GE’s Mining for Tomorrow

Introduction to Engineering Design

Section 008
Team 8

Submitted by: Shaylen Amin, Jingxin Wang, Reagan Thomson, Ryder Rigby, Eric He (left to right)
Submitted to: Xinli Wu

Prototype

Abstract (Reagan Thomson)

Date Submitted: 4/29/17

Group 8, designed a system to improve the current process of block mining. The team focused on

the transportation and extraction method. The following report demonstrates the effectiveness of

combining the process of scooping and crushing the ore body into one machine.

FIG. 1 Image of Prototype

Model C introduces a
new separation
Table ofmethod
Contents
in which ore
is sorted by density in
Cover Page (Team)
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Abstract (Reagan Thomson)…………………………………………………..…………………..I

Table of Contents (Team)……....…………………………………………..…………...………...II
Introduction (Jingxin Wang)……………………………………………….……………………...1
Description of the Design Task
● Problem Statement (Shaylen Amin and Reagan Thomson)..…………….……………….1
● Mission Statement (Jingxin Wang)………………………………………………………..2
● Design Specifications (Reagan Thomson)…………………………………………..…….2
Design Approach-Design Matrix
● Project Management--Gantt Chart (Ryder Rigby)………………………………....….…..3
● Concept Generation-Brainstorming (Ryder Rigby)…..………..………………………..3-6
● Design Selection Matrices (Jingxin Wang)…...………………………………………...7-8
● Description of the Best Design Selected (Shaylen Amin)………………………………...8
Prototype/Model
● System Diagrams (Shaylen Amin)………...........................................................................9
● Prototype Scale and Digital Image of the Prototype (Ryder Rigby)……............................9
● Design Features (Shaylen Amin)..….................................................................................10
Analysis
● Rationale for the Selection (Reagan Thomson)……………………………..…………...10
● Concept of Operations (Eric He)………………………………………...……………....11
● Life Cycle Analysis (Ryder Rigby)……………………………………………………...12
● Assessment of Important Aspects of the System for Feasibility & Adoption (Eric He)...13
● Economic Viability of the System (Shaylen Amin)………………………………….......13
Summary and Conclusions (Reagan Thomson)……………………………………………….....14
Powerpoint Presentation Slides (Team)......……………………………………………………...15
Tri-Fold Brochure (Jingxin Wang)…………………………………………………...……....15-16
Acknowledgement (Jingxin Wang)………………………………...…………………….…..16-17
References (Jingxin Wang)………………………………………………..……………….....17-18

I. Introduction (Jingxin Wang)

This report contains the steps and procedures that
ModelwereCused in developing
introduces a and improving
processes of the modern block mining method.new
Thisseparation
project is called “Mining for Tomorrow”,

method
and is sponsored by General Electric. The improved in which
system oremining will make the
of block

current process more efficient and accessible. is sorted

This by density
will bring in
many benefits to aspects including
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

the industry, the surrounding environment, and the local community. This improved process of

block mining is more efficient, more environmentally friendly and safer for the workers. After

designing several concept generations, the best feature of every team member’s design was

extracted and combined into the final design. Using the overall design, a prototype was generated

as well as concept drawings. The report also contains the working mechanism, concept of

operations, and other aspects regarding the new and improved process of block mining.

II. Description of the Design Task

Problem Statement (Shaylen Amin and Reagan Thomson):

The current process of block mining is not as efficient and productive as it could be. It involves

harmful emissions that compromise the health of the workers, it requires large amounts of

expensive energy, it takes years of preparation and digging before extraction can be made

possible, and it impacts the surrounding communities.

Mission Statement (Jingxin Wang):

Our mission is to create a cost-efficient and environmentally friendly block mining system. This

system will reduce the negative effects caused by block mining and maximize the profits.
Model C introduces a
new separation
Design Specifications (Reagan Thomson):
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

1) Airborne contamination: including chemical and particulate emissions released to the

environment.

2) Occupational health and workplace safety: including an emphasis on prevention or mitigation

of workplace hazards.

3) Operating costs and productivity: including development and operation of the REE mine and

ancillary costs for mining equipment, fuel, labor, electricity, water, etc.

4) Local community engagement: including the challenges that may be encountered in engaging

local and adjacent communities and the emphasis on its social license to operate as a good

neighbor.

5) Mine closure and rehabilitation: including prevention or mitigation of long-term degradation

impacts to the environment and consideration of future sustainability of the site.

III. Design Approach

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Project Management--Gantt Chart (Ryder Rigby):

Concept Generations (Ryder Rigby):

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Model A is strictly an extraction based plan.

It features a 20 degree grade conveyor belt
extending from the ore body to further assist
gravity. Furthermore, it includes a
revolutionary hook feature which corrals
and crushes ore together.

FIG. 2: Model A (Jingxin Wang)

Model B highlights an alternative

FIG. 3: Model B (Shaylen Amin)
strategy for drilling and blasting
points. Unlike the traditional below
ore work, this design works from all
angles, spiraling around the ore from
top to bottom
Model to createthe
C introduces more
idea of
blast/extraction sites.using large
sorting by density
Model C introduces a
water containers. The goal is to
new separation
speed up the gathering and
method inrefinement
which ore process by having
thedensity
is sorted by REE allinin one place.

water containers. The

goal is to
eliminate/cut down on
 discover REE quicker.

FIG. 4: Model C (Eric He)

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Model D simplifies the

extraction process
ingeniously. It places the
crushing mechanism at the
point of extraction, allowing
for the ore to be reduced in
size on site and taken away
by conveyor belts.

FIG. 5: Model D (Reagan Thomson)

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Model E display the implementation

of a continuous moving vehicle
circling the ore body. This looped
track serves to collect REE in a
single sweep and deliver it to the
crusher area.

FIG. 6: Model E (Ryder Rigby)

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

FIG. 7: Model F (Reagan Thomson, Ryder Rigby, Eric He, Shaylen Amin, Jingxin Wang)

Model F ultimately combines many of the previous designs with a central focus placed on

extraction. The new system places the revolutionary crusher (similar to a wood chipper)

from Model D at the base of each draw point with the goal being to speed up extraction

of the REE. The crushed ore is then shot onto a conveyor belt perpendicular to the mine

which includes guard rails to ensure no material goes to waste. These series of belts then

dumpoff to a parallel conveyor that takes the ore away from the extraction points and

towards the vertical shaft. Lastly, the traditional vertical shaft is replaced by looping
Model C introduces a
series of bucket-like containers which simultaneously collect ore from the belt and
new separation
deliver it up to the surface. method in which ore
is sorted by density in
Design Matrices (Jingxin Wang)
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Concepts

Selection Model A Model B Model C Model D Model E Model F

Criteria (Reference)

Efficiency + - 0 - - +

Worker Safety - + 0 - - +

Environmental + + 0 - + 0
Safety

Cost Efficiency - 0 0 0 - -

Sustainability - - 0 + + +

Stability of 0 0 0 - 0 +
Design

Community 0 + 0 + - +
Impacts

Sum of +’s 2 3 0 2 2 5

Sum of 0’s 2 2 7 1 1 1

Sum of -’s 3 2 0 4 4 1

Net score -1 1 0 -2 -2 4

Rank 4 2 3 5 5 1

Continue? No Yes Yes No No Yes

Model C introduces a
new separation
method in which ore
Model B
is sorted byModel C
density in Model F
Selection Criteria Weight (Reference)
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

(%) Rating Weighted Rating Weighted Rating Weighted

score score score

Efficiency 20 3 0.60 3 0.60 4 0.80

Worker Safety 20 3 0.60 3 0.60 5 1.00

Environmental 15 2 0.30 3 0.45 4 0.60

Safety

Cost Efficiency 15 3 0.45 3 0.45 3 0.45

Sustainability 10 4 0.40 3 0.30 2 0.20

Stability of
10 3 0.30 3 0.30 3 0.30
Design

Community
Impacts 10 1 0.10 3 0.30 5 0.50

Total score 2.75 3.00 3.85

Rank 3 2 1

Continue? No No Develop

The Best Design Selected (Shaylen Amin):

Each design that was evaluated had its very own strengths: however, Model F scored the highest

due to its simplicity and ability to attack the problem in an efficient manner. It eliminates the

need for a separate crusher, which in turn will save money on machinery, save time in

transportation, and it will require less digging. These three advantages, in combination, make for

a design that will decrease General Electric’s spending on the project and, at the same time,

increase the net profit from the project. Model C introduces a

new separation
IV. Prototype/Model
method in which ore
System Diagrams (Ryder Rigby):
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Surface

Ver
Ore
Body
tic
al
Bu
ck Cru
et Conve
Sh she yor
aft
r Belts

FIG. 8.

Prototype Scale and Images (Ryder Rigby)

Model C introduces a
Design Features (Shaylen Amin):
new separation
This design involves the use of mobile crushers, conveyor
method belts, and
in which orea complex vertical shaft in
order to extract ore efficiently. The components
is of ore extraction
sorted wereindesigned to be compact so
by density
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

that minimal work would be needed to completed in order to move ore throughout the process.

More specifically, the crusher was designed to be inside a movable cart so that miners would not

need to dig further down into the earth in order to place a crusher. This eliminates unnecessary

energy expenditure and costs.

V. Analysis

Rationale (Reagan Thomson):

Team 8’s idea is an improved model of the current system. The team’s new system focuses of

extraction through a dual process vehicle, conveyor belts, and an improved vertical shaft. This

new vehicle combines the traditional scooping of the rock, with the tedious process of crushing

the ore. It can be compared to the idea of a woodchipper. By eliminating the need for a large

crusher, the block mining process can be carried out quicker and more efficiently. Without the

need to dig deeper into the mine, costs will be reduced and energy will be saved. Additionally,

the use conveyor belts will help to lower harmful emissions produced from vehicles and

machines. While the new vehicles will still run on diesel, the use of conveyor belts will limit the

distance they have to travel and therefore contain the harmful waste and allow us to focus our

efforts of ventilation and containment. The third aspect of the project is an improved vertical

shaft.

Concept of Operations (Eric He):

Model C introduces a
The goal is to design a more efficient way to obtain ores by limiting the steps taken to get the
new separation
raw ore. By using more conveyor belts we cut down on fuel from the trucks and by integrating
method in which ore
the conveyor belts so that it is also under the ore crushers at all time, we eliminate the need of
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

vehicles underground and the use of fuel for those vehicle therefore making it much

environmentally safe as well. By focusing on improving extraction, the design becomes more

cost-efficient and saves time and energy.

Ore from ore body Ore crusher crushes

falls into ore crusher and fragments rock

System
Buckets bring
Coordinates with Fragmented rock falls
fragmented rock to
every aspect to use all onto conveyor belt
surface
aspects efficiently

Conveyor belt brings

fragmented rock to

buckets

Life Cycle Analysis (Ryder Rigby):

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Construction Mine Closure

Vertical Bucket Shaft Tailings Sealed
Drilling Concrete Covers For Drilling Points
Vehicle Ramp Drilling All Waste Materials Delivered to
Diesel Machines Inserted Chemical Plants
Blast Points Selected Conversion of Lowered Surface to
(Lower Sides) Water Park/Ski Resort

Environmental Extraction
Procedures Crusher Delivers Ore To
Ventilation Shaft Drilled Conveyors
Conveyor Belts Installed Conveyors Deliver Ore to
Machines Move Limited Shaft
Distances Bucket Shaft Delivers Ore
Not Digging Below the to Surface
Ore (Continuous Process
Limits Wasted Time and
Emissions)

Model C introduces a
new separation
method in which ore
is sorted
Assessment of Important Aspects of the System by density
for Feasibility andinAdoption (Eric He):
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

Being that conveyor belts are already part of the original system, it is highly feasible that adding

conveyor belts would be beneficial. After careful research, it was also found that energy used for

conveyor belts are relatively low and that since they are sold wholesale, each part of conveyor

belts do get cheaper. Also the fact that conveyor belts are already part of the system, it would be

much easier to improve the current system. The system would be able to be easily adapted since

conveyor belts had already been used prior to the new addition. As for the ore crusher cart,

building an ore crusher would create emissions just as a vehicle would. The crusher would not

only be more time efficient but due to its good use of time, it may even be more environmental

friendly. Both cost-efficiency and environmental safety are important to the design and therefore

is a great improvement to the system.

Economic Viability (Shaylen Amin):

When any project is executed, the project managers must consider cost as a limiting factor. Team

8’s design is somewhat centered around this concept. The combination of a crusher in a single

vehicle does not require the company to dig further into the ground in order to create a separate

crusher. In addition, the bucket transportation system leads to less waste of materials since all of

the REE is brought up to the surface without any loss. Furthermore, one can see that this design

makes the process go much faster, which could allow General Electric to move onto a different

ore deposit in a shorter amount of time. These factors, when combined, increase the overall profit

of excavation and prove that Team 8’s design is quite exceptional.

Model C introduces a
new separation
method in which ore
VI. Summary and Conclusion (Reagan Thomson)
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

The most challenging aspect of this project was coming up with an idea. Given that no group

member had any mining experience, and no one on the team had ever heard of block caving, the

challenge was to overcome that first step. In order to do this, Team 8 spent a lot of time in the

first few weeks researching and watching videos on block caving. It wasn’t until the third week

that a final concept was agreed upon. Instead of choosing one person’s concept, the ideas were

combined into one final system with a focus on efficiency and extraction. However, in the weeks

afterwards, there was still little fixes and adjustments that were made. During that time of

brainstorming and information gathering, the project report was started. It was helpful being able

to refer back to our mission statement to respond to any questions or confusion.

If there had been more time allotted to this project, it would have been beneficial to speak to

mining experts, or even take a trip to visit a mine in Pennsylvania. It can be hard to understand

the large scale scope of a project like this, and being able to see a mine may give more incentive

to a team. Another aspect of this project was the ambiguity of it. There was no right or wrong

answer which allowed for discussion. Having more room for creativity allowed for diverse

opinions from team members in different fields of engineering.

Model C introduces a
VIII. Powerpoint Presentation Slides
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

https://docs.google.com/presentation/d/1FqTu-OV1bhnaP--

Yiu9UsjtUlS_qFi4V9DyKD9xNtZo/edit?usp=sharing

IX. Tri-Fold Brochure (Jingxin Wang)

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

XI. Acknowledgement (Jingxin Wang)

We would like to express our gratitude as a team to our professor Xinli Wu for his assistance

throughout the entire process of this project. Professor Wu gave many vital suggestions, advices

throughout the process. Professor Wu also inspired and taught us so much through guiding us

through this project. We would also like to thank General Electric for sponsoring this project, we
Model C introduces a
have gained many new perspectives throughout the process. Special thanks to all the TAs that
new separation
helped us throughout the process as well. method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

XII. References (Jingxin Wang)

Hem, Priyadarshi. "Block Caving ." TechnoMine. N.p., n.d. Web. 28 Apr. 2017.

<http://technology.infomine.com/reviews/Blockcaving/welcome.asp?view=full>.

"Underground Block Caving: A Guide for Investors." Investing News Network. N.p., 16 Apr.

2013. Web. 28 Apr. 2017. <http://investingnews.com/daily/resource-investing/underground-

block-caving-guide-investors-open-pit-mining-rio-tinto-codelco-freeport-grasberg-

chuquicamata/>.

Matrix. "Research to Improve Block Cave Mine Ventilation." International Mining. N.p., 27 Oct.

2014. Web. 28 Apr. 2017. <http://im-mining.com/2014/10/28/research-to-improve-block-cave-

mine-ventilation/>.

AtlasCopcoUG. "Block Caving Mining Method." YouTube. YouTube, 15 Jan. 2016. Web. 28 Apr.

2017. <https://www.youtube.com/watch?v=MVDAw56s5dU>.

"Block Cave Mining at Northparkes Mines." YouTube. YouTube, 23 Dec. 2013. Web. 28 Apr.

2017. <https://www.youtube.com/watch?v=5woCaxXB7Jk>.
Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on
 discover REE quicker.

N.p., n.d. Web. 28 Apr. 2017.

<http://www.groundtruthtrekking.org/static//uploads/figures/e3e91810-a88a-47bb-a19b-

71cc927045a6/block%20caving%20small-04.jpg>.

Model C introduces a
new separation
method in which ore
is sorted by density in
water containers. The
goal is to
eliminate/cut down on