable bolts and shotcrete. At the pillare walls of the draw crosscuts, four rows of cable straps at 0.8 meters vertical distance are installed. The straps are grouted at both ends.
Rock bolts, wire mesh, tendon straps, cable bolts and shotcrete in place of steel sets and reinforced concrete now reinforce most of the draw points. This support system is installed at areas where the rock mass are blocky. Draw points where lithologic contact are present are supported by reinforced massive concrete with rigid steel sets.
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CHAPTER 5 MINE DEVELOPMENT 5.1 Driving
Openings
Sizes
(m)
Height x Width
Production Lines
4.0 x 3.5
Undercut Lines
3.5 x 3.5
Draw Crosscuts
3.5 x 3.5
Access Ramps
4.0 x 4.0
Ventilation Drifts
3.5 x 3.5
Drainage Drifts
3.5 x 3.5
5.2
Drilling / Charging and Blasting It is obvious that it is of outmost importance that the holes should be drilled at the right location. The drilling pattern also includes information on the lookout angle needed at the different points on the tunnel face. The lookout angle between the
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practical tunnel profiles. If the contour holes were drilled parallel to the theoretical line of the tunnel, the tunnel face would get smaller and smaller after each round. To ensure that the correct tunnel profile is unattained, each contour hole is drilled at a slight angle, which of the profile of the rock drills. As a guide value, the lookout should be more than or less than 10 cm, 3 cm/m hole depth or for a 10 ft or 3 m drilled the look should be 30 cm. Adjusting the lookout angle by eye requires an experience and skillful operator. An incorrect lookout angle produces over or under breaks, both of which give uneconomical. Drilling Accuracy In accurate drill set and rig set-up is often the result of natural causes or error of human judgment. The tunnel may not provide enough room for proper alignment of the drilling unit. In accurate rig set-up causes misalignment of whole tunnel and leads to over and under breaks. Rectifying the whole tunnel alignment later is extremely expensive. The rock face frequently has cracks, joints, bumps and holes that prevent the hole from being drilled at its optional position; when the hole is drilled in a new position, it can become misaligned or does not end in the same plane as the other holes. In accurate hole length leads to difficulties in blasting causing uneven tunnel walls, roof and floor once started, misalignment can easily become compounded making the following rounds even more difficult to drill.
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Charging / Blasting Follow the usual procedure of charging but by this time, the holes loaded charge with ANFO like the cut holes and lifter, trimmer holes should not be loaded up the collar leave one foot not loaded. 5.3 Hauling The transport of ore in the underground is by means of LHD units and CBC system. LHD hauling system is used at the production levels while the FBC (Feeder Belt Conveyor) and CBC (Cable Belt Conveyor) are found in the 773 and 745 level respectively. These systems bring the run-of-mine ore to the dump bin in the mill. The cable belt conveyor consists of seven feeder conveyors, which is connected to the collecting bins of the concentrator. 5.4 Drainage An effective drainage system is the primary purpose of maintaining the subsidence area for safety of the workers underground. Backfilling operations at this area are continuously undertaken throughout the year to maintain the required -4% minimum gradient towards the main Albian Creek and Alang Cut. Backfill materials are mechanically hauled by dump trucks to the low areas of the pit floor in order to maintain the required slope. 5.5 Ventilation The primary of objective of designing the mine ventilation system for an underground mining operation is to provide as suitable volume-temperature supply
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of fresh air to the working areas while simultaneously diluting airborne toxic gases and dust contaminants generated in the course of mining. Effective mine ventilation systems are necessary to support healthy human life underground. The beneficial physiological and psychological side effects enhance employee safety, healthy, comfort and morale. The direct operational benefits to be gained include increased workers efficiency and productivity, reduced accident rates and absenteeism. 5.6 Supports General Principles in Underground Rock Support and Reinforcement Practices a. Install the reinforcement close to the face soon after excavation. b. There should be good contact between the rock mass and the reinforcement. c. The deformability of the reinforcement should be such that it can confirm the displacement of the excavation surface. d. Ideally, the reinforcing system should help prevent deterioration in the mechanical properties of the rock mass with the time due to weathering. e. Repeated removal and replacement of reinforcing elements should be avoided. f. The reinforcing system should provide minimum obstruction to the working face. g. The rock mass surrounding the excavation should be disturbed as little as possible during the excavation process. h. The reinforcing system should be adaptable to the redistribution of stresses associated with the progress of mining.
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I. Driving of Production Line During the driving of production line, initial supports must strictly implement such as rock bolting/wire mesh to be followed by shotcreting. Initially, a 50% (2 inches thick) of the required thickness must be applied or sprayed. Additives must be added to the mixtures or lumps to fast track the setting and increase the compressive strength. The final shotcrete and cable bolting will be done once or after the draw crosscuts is open up the 10m distances from the face to the last support must be maintained. Dont allow the heading to stand for a long time without any supports to prevent deterioration. a. Initial Support At an advance of 5 meters initial application of shotcrete at two (2) inches thickness must be done followed by rock bolting at an interval of two (2) meters per ring and eleven (11) piece per ring then continue driving following the sequence until the total stretch of PLs is completed. The location of draw crosscuts to be driven must be left unsupported. b. Final Support At a distance of 60 meters with initial support the final support must be started. Install wire mesh / cyclone wire with rock bolt and cable bolts. II. Opening / Driving of Draw Crosscuts Driving of draw crosscuts from the production line is not allowed not unless the initial supports of the production line are completed such as rock bolt, wire mesh and shotcrete. Precession drilling and efficient blasting is very
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important to avoid over break and excessive vibrations that might damage the pillars especially the camel back and bull nose. In case the pillars is damaged, this must be reconstructed / concreted during the final supports, so that the ore will not flow to the production line during the extraction of ore. Likewise, during the driving, the floor must be even, the drilling of lifter holes, the lookout angle is emphasized and implemented to reduce the fast wearing of tires during the extraction stage. During the driving of draw cross cuts, the trenches must not be driven. 1. Follow the sequence of opening. 2. At an advance of four (4) meters initial shotcrete must be done followed by rock bolting at 2 meter s interval (outside Sta. Fe Fault) or 1 meter interval (within Sta. Fe Fault) at nine (9) pieces per ring. 3. Drive the remaining balance following the same sequence. 4. Wire mesh / Cyclone wire with 9 pieces rock bolts in between the initial rock bolts. 5. Cable lacing 6. Final Shotcrete 7. Steel set and concreting if needed depending on the ground condition. Driving of Draw CrossCuts First Stage (Widening) Please refer to preceding plan showing driving of Draw Crosscuts using the bull nose side as reference, widening starts by drilling holes perpendicular to the draw
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crosscut opening (Slabbing). Half of the opening is taken into account. The purpose of which is to give a free face for the next round. Blasting sequence starts by charging and initiating the holes located near the production line, which will give a free face for the other holes. The pull will depend on the drilling accuracy and correct blasting method. On ground vibration, this will be controlled by the drilling design, types of explosives and blasting delays to be used. Second Stage (Widening) Having a free face from the first blast, the second round of holes is then drilled in the direction of the DXC. Hence; half of the opening is taken into account. Blasting sequence starts at the free face alley towards the other holes. Pull will depend on the drilling pattern and charging of blast holes. To control ground vibrations; the perimeter is loaded with explosive which has a relatively low energy output per meter of blast hole. Third State and Fifth Stage (Pilot Driving) Drilling pattern have been presented and this will be used to advance more than half of the opening, hence a provision of a burn cut is done in order to provide free face for the other blast holes. The pull will depend on the drilling accuracy, accurate hole placement and proper blasting method. If these aspects are satisfied it could yield to a 90% pull. Ground vibration is controlled by the holes along the perimeter area. This includes proper spacing, delays to be used and explosives. This advancing set up is repeated twice.
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Fourth and Sixth Stage (Pilot Driving) Remaining dimensions to be widened are located at the left side of the opening.
Blasting sequence starts at the free face area and pull will depend on the drilling pattern and charging of blast holes. Ground vibration is controlled by the perimeter holes, which is loaded with explosives. This set up is repeated twice. After completing the above mentioned series of widening activities then we could start driving with full face drilling and blasting pattern. Seventh Stage (Face Driving of Draw Crosscuts) A typical drilling patter is presented and it ensures the distribution of the explosives in the rock. The desired blasting results and the optimum drilling and blasting economics are taken into account. Support of Draw Crosscuts Rock bolts Specifications: Length = 7 ft Diameter = inches Spacing = 2 meters outside Sta. Fe Fault, 1 meter within Sta. Fe Fault Cemextra Used = 15 cartridges for roof bolter machine, 12 cartridges for jack leg Face Plate = 6in X 6in
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Shotcrete This initial shotcrete of 2 inches thick should be applied immediately after driving 4 meters advance to prevent key blocks from falling during blasting operations of adjacent openings and also to prevent dilution.
Cable Bolts These are required in places where massive wedges are likely formed by intersecting fault structures. Due to the limited length of the rock bolts, cable bolts are recommended because its length can be varied to anchor the massive wedge to a more competent ground.
Steel, Timber, and Concrete Sets This support system aims to protect the Draw point brow from stress concentration and from scouring of trench by mining activity. This can be installed anytime before trench drilling and blasting.
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CHAPTER 6 MINE PRODUCTION BLASTING AND EXPLOSIVES 6.1 Types of Explosives When properly initiated, commercial explosives are rapidly and violently converted into gasses at very high temperatures and pressures. This rapid conversion of solids and liquids into gasses is called detonation. The effectiveness of explosives in blasting is due to the speed with which the gas pressure is developed. The energy released in the detonation acts equally in all directions but, as one would expect, tends to escape paths of least resistance. Blast holes should be charged and stemmed as appropriate, so that the gasses will be confined and forced to provide optimum breakage, displacement of the surrounding rock. Some explosives with very high sensitivity can be detonated by mechanical impact and/or friction, especially in the presence of grit. In practice, detonation is achieved but shock from a primer, detonating cord or detonator. An explosive is classified as detonator sensitive if it can be reliably initiated, in an unconfined state, by a no. 8 blasting cap, which has a 0.45 g PETN base charge. The Principle of Rock Breaking In order to understand the role of blasting with delays, it is first necessary to understand the process of fragmentation or the mechanics that follow the explosives detonation in the drill hole.
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Investigations have shown that the liberated energy is transmitted to the surrounding rock as dynamic load at the moment the detonation. In order to reach the best blasting result, it is paramount importance to control the sequence of the round. The sequence develops in four phases from the moment of initiation. The time frames are defined as follow: 1. Detonation This is the beginning phase of the fragmentation process. The ingredients of an explosive consisting of fuel and oxidizer combination, upon detonation, are immediately converted to high pressure and high temperature gasses. Pressures just behind the detonation front are for the majority of the civil products in order of 2,000 to 20,000 MPa, while temperatures range from approximately 2,000 to 4,000 degrees centigrade. Detonation pressure and Velocity of Detonation are the components or parameters that are accomplished or satisfied during this stage. In a typical 10 meter explosive column loaded with an explosive having detonation velocity of 3,000 meter/second, complete detonation and energy release within the entire column would occur in about 3 milliseconds. For an explosive with a velocity of detonation of 5,000 meters/second, detonation and energy release would be complete in 2 milliseconds. Detonation of this kind is self sustaining due to the inertia of the explosive itself that provides confinement necessary to maintain conditions for fast chemical reaction rates.
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2. Shock or stress Propagation The second phase, immediately following after detonation or in conjunction with detonation phase, is the shock and stress wave propagation throughout the rock mass. This disturbance or emitted pressure wave transmitted through the rock mass results, in part, from the rapidly expanding high pressure gas impacting the borehole wall. The geometry of dispersion depends on many factors such as the location of the initiation point or detonation velocity and shock wave velocity in the rock. In typical bottom primed cylindrical shot hole normally encountered in bench blasting, the strain waves originally formed near the point of initiation are already in progress and propagating into the surrounding medium, while the detonation is still progressing within the explosive column. The pressure next to the borehole wall will rise quickly to its peak and then rapidly decay exponentially. The quick decay is due to the cavity expansion around the borehole can range anywhere from 1 to 3 times depending on the medium and explosives use. 3. Expansion of Detonation Products During and or after the propagation, the high pressure, high temperature gases impart a stress field around the borehole, extend radial cracks, and jet into any discontinuity. It is during this phase that some controversy exists over the main mechanism of fragmentation. Some believed that fracture network throughout the rock mass completed, while others believe that the major fracturing is just beginning. In any case, it is the gases jetted into discontinuities, and the fracture
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network that is either fully develop or being developed, along the impulse imparted into the material by the detonation, that are responsible for the displacement of broken material. It is not clear as to the exact travel paths that ages take within the rock mass, although it is agreed that they will always take the path of the least resistance. This means that the gases will first migrate into the existing cracks, joints, faults and discontinuities, in addition to seam of material that exhibit low cohesion of bonding interfaces. If a discontinuity or seam between the borehole and the free face is sufficiently large, the pressure gases will immediately went to the atmosphere, rapidly reducing the total confinement pressure, which will result in reduced displacement of broken and fragmented material. This of course, applies to large and well defined discontinuities. 4. Mass Movement Mass movement of the material is the large in the breaking process. The majority of fragmentation has already been completed through the compression and tensile stress waves gas pressurization or a combination of both. However, some degree of fragmentation, although slight, occurs through in flight collision and also when the material impacts the ground. Generally, the higher the bench height, the greater is this type of breakage because of increased impact velocities of individual fragments when falling into the bench. Recommendations for bench blasting:
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a. Make it possible for the rock to move 1/3 of the burdens length before the subsequent row detonates. This suggests a delay of the 30 millisecond per meter burden. b. Delay drill holes of the same row of 5-10 millisecond per meter spacing. 6.2 Blasting Design
Modern blasting can be grouped into two principal categories: 1. Blasting Agents (Primer sensitive explosives) 2. Detonator Sensitive explosives Blasting agents are explosives, which contain no ingredients, which are explosives. All blasting agents contain the essential components below: a. An oxidizer which is a chemical incorporating more oxygen than is required for its own complete combustion. Typical oxidizers are ammonium nitrate and calcium nitrate. b. Fuel(s), which are materials that consume oxygen when burnt. Common fuels include fuel oil (distillate) and aluminum. c. In the controlled chemistry of an explosive the oxidizers and fuels are combined, and the product sensitized to yield the desired properties. Sensitization is largely achieved through the formation of hot spots. The presence of air/gas bubbles is a prerequisite of satisfactory of all bulk products and most packaged products.
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CHAPTER 7 MINE SAFETY 7.1 SAFETY INSPECTION
Safety inspection is the best method of carrying out the fundamental principle of accident prevention and its objective is to maintain, establish and accept the standard of safety. It is quality control of accident prevention. 7.1.1 Steps:
1. Prepare for inspection 2. Indentify the conditions or practices 3. Write the report 4. Follow-up 7.1.2 Purposes:
1. Poor Housekeeping 2. Poor Ventilation 3. Poor Lightning 4. Noise 5. Poor maintenance of equipments 6. Poor training or workers
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7.1.3
Deviation from established standards:
1. Servicing equipment in motion 2. Overloading equipment or machinery 3. Operating equipment without authority 4. Using of wrong tools 5. Making safety device inoperable 6. Failure to use Personal Protective Equipment 7. Failure to use warn or secure 8. Operating equipment at improper speed 9. Violation of Standard Operating Procedures 10. Improper position for task 11. Horse playing at work 12. Reporting to work under the influence of liquor or prohibited drugs 7.1.4 Types of Safety Inspection
1. Multiple random observations 2. Periodic check equipment 3. Physical property condition 4. Accident cause inspection 7.1.5 Importance of Safety Inspection
1. It determines the need for an effective method of hazard appraisal. 2. For correction with/or improvement of deficiencies. 3. The use of standard and development forms and procedures.
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4. Immediate corrective action maybe possible. 5. Procedures safer as well as more efficient method. 6. It demonstrates managements sincerity regarding accident prevention. 7. It determines the required emphasis of operations employee training. 7.2 Safety Training Program
Incident prevention in order to have an effective safest control that will provide a working environment in which operations can be conducted economically, efficiently, and safely are the goal in underground mine operation provided by the Safety Department and Loss Control Division of Philex Mining Corporation. The following are the prepared programs in order to achieve their main goal: 7.2.1 Specific objectives:
1. To improve the mine operations group safety performance. 2. To develop and implement a system that will determine hazards resulting to physical harm to people and economic losses or delays of the mine operations. 2.1 Upgrade and maintain underground employees awareness, consciousness and compliance to safety policies and procedures. 2.2 Identify occupational health and safety hazards and their
corrective/preventive measures. 2.3 Achieve 100% employee participations. 2.4 Improve underground safety information system.
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7.2.3
Actions Plans/Strategies
1. Safety Inspection System 1.1 Conduct a regular safety inspection on all active working areas in the Mine Operations. 1.2 Results of inspection shall be informed to all concerned for their immediate attention. 1.3 Action to recommendations shall be monitored for proper implementations. 1.4 Maintain screening of underground personnel reporting to work. 2. Incident and Accident Investigation 2.1 Operations supervisors to accomplish a Supervisors Preliminary Accident Report for any undesired event that may happen in their areas of responsibility. The shift managers and shift superintendents concerned shall review reports. Submission shall be within 24 hours from the time the accident happened. 2.2 Safety Supervisors to report and investigate the same by accomplishing a Safety Supervisors Accident Report. 2.3 In case which involve property damages, loss or delays of operations, proper investigation shall be coordinated with the Loss Control Division. 2.4 Written statement of witnesses especially on Loss of Time Accidents Cases shall likewise be accomplished. 2.5 Action plans and recommendations taken shall be monitored for strict implementation.
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3. Job Safety Analysis (JSA) 3.1 Conduct a critical job inventory. 3.2 Conduct a job analysis to help improve productivity, quality and safety. 3.3 Coordinate with the mine operation supervision in the formulation of additional SOPs needed. 4. Safety Information System 4.1 Improve and update safety slogans. 4.2 Improve the conduct of safety meetings and pep talks. 4.3 Generations of safety reports and proper dissemination to all concerned. 4.4 Campaign for the dissemination of the newly formulated SOPs. 5. Education and Safety Training 5.1 Conduct employee training through implant and outside seminars. The need to conduct refresher courses after three to four years for the programs continuity. 5.2 Scheduling of the desired training requirements of underground personnel which includes the Contract Groups. 5.3 Training of employees and continue giving of awards, incentives and citations. 6. Occupational Health and Safety Hazards 6.1 Monitor and identify hazards and implement corrective and preventive measures. 6.2 Conduct orientation on environmental control. 6.3 Conduct hazards survey audit on the following:
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6.3.1 Equipment 6.3.2 Tools and Machineries 6.3.3 Structures 6.3.4 Other installations or features in the various working areas. 7. Provisions for Personal Protective Equipment (PPE) 7.1 Safeguard personnel by equipping them individually with specialized protective equipment. 7.2 Strictly enforce the correct usage and proper maintenance of available safety gadgets. 8. Disaster and Emergency Preparedness 8.1 Maintain underground Emergency Organization (UEO). 8.2 Maintain equipment; fire protection and manpower capabilities. This includes the ready availability of Mine Rescuers and First Aiders. 8.3 Conduct the needed training and mock drills considering all types of underground emergencies. 9. Safety Programs Audit 9.1 Require all Departments and Sections to submit their Annual Occupational Health and Safety programs within fifteen days before the start of every calendar year. Submission shall include all Service contractors being themselves a part of the overall operations. 9.2 Apply the International Loss Control Management regarding the Five Star Rating. 9.3 International Safety Rating program has the following objectives:
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9.3.1 To carry out a systematic critical evaluation of all elements of the safety programs. 9.3.2 To analyze and appraise critically a companys effort to identify, evaluate and control all potential accident losses. 9.3.3 To critically evaluate the level of Occupational Health and Safety Standard compliance to legal requirements.
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CHAPTER 8 METALLURGICAL AND MILL OPERATION Mineral Processing Simplified flows sheets are provided for the whole operation of the milling process. 8.1 Crushing and Grinding Operation 8.1.1 Primary Crushing
Equipment used: Jaw Crusher The Jaw Crusher is basically a primary crusher designed for use of mine quarries or gravel pits. Rocks smaller in size than the jaw opening, fed between the stationary are reduced from their original size, down to the final product or down to sizes small enough for secondary crushers to handle. The adjustable opening set at the bottom of the jaws determines the product size and the capacity of the jaw crusher. Operation of Equipment The Jaw Crusher operates at 250 RPM. As the eccentric shaft applies the circular motion of the flywheels to the top of the moving jaw, the toggle plate at the bottom of the jaw changes the jaw motion to an oval. This motion crushes the rocks entering the upper jaw opening and crowds them downward, so at no point between the top and bottom of the jaw is there a neutral zone, or plate for material in its downward path. At the bottom of the jaws, there is which product sizes are being fed.
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Equipment used: Vibrating Screen Vibrating screens are the most important screening machines for mineral processing applications. They handle material up to 25 cm in size down to 250 microns. Their main application is in crushing circuits where they are required to handle material ranging, in general, form 25 cm to 50 mm. Vibration is induced vertically either by the rotation of a mechanical reciprocating device applied to the casing or by electrical operating directly on the screen. Vibration in the finer screening ranges is often produced by unbalanced weights or flywheels attached to the drive shaft. It consists of heavy machined, steel shaft running in double row, ball bearing, and Plummer blocks bolted direct to the screen main frame. To the middle of the shaft are keyed two eccentric weights which when rotating at correct speed produces a smooth positive vibration, operating with equal intensity over the whole screen mesh. 8.1.2 Secondary Crushing
Equipment used: Secondary Cone Crusher The crushing chambers that are fitted to various machines are often referred to by terms arising out of common usage, such as the secondary con crusher which accept the suitable feed size material either prepared by a primary crusher or occurring naturally and reduce it to a size suitable for marketing in one stage or make the feed for subsequent crushing or grinding stages. Secondary crushers most commonly operate in open circuit. The cone crusher is characterized by its higher speed and a flat crushing chamber design, which is intended to give a high capacity and reduction ratio for materials suitable to this
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type of processing. The aim is to retain material longer in crushing chamber too do more work on material as its being processed. The number of times material will be nipped during crushing will depend on material size, friability and the geometry of the crushing chamber as well as its speed and eccentric flow. 8.1.3 Tertiary Crushing Short head cone crushers are use for tertiary crushing, which refer specifically to the Symons design. These are cone crushers that normally take secondary crusher product and reduce it to a marketable product or make it suitable for subsequent comminution steps. The reduction achieved is a function of the crusher design and the properties of the material to be treated. The reduction ratio normally lies in the range of between 1:5 and 2:1 and seldom used 3:1. Crushing setting can be change mechanically by screening the bowl or top shell or changed by direct htdraulic actuation of the crushers main shaft or through hydro mechanical devices. The tertiary crushers normally operate in closed circuit with the vibrating screen and makes product smaller than all passing or 5/8 inches. 8.2 Flotation and Leaching Operations Most of the mining companies in the world use those kinds of flotation machines. These are used to agitate the pulp coming from the overflow of the ball mill cyclones. With the aid of reagents such as SIBX, frother and lime, and introduction of compressed air, the agitating motion of these machines is carried out to produce the concentrate.
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This machine has a mechanism where bearings can be found on the lower and upper portions. The bearings are mounted on a hollow shaft where compressed air passes through during operation. On the lower portion of the lower shaft is also hollow so that the compressed air can reach the bottom of the tank. In order to agitate the pulp efficiently, a circular impeller is also a stabilizer. It is used so as not to spread out the pulp being agitated by the impeller. In order to protect the tank from wear and tank from tear, padding is provided 8.3 Filtering and Thickening Operations Most mineral separation processes involve the use of substantial amount of water and final concentrate has to be separated from the pulp in which the water solid ration is significantly high. Filtration is the process solids but allows the liquid to pass. Philex makes use of the drum filter machine where it uses vacuum to suck off the excessive moisture. In mineral processing, filtration normally allows thickening. Thickening, otherwise known as gravity sedimentation, is the most widely applied dewatering technique. Thickening is relatively cheap, high capacity process, which involves very low power consumption though providing good condition for flocculation of the fine particles. The bulk of water is first removed by thickening, which makes thickened pulp top contains 55% to 65% solids by weight. Up to 80% of the water can be removed in this process. Filtrations of thickened and pulp then produces a moist filter cake between 80%-95% solids.
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At Philex, the filtered final concentrate is hauled by trucks to the ship loading point at Poro, San Fernando, La Unio and sells to buyer from Japan and PASAR in Leyte.
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MINE AND MILL PRACTICE Related Picture
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SECONDARY CRUSHING
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BALL MILL/GRINDING
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FLOATATION
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LIME PLANT
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CHAPTER 9 MINE ENVIRONTMENTAL CONCERNS 9.1 Mill Tailings Disposal System For a daily tonnage of 28,000 tons of ore milled, only about 500 DMT of copper concentrate are produced; the rest constitutes the tailings. The company is very much aware of its commitment to protect its surrounding area from pollution that it may cause due to its mining and milling operations. In this regard, Philex Mining Corporation has constructed three impounding dams. The first dam, known as Tailings Dam No. 1, had its construction began on December 1967 at a cost of P 8.633 million and was immediately put into operation on April 1971. This dam is no longer operative for tails impounding but is still being maintained. The total mill tailing impounded at Dam 1 was about 88 million DMT. The construction of the Tailings Dam No. 2 started in July 1973 and was completed December 1981 at a cost of P 37.137 million. It started its operation at the same year it was completed, receiving an average of 50% of the mill tailings, while the other 50% remained at Tailings Dam No. 1 for the continuous build up of its Toe Dam downstream. Tailings impounded at Dam No. 2 were about 79.8 million DMT. The construction of Tailings Dam No. 3 was started in September 1983 and became operational in April 1992. As the impounding operation progresses crest of the main rock fill dam, its downstream supporting benches and the penstocks are being raised to maintain the required freeboard. Total construction cost Dam No. 3 as of
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December 1998 is 331 million pesos and for 1998 alone, the amount spent for construction was 9.087 million pesos. Its impounding capacity is 142.6 million DMT. Total height of clan is 160 meters. At the end of December 1998, the company had spent 11 million pesos for the operation and maintenance alone of the Tailings Pond No. 3. Aside from that, the company complies with PD 1251 and spent a total of 10.85 million pesos for tailings fee, covering the period 1974 to date. In spite of the enormous expenses involved, which are non-revenue, Philex Mining Corporation will continue to spend money, time and effort to implement all governmental regulations to prevent pollution. 9.2 Mine Waste Dumps The iron and metal scraps as well as used tires are deposited at the scrap yard at Benguet/Tailings Pond No. 1 and are disposed to buyers and other interested parties. At the scrap yard, sorting according to dominant metal contents and proper filling are being undertaken. Assorted scraps sold to buyers for the period June 1997 May 1998 was 4,509,483 tons and generated a sale of P 9.77 million. 9.3 Reforestation and Rehabilitation of Mine Affected Areas Massive reforestation and forest protection activities had been conducted in the Philex Mining areas and its vicinity since 1976 even before First Lady Imelda Marcos conceptualized the Man and Biosphere project in 1978. This was one of the community pet projects of the wife of the former Vice President of Operations of Philex, Mrs. Marie D. Smith. Wives of miners were hired on seasonal basis to plant within the designated areas. From 1976 to 1983, twenty-seven reforestation areas were established covering
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260 hectares, more or less. Almost 1 million of seedlings of various tree species were planted such as Benguet Pine, Ipil-Ipil, Alnus, Agoho, Eucalyptus etc. the survival rate was low at 32% on account of forest fires, which are common particularly during the dry season. In 1987, the Forestry Section was formally organized hiring of licensed forester. A forest nursery was established with the capacity to propagate 500,000 seedlings annually. From 1987 to present, PMC planted 1.8 million assorted seedlings over 730 hectares. From a very low survival rate of 32% in 1976 to 1983, the survival rate improved considerably to 72%. The total involvement and cooperation of all members of the community and purok organization contributed much to the success and improvement of the survival rate. Every year, planting areas are maintained and replanted to offset the mortality in the established forest plantations. In the year of 1989 about 315,600 seedlings were planted to an approximate total area of 150 hectares and in the year of 1990, about 207,00 assorted seedlings were planted to an area of 82 hectares within the mining areas. In 1990, best mining industries nationwide in the Adopt a Tree a Mining Forest Movement sponsored by the DENR. In 1991, Philex Mining Corporation was adjudged as the First Place as the Best Mining Forest in the nationwide Adopt a Tree a Mining Forest Movement of the DENR for all mines. 315,000 assorted seedlings were planted to a grand total of 110 hectares. The company was also awarded the Presidential Trophy for the same contest on 1994 for the underground mining category.
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MINE AND MILL PRACTICE Program was implemented wherein all the
In
1992,
Agro-Forestry
kaingeros/sayote farmers were encouraged to participate. This program aims to uplift the socio-economic conditions of the farmers dependent on the forest lands for livelihood and at the same time protect and improve slopes from environmental degradation such as erosion. The farmers in the area were required to intercrop fruit bearing trees (coffee, guava, etc.) in their plantations for the protection of the areas from erosion and also they were required to protect the forest areas from destructive forest fires during the dry season. Assorted forest tree seedlings were also donated to the different schools in the outlying areas of Philex as part of the outreach program. In 1995, Philex Mining Corporation was one of the Likas Yaman awardees by the DENR-CAR as an acknowledgement and commendation of the efforts, commitments, and participation of the company in the protection and enhancement of the environment of the environment and natural resources. Forty one (41) hectares were replanted with 110,156 seedlings of various tree species. For the year of 1996, about 133,544 assorted seedlings were planted to an aggregate area of 30 hectares. Philex was the first runner up in the Best Mining Forest Contest. In 1997, about 110,136 assorted seedlings were planted within the mining forest areas covering a total of 40 hectares. Second runner up was awarded during the 44 th Annual Mine Safety and Environmental Conference held in Baguio City last November 25-29, 1997. In 1998, 260,311 assorted seedlings were planted over 105 hectares. The survival rate of the trees planted has greatly improved to 86%. First runner up was garnered on the much coveted Best Mining Forest Award, presented during the 45th Annual Mine Safety and Environmental Conference held in Davao City on November 25-28, 1998. Philex Padcal operations,
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bagged the much coveted Presidential Mineral Industry Environmental Platinum Award in recognition of the companys dedication, initiative, and innovation on the pursuit of environmental excellence. Today, the reforestation and forest protection program of the company is moving on with great success on account of participation of all concerned sectors in the community, the workers, purok leaders, and members, civic, cultural, religious and professional organizations, the outlying communities and the local baranggay units. 9.4 MINE COMMUNITY DEVELOPMENT 9.4.1Community Relations and Socio-outreach Program The companys outreach and socio-development programs continue to provide assistance to the community and neighboring sitios. For one, Philex built and continually maintains the Philex-Kias provincial road, which benefits all residents along the stretch of the road. Assistance provided to the neighboring sitios is in the form of materials, technical assistance, and medical missions, among others. Various livelihood projects are being initiated and implemented by the Philex Mining Company for the employees dependents and residents. These include loom weaving, sewing, bag and stuff toy making, food processing, candle and floor was making, and flowerpot making livelihood associations were established to ensure continuity of these projects. 9.4 `Labor Relations, Employment and Employee Benefits The company, which has been adjudged as one of the best managed firms in the country, employs about 3,300 employees supporting more or less 24,00 dependents.
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Employees and their families are provided with the basic amenities of life such as free low cost housing, water and electricity services, transportation and logistics, communications and recreational facilities, medical, dental and hospital services, rice subsidy and free elementary and heavily subsidized high school education.
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REMARKS AND RECOMMENDATIONS On Social Acceptability: 1. Call for the participation of the people and groups involved such as NGOs, LGU, and community council in the completion of projects from the preliminary stages of planning, carry out assessment and monitoring of compliance such involvement enables the concerned parties to take the responsibilities for environmental protection and management through active partaking in decision making. 2. Firm execution of the programs in community relations towards distinguishing concerns and apprehensions of several different groups can be useful solution of resolving disagreement and developing workable plans. On People Problems Common People Problems Includes: a. Motivation and monitoring b. Performance disagreements (superior-employee, employee-employee) c. Job assignments d. Working conditions (i.e. equipment familiarity) e. Programs We recommend that the company could establish performance standards that distinctive and clear cut and the measurement of performance should be certain and appropriate. Be alert in pitfalls and upgrade information regarding complaints that need
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to be specified. It should be noted that programs, plans, policies, and regulations should be updated and regularly assess to achieve a more dynamic and incorporated long term strategy not only to meet domestic need but achieve self sufficiency. On Mining Operation: 1. Performance Upgrading Program To further improve and enhance the quality of service through the reduction of system losses, guarantee sufficient maintenance of regulations, and minimization of service disruption, we are proposing for an institutional strengthening courses for the employee, personnel and miners such as appropriate technical training of circulation system testing and workshops in safety and protection, relay setting, and other aspect of service operation must be offered. 2. Information Dissemination We must recognize the intricacy in the operation and in turn to help the people involved value the corresponding benefits of knowing the operation. A review process that states the purpose and the workings would be important in promoting labor support for the plan to move. 3. Reduction in cost disparity and cost accumulation To further tackle the reduction in cost disparity and cost accumulation, we are suggesting that the company should work at improving operational efficiency of distribution utilities especially in helping the miners/employee in equipment familiarity, go in for least cost supply by initiating activities such as market development and survey, market characterization of supply and demand, market
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projections and doing the feasibility studies (including pre-feasibility and detailed feasibility studies in market plans) among others. On Mine Planning and Design: We suggest that to be able to increase productivity, additional workforce especially mining engineers, civil engineers and skill draftsmen should be designated in the mine planning and design because there is an insufficient workforce to be able to meet the demand of the company especially in engineering works which includes but not limited to lay-outs, plans, and cross-section of underground workings. On Software Program and Technology: Since the mining computer software programs and other technologies are costly and to change software programs may cause more difficulties than advantages, we recommend that even if the financial problems occur in developing these technologies, the company could pay heed to improving the performance of technologies which have been commercially proven adaptable to local conditions. On Hauling 1. Equipment should not be idle because a mine loading equipment working hours are computed in operating costs so if a one mine loading equipment remained idle even just for a moment, money is lost and the machines maximum performance cant be optimized. Also, it is better to let the machine be in continuous operation because the start-up is a time consuming and cost generating step.
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2. Equipment should be suitably sized with each other in a mining operation because it can: a. Maximize working hours and performance of the equipments because both operational and labor costs are being paid. b. To have a continuous operation without delay or stand-by equipment. c. To work an effective design especially in road design, production, etc. On Drainage: We highly suggest that in order to reduce the water accumulation on the underground workings that is a potential hazard which can cause accidents, additional drainage pattern and systems be adopted. It is much safer and effective for the workers and equipments to work in an area where there is no or little amount of floodwater and mud. On Supports: We recommend for close supervision and tight monitoring regarding the installation of supports especially in putting cemextra capsules because there are workers who does not follow the standard monitoring procedure in proper installation and amount to be installed in such areas. Such occurrences may result to catastrophic events regarding accidents and poor working conditions and production problems. On Ventilaiton: We highly suggest for additional set up of proper and adequate ventilation system that would give a stable atmosphere for miners working in the underground. We
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also recommend for tight monitoring of the air flow system that would easily determine the sources of problems that affects the ventilation proper underground. On Blasting and Explosives: 1. In hauling and loading of explosives to deliver in the working area, we suggest that they should have a separate loading equipment to be used instead of using the scoop tram or the LHD unit to deliver the explosives in the designated working area. This causes loss of time in the production operation. 2. We also suggest for the regular maintenance of the Blasting equipments used in the operation. Trouble shooting or maintenance of the equipments is usually done during the blasting proper. Again it causes loss of time. On Road Maintenance: Road maintenance is important so we suggest the necessary requirements and conditions to be able to maintain road efficiency so as to help in making efficient equipment performance because improperly maintained road, could lead to equipment damaged especially its tires and to prevent delay and traffic since working hours are payable and unnecessary stops and delays can cause additional payment and loss money. Delay in hauling also causes the operation to stop. On Mine Dewatering: To ensure safety and workable condition in the subsidence area especially during rainy days, near locations of sources of water that may cause problems during operation and geotechnical hazard if the slope stability is not maintained, should all be
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located. Proper dewatering patterns should be maintained and strictly monitored. Pumps should also be installed in working places underground which has a large volume of water accumulation. On Mine Safety particularly Underground Operations In dealing with emergencies such as natural causes we recommend to eliminate if not minimize recurrence of such incidents in the future by proper coordination of the department concerned by implemented which includes: a. Placing of supervision and alarm system for immediate recognition of leaks on pipeline networks. b. Frequently conduct drills and survey for accident preparedness and prevention and visual and firs hand monitoring. c. Ensuring the accessibility and availability of safety materials and equipment when the need arises. On Mine Engineering and Draw Control Division We would like to propose for the active involvement of student trainees particularly in giving suggestions concerning their schedules and what department or sections or topics they think should have more time and lectures, hands-on approach and participation are also recommended. This will be most beneficial for us students if we know the issues and areas that should be most focused on. determining and citing mitigating procedures to be
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On Geology Department The geology department was one of the vital divisions which we believe can most educate us students. On our case, we only had 1 day of visit and orientation on this department. We havent have enough time to be exposed on geology departments activities such as mapping, recording and compiling geological data in and around the mine, exploring, dating and sampling mineral deposits,
interpreting and mapping the geology of the mine, preparing and presenting data; checking the quality levels of materials produced for reserve assessment, classifying resources, asse ssing geo-techniques, and updating detailed databases etc. We propose for a longer schedule of days for trainees to be assigned in this department for better assessment and understanding of the geology of Philex Mining Corporation. On Mill Division Similarly with the geology department, we were scheduled with 1 day visit only on the mill division. One day of visit on this division is relatively insufficient for us trainees to understand the flow of operation especially if u would consider the population of trainees. We were also expecting for activities like sampling and computations of certain data to be exposed to us, but due to mill guidelines, we were not allowed to interfere with the operation. Nonetheless, the mill division visit is still very beneficial for us. We suggest for at least a week of exposure on the mill division, considering that this division is one of the major divisions of Philex Mining Corporation.
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On Assay Department Also with the geology and the mill division, we only had a day of visit on the assay department. And our visit on the department was not fully beneficial. We were not allowed to be involved in their operations. They just advised us to conduct pure observation for us not to delay the flow of the operations. We were expecting also for hands on activities of which is the best way for us to learn things which our important on our field. We ask for better interaction between the trainees and the employees at the assay department. And analogous with the geology and mill division, we propose for longer schedule of days for trainee exposure in this department.
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On Human Resource Training and Development Department This department is the department which considered us a family. The human resource department, or the HR which we termed, did not fail to guide, instruct, and educate us while we are staying within the vicinity of Philex Mining Corporation. This department in the person of Mr. Ferdinand Banggiacan (Sir KOKOY), and Ms. Sheryl Balcita (Mam She) stood us the backbone and foundation for us trainees. They were always there to check on us, to organize us, and to whip our ass if we did wrong. We would like to express our deepest gratitude fully to this department for the assessment of the trainees, for preparing everything for us including the accommodation during our training period, and of course for increasing our allowance (hahaha ). Thank you for treating us as one of your own and for accepting us as a part of the community. No words can further express more of our appreciation to the people behind this department. We thank this department for the guidance, inspirational ideas, and for all the learning that they taught us whether job related or not, and for enhancing our character within us. Overall, we thank you for making our On-the-Job training fruitful, bountiful and highly educational. We will always remember this period in our lives as we chase the road of success in becoming a Mining Engineer.
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MINE AND MILL PRACTICE PHOTOS of SLU MINERS
First day of Our Trainingtraining in the Department First day of our in the Mining Mining Department.
A picture taken at the Subsidence Area during our training in the Draw Control Department.
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Geared up for the job! SLU Miners ready to go to work with full PPE.
First day of our stay Philex Mines.
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Trainees taking refuge from the searing heat of sun under mango tree during our tour in the nursery.
A picture taken during the Farewell Party at Smith Hall.

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Mr. Ferdinand Banggiacan orients the trainees on their Mine Camp tour.
A picture taken at Saint Louis High School Philex.
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Trainees from SLU, CIT-U, MSU, BU, AU, and UP visits the subsidence area during the Mine Camp Tour.
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Trainees visit the tailings dam of Philex Mines.
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The OJT exposes not only our technical skills but also team work in dish washing.
Students from SLU and CIT-U take a short leisure of playing basketball. SLU always dominate the court.
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The trainees enjoyed one day of fun in an outing at Itogon Hotsprings.
A picture taken at the Concentrate Stockpile during our Mill visit.
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I, enrolled in Saint Louis University as a Bachelor of Science in Mining Engineering student, hereby certify that the contents of this report are based on the actual training process during my training period. Sucilan, Carol Rose Buada, Mark Efren III Cuntig, Eunice Dictag, Russel Dulinen, Delfer Lardizabal, Johnray Lee, Jerome Yulo Lingwayon, Joseph Malis, Jordan Mama-o, Elmo Mangliwan, Lester Ollabis, Billy Jr. Ong, Vincent Ostrea, Jason Valenzuela, Junelle
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A call for Responsible Mining Rizal, in his essay The Philippines A Century Hence said: Very likely the Philippines will defend with inexpressible valor the liberty secured at the price of so much blood and sacrifice. With the new men that will spring from their soil and with the recollection of their past, they will perhaps strive to enter freely upon the wide road of progress, and all will labor together to strengthen their fatherland, both internally and externally, with the same enthusiasm, with which a youth falls again to tilling the land of his ancestors who long wasted and abandoned through the neglect of those who have withheld it from him.
.Then the mines will be made to give up their gold for relieving distress, iron for weapons, copper, lead, and coal. Perhaps the country will revive the maritime and mercantile life for which the islanders are fitted by their nature, ability and instincts, and once more free, like the bird that leaves its cage, like the flower that unfolds to the air, will recover the pristine virtues that are gradually dying out and will again become addicted to peace cheerful, happy, joyous, hospitable and daring.
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Summer 2012

MINE AND MILL PRACTICE

The location of Philex Mining Corporation in the Baguio Mineral District.

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Benguet as one of its valued and treasured began properties. Philex

Open Pit Mining (March 59)

Block Caving - Slusher System (1963-1996)

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GEOLOGY OF STO. TOMAS II PORPHYRY COPPER DEPOSIT

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1.4 + 0.4 Myrs

phenocrysts, color and

weakly mineralized. 2. Clear

gray in color, fine to medium

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MINERALOGY OF PHILEX ORE

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-3-5% Anhydrite/gysum -1-2% Calcite.etc.

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Aerial Location of Sto. Tomas II Deposit

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Plan view of Level 908 showing Sta. Fe Fault

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Lithology of Sto. Tomas II deposit (Top View)

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CHAPTER 4 MINE PLANNING AND DESIGN 4.1 Underground Mine

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