CAPITAL AND OPERATING COST ESTIMATING SYSTEM MANUAL FOR MINING AND BENEFICIATION OF METALLIC AND NONMETALLIC MINERALS EXCEPT FOSSIL FUELS IN THE UNITED STATES AND CANADA
BY
GEORGE K. CLEMENT,
JR.~
LOUIS AVERY;
ROBERT L. MILLER,2 AND
PHILIP A. SEIBERT,3
HAROLD BENNETT
5
1·3 COMPUTER SERVICES AND MANAGEMENT CONSULTANTS, INC. 21243 VENTURA BLVD., SUITE 226 WOODLAND HILLS, CA. 4 PRIVATE CONSULTANT, LOS ANGELES, CA.
5 MINERALS AVAILABILITY FIELD OFFICE BUREAU OF MINES, DENVER, COLORADO.
}'or sale by the Superintendent of Documents. U.S. Government Printing Office Washington, D.C. 20402
PREFACE
Mining relies on anomalies within the surface of the earth for a base of activity. Hining and evaluation engineering are confronted repeatedly with problems of determining how and at what rate a particular deposit can be mined, how to get the equipment, personnel, and money for mining and processing, and how to set up the related infrastructure. When these problems are resolved, the engineer becomes involved in financial considerations. For example, what is the ratio of equity capital to borrowings, and what is the rate of return that may be achieved before a recommendation for the approval or rejection of the property can be made to management? Articles on cost for site-specific operations appear frequently in the technical literature. They may be useful i f an engineer is conSidering a similar property, but this is seldom the case. Often the engineer is required to consider specially designed extraction and treatment methods applicable to unique or nearly unique deposits. In addition, the engineer is plagued by rapid changes in capital and operating costs. Recognizing this situation, the Bureau of Hines undertook the development of a methodology or cost system, usable by a mine evaluation engineer in generating capital and operating costs applicable to a feasibility study of a particular property or operation. This handbook, the product of this undertaking, is not intended to be the final solution to the problem of cost determination; it is also not a "black box" usable by the unskilled. It will, hopefully, be a useful adjunct to the "tool kit" of mining engineers responsible for property evaluation. Periodic updating and refining of the important data on which the handbook is based will improve its usefulness in the future.
A~~~ Chief Hining Engineer
PAGE
TABLE OF CO.TEITS 1. IITBODUCTIOJ
1
1.1. leed Par The Handbook
1
1.2. Us. Of The Handbook
1.3. Acknowledgeaents
2
2. GEIERAL I1FOBRITI01
4
2.1. Users Of The Handbook
4
2.2. Procedures for Estiaating ADd U.e Of Factors
4
2.3. Data RequireaeDt. For ID !sti.ate
5
2.3.1. General
5
2.3.2. Surface And Underground Bine
5
2.3.3. 8enefic.tion
5
2.3.4. Exploration
5
2.3.5. C.pital Cost
5
2.4. Bates - Labor, Paver ADd Water 2.~.
Types Of Rinino And BenefiCiation Included.
5 5
2.6. Environ.ental I.pact Statements
5
2.7. Definition 'Of Teras
6
2.8. Cost Indexes
6
3. BIlE OPEBlTIIG COST ESTIRITICI 3.1. Surface Rinino - Operatino Costs 3.1.1. ProductioD
Develo~aent
7
7 7
3.1.1.1. Clearing
7
3.1.1.2. Drill And Blast - Overburden And Vaste
7
3.1.1.3. Excavation. Load And Haul'- OVerburden And
8
hs~
3.1.1.4. Core DrillinV
11
3.1.2. Binino Of Ore
11
3.1.2.1. Drill And Blast - Ore -i-
11
PAGE 3.1.2.2. Excavation, load And Haal - Ore
12
3.1.3. B•• toratioD Darino ProductioD
14
3.1.4. Ceneral Operations
14
3.1._.1. General It •• s - Co •• unlcatlons, Sanitation, HousekeepinQ, Fire Protection And Electrical
14
3.1.4.2. Yater Sappll Slstea
15
3.1.4.3. Drainaoe And Disposal Slstem
15
3.1.4.4. Camp
O~eration
16
3.1.4.5. Lono Distance Transportation
16
3.1.4.5.1. Rail TraDsportation
16
3.1.4.5.2. Truck
Trans~ortation
17
3.1.4.5.3. iater
Trans~ortation
17
3.1.4.5.4. Pipeline
Transpor~tion
3.2. Surface Binino - Administrative Costs 3.2.1. Ceneral
Expen~e
17 17 17
3.2.1.1. Adainistrative Salaries And Vaoes
17
3.2.1.2. AdainistratiYe Purcbases
18
3.2.1.3. AdainistratiYe Equipaent
O~eration
3.3. Underoround Binino - Operatino Costs
3.3.1. Production Developaent
18 18 18
3.3.1.1.1. Small DriftE For Rail Haulaoe
18
3.3.1.1.2. Small Drifts For Rubber Tired HaulaOE
19
3.3.1.1.3. Laroe Drifts For Rubber Tired HaulaOE
~
3.3.1.2. Sinkino Shafts
20
3.3.1.3. Drivino Raises
21
3.3.1.4. PreparinG Stopes
21
-ii-
PlGI
3.3.1.5. Core Drllllno
D
3.3.2. Rlnlno Of Ore
D
3.3.2.1. Shrlnkaoe Stope.
D
3.3.2.2. Cut Alld FU1 Stope.
23
3.3.2.3. O.erhand Stope.
23
3.3.2.11. Lonohole Stope.
~
3.3.2.5. Rooa And Plllar
~
3.3.2.5.1. le41u. To Hard Bock
•
3.3.2.5.2. Soft Bock (nona.talllc)
~
3.3.2.6. Block Ca.lno
•
3.3.2.6.1. Block Caylno - Load-haul-du.p lethod
•
3.3.2.6.2. Block raylna - Slu.her And Graylty
Reth04s
•
3.3.3. Haulaae Of Ore
•
3.3.3.1. Holstlno
•
3.3.3.2. Ball Haulaoe
D
3.3.3.3. CODYeYOr Haulage
D
3.3.3.11. Truck Haulage
•
3.3.3.5. Load-hlul-duap Haalaoe
•
a
3.3.4. General 0;eratl0.8 3.3.q.1. General Ite •• - Co •• unlcation., Sanltat10n,
Housekeeplno, 'lre Protection And Electrical
a
3.3.q.2. Ventllitlon Syste.
a
3.3.1t.3. Co.pre •• ed Air Plant
30
3.3.11.11. lIater SultPlr S,.te.
31
3.3.4.6. Caap
O~eratlon
U
3.3.11.7. Lono Dlstlnce Trallsportatlon
U
3.3.IJ.1.1. Rall Transportation -111-
U
PAGE 3.3.4.7.2. Track 3.3.4.7.3~
T~ns~ortation
33
Water Transportation
~
3.3.4.7.4. PIpeline Transportation 3.4. Underoround !1nino - Adainistrative Costs 3.4.1. Ceneral
Expens~
~dainistrative
~
~
3.4.1.1. Adainistratlve Salar1es And Waves 3.4.1.2.
33
Parchases
3.4.1.3. ·Adalnletrative EQuipaent Operation 4. !IIE CAPITAL COST ESTI!ATIOI
4.1. Exploration And Access Roads
~
34 34 ~ ~
4.1.1. Exploration
~
4.1.2. Access Roads
~
4.1.2.1. Clearino
36
4.1,2.2. Excavation
~
4.1.2.3.· Drill ADd Blast
41
4.1.2.4. Gravel Surfacino
42
4.2. Surface
~inino
- Capital Costs
4.2.1. Preproduction Developaent
43 43
4.2.1.1. Clearino
43
4.2.1.2. Drill And Blast - Overburden lnd Waste
~
4.2.1.3. Excavation, Load And Haal - Overburden And Waste
44
4.2.1.3.1.
Excavation, Load And Haul Truck Haulage
46
4.2.1.3.2.
Excavation, Load' And Haul Scrapers
47
4.2.2. line Plant And Buildinos
47
4.2.2.1. Railroad Construction
.46
4.2.2.2. Vater And Drainaoe Slst.a.
46
4.2.2.2.1. Viter Slstea
46
4.2.2.2.2. DralnaOe Slste.
46
-iv-
PAGE
'.2.2.'.
'aelin, Sfstea
~
4.2.2.5. Electrical Sfstea
49
4.2.2.6. I'pair Shops ADd Warehouses
~
4.2.2.7. Office. And Lahoratories
~
Q.2.2.8. Sarface 8a1141nV8
51
'.2.3.
Townsite
61
Q.2.'. Restoration Durina Construction
62
'.2.5. Bine Equipaent
62
4.2.5.1. Surface BiniDG Iqulpaent
52
4.2.5.2. DradGes
63
Q.2.6. InGineerinG And CODstruction Banageaent Fees
53
'.2.7.
~
'.3.
Vorking Capital
Underoround Rinino - Ca,ital Costs
4.3.1. Preproduction D•• elopaent
Q.3.1.1. Developaent Drifts
~ ~ ~
Q.3.1.1.1. Saa11 Drifts For Ral1 Haulage
~
4.3.1.1.2. S.a11 Drift. for Ruther Tired HaulaGE
~
Q.3.1.1.3. Larve Drifts for Ruhher Tired Haulage
~
Shafts
~
4.3.1.3. DriviDG Raise.
~
Q.3.1.4. PreparinG Stopes
67
'.3.1.5. Core Drl11inG
00
4.3.1.6. C1.arinG
~
'.3.1.2.
Sinkin~
4.3.2. Blne Plant And Bui1dlngs
69
4.3.2.1. Co.preEsed Air facilities
59
4.3.2.2. HoistinG Facilities
59
4.3.2.3. 'enti1ation SY8t..
00
4.3.2.'. Vater Syst..
00
4.3.2.5. Drainage Systea
81
PAGE 4.3.2.6. Co •• aDications S7st ••
81
4.3.2.7. Faelino S7ste.
G
4.3.2.8. Electrical S7st ••
G
4.3.2.9. Repair Sho,s And Wareheuses 4.3.2.10. Office. And Laboratories
a a
4.3.2.11. Surface BuildinGs
M
4.3.3. TOWDslte
~
4.3.4. Restoration Durlno [onstructicn
~
4.3.5. !ine Equipaent
~
4.3.6. Engineering And CenstructioD !anageaent Fee.
~
4.3.7. Working Capital
87
5. BEJEFICIATIOI OPEBATIIG COST IST181TIOI 5.1. BeDeficiation - OperatinG Costs S.1~1.
CrushiDG
5.1.2. GrIndIng
~ ~
• 69
5.1.3. ConceDtratinG
70
5.1.3.1. FlotatIon
70
5.1.3.1.1. Sinole-,roduct Flotation
71
5.1.3.1.2. Two-product rlotation
71
5.1.3.1.3. Three-product Flotation
72
5.1.3.2. Concentrate Thickening
72
5.1.3.3. Concentrate Filtration
73
5.1.3.4. leachino
73
5.1.3.4.1. Cyanide 'at Leach
73
5.1.3.4.2. Duap, Heep Or 'at LeachinG
74
5.1.3.4.3. Uraniaa Ac1d leach
75
5.1.3.5. laonetic Separation
75
5.1.3.6. Heavy Bedia Separation
76
PAGE 5.1.3.7. era.ltl SeparatloD
78
5.1.3.8. Drlino Concentrate
78
77 77 5.1.4.1. Tal11n08 Dewaterln9
77
5.1.4.2. Transport And Place Tailings
78
5.1.4.3. Water Recl.a.tion
78
5.1.5. Restoration Durino Productlon
78 78
5.1.6.1. General Iteas - Ce •• unications, Sanitation,
Housekeepino, Fire Protection And Electrical
78
80
5.1.6.3. Water Supply Slstea 5.1.6.k~
Drainage And Disposal SysteM
5.1.6.5. Camp Operation
81
5.1.6.6. Lono Distance Transportation
81
5.1.6.6.1. Rail Transportation
81
5.1.6.6.2. Truck Transportation
82
5.1.6.6.3. Water
82
Tr.ns~ortatlon
5.1.6.6.4. Pipeline Trans,ortatlon 5.2. Beneficiation - Adainisttative Cests 5.2.1. General Expense
82 82 82
5.2.1.1. Administrative Salaries And Wages
82
5.2.1.2. Ad.iniatrative Purchases
83
5.2.1.3. Adainistrative Equip.ent Operation
83
6. BENEFICIATION CAPITAL CeST ESTI!ATICI 6.1. BenefiCiation - Capital Costs 6.1.1. Crushino
85 85 85
-vll-
PAGE 6.1.2. Grindin9
•
6.1.3. ConcentratinG
H
6.1.3.1. Flotation
88
6.1.3.2. Concentrate TbickenlnG
88
6.1.3.3. Concentrate Filtration
n
6.1.3.4. teachiD9
87
6.1.3~4.1.
Cyanide 'at t.ach
87
6.1.3.4.2. Duap, Heap Or 'at teach
U
6.1.3.4.3. Uraniu. Acid teach
•
6.1.3.5. 8a9netic Separation
89
6.1.3.6. Hea.y Bedia Separation
89
6.1.3.7. Gravity
Se~aratlon
89
6.1.3.8. DrJinQ Concentrate
" "
6.1.3.9. ti.estone Clinker
6.1.4. Waste And Ta1linQ. Disposal
91
6.1.4.1. TaillnQs DevateriDQ
91
6.1.4.2. Transport And Place TailinGS
91
6.1.4.3. Water Becla.ation
91
6.1.4.4. Earthfill Dikes And S.al1 Da.s
92
6.1.5. Site Preparation 6.1.5.1. Clearin9
~ ~
6.1.6. Utilities And Facilities
93
6.1.6.1. Vater Supply Syste.
93
6.1.6.2. Electrical
M
S~st••
6.1.6.3. 8ill Buildin9s
M
6.1.6.4. Officea And La.oratori8.
~
6.1.6.5. 'ebicl ••
~;
6.1.6.6. Riscellanaoua Equip.ent
H
CAPITAL AND OPERATING COST ESTIMATING SYSTEM MANUAL FOR MINING AND BENEFICIATION OF METALLIC AND NONMETALLIC MINERALS EXCEPT FOSSIL FUELS IN THE UNITED STATES AND CANADA
1. I1TRODUCTlOR
companies, were used as the basis of this handbook. The handbook presents cost curv~s and equations for each component of the mining and heneficiaticn process. factors for each cost component are also Qiven, thereby allowing the updating of cost for time, oeoQraph1c location, labor rates, and ~ining and milling conditions. Included in the latter conditions are items such as the lenqth of haul, need for rock bolts, and ~ rock work index for ores and rocks of various hardnesses.
1.1. REED fOR THE HANDBOOK The United States Bureau of Mines is establishing a computerized mineral inventory system to help the Federal Government appraise its mineral position and prepare programs insuring against critical shortages of materials. This system, called the ~inerals ~vailahility System (MAS), is a component of the Bureau's minerals intelligence function designed tc conduct and maintain an inventory of minerals important to the Nation. The ~AS defines the physical and commercial availability of the mineral resources. Known resources are evaluated and classified by deposit for entry into a computer storage and retrieval system. An integral concern of these evaluations is the cost of mining and beneficiatinQ the ore contained in specific deposits. To meet this concern, a cost handbook was developed as an aid to preparing feasibility-typ~ estimates for capital and operating costs of mining and primary beneficiation of various types of mineral occurrences. Cost data, obtained from U.S. and Canadian
1.2. USE OF THE HARDBOOK Using the handbook a feasibility-type estimate falling within 2S~ of expected actual cost is obtainable by su~marizin9 cost cornpon~nts. This handbook should not be used to determine the cost of any single com~onent of a mining or beneficiation system, as any sinole component mHY not fall withiri the 2S~ limit. It must be understood that anyone who uses the handbook must have a comprehensive knowledge of .1n1ng and processing technology and cost estimating r,rocedures. The handbook was intended to be used internally by the Minerals Availability System. Because 1
of outside interest the Bureau of Mines decided to ~ublish the handbook to make it readily available to the public. The text and curves contained in the handbook an'! essentially identical to those obtained from the contractor that oriqinally developed the handbook for the Bureau. STRAAM EnQineers, Inc. Some editorial work was performed on the layout of the text in order to confor. to Bureau standards. The data. however, are Qenerally as originally presented, and the vi&ws and conclusions contained in this document are those of STRAA~ F.nQine~rs, Inc., an.d should not be interpreted as necessarily repr~senting the official policies or recommendations of the Interior Department's Bureau of Mines or of the U.S. Government. STRAAM Engineers, Inc., believes the data to be accurate and reliable; however the! or the authors do not accept any responsibility, financial or otherwise, for any consequences arising out of the use of this handbook.
The Cleveland-Cliffs Iron Co. Cotter Mining Co. J. Irving Crowell, Jr.
& Son
Cyprus Mines Corp. Diamond Springs Lime Co. Dresser
Min~rals
Division
Duval 5ierrita Corp. The Feldspar Corp. Gaspe Copper 1. td • )
~ines
Ltd. (Moranda Mines
Georgia-Pacific Corp. Getty Oil Co. Goodnews Bay Mininq Co.
W. R. Grace & Co. 1.3. ACINOYLEDGftEMTS Hallett Minerals Assistinq STRAAM Engineers, Inc., formerly A. A. Mathews, Inc., In the plan development and field data collection was Hehre Dolbear & Co. Many mining equipment manufacturers and suppliers also provided assistance in developing equipment operating and capital costs. Field data used in compiling this handbook were obtained from the following sourcp.s:
The lIanna Minin'} Co. Homestake
~ining
Co.
Idaho MininQ Corp. Idarado Mining Co. Inspiration Consolidated Copper Co.
Amax Chemical Corp.
International Minerals r. Chemical Corp.
American Colloid Co.
Interpace Corp.
The Anaconda Co.
Johns-Manville Products Corp.
Apco 011 Corp., Minerals Divislon
Jones
American SmeltinQ and Refining Co.
Kennecott Ccpper Corp.
Beker Tndustries Corp.
Kyanite Mining Corp.
Brenda Mines, Ltd. (Noranda Mines Ltd.)
lamaque
California
~on-Metallics
LauQhlin Steel Corp.
~ining
Co., Ltd.
hivinoston-Graham Co.
Inc.
California Portland Cement Co. Ca~p
e
Mattagami Lake Mines, Ltd. (Moranda Mines Ltd.)
Bird Colorado, Inc. Meramec Mining Co.
Carlin Gold Mining Co. (Newmont MinIng Co. )
"ilchem Inccrporated
Clayton Silver Mines
2
Reynol~s
~lninQ
r.orp.
Mineral Industrial Commodities of America
Siqma Mines (Quebec) Ltd.
Molytdenum Corp. of America
Southwestern portland Cement Co.
Monolith Portland Cem@nt Co.
Standard Metals Corp.
~onsanto
In ..~u~_trial Chemicals Co.
Stauffer Chemical Co.
National Gypsum Co.
St. Joe Minerals Corp.
N L Industries, Tnc.
Sunshine MininQ Co.
Phelps Dodge Corp.
Teck Corp., Ltd.
pitkin Iron Mine
Texada Mines, Ltd.
PittsburQ Pacific Co.
Titanium Enterprises
Ranchers Fxploration & nevelop~ent Corp.
Utah Mines, Ltd. (Utah International)
Reserve
~inino
Co.
York Pullders
3
~upplJ
Co.
2. GEIERIL IIFOB"ITI0N
either laber index number 1. or 2. in Section 2.8. (Cost Indexes). This lu.p sum factor can be used for all classes of l~bor throuobout the estimate. Either factor can then be entered in the proper location.
2.1. OSEBS OF TBE HANDBOOK It is presumed the user will have adequate knowledge of both mining and estimatino procedures before attemPtinQ to prepare an estimate usinQ the methods presented herein.
All curves in this handbook are adjusted to a common base, i.e. all effort has been oeared to presentation of average data for the particular minino method or process und€r consideration. Should the user have an abnormal situation, proper adjustment of curve data, either upward or downward, should be made.
2.2. PBOCEDORES FOR ESTI"ITIIG liD OSE OF FICTORS By its very natur~, any compilation of data such as that used in the .preparation of the curves, tables and factors, must deal in 8vera~es. The user must be able to discern any differences between the method or process under consideration and that presented in this handbook. For that reason, wh€rever it is applicable that certain adjustment factors should be used, they have been referenced.
When determining the quantity to be used, unless otherwise noted in tbe specific component text, use tons mined or tons f~ed to the beneficiation component. After the data requirements have been prepared, the curves and narratives that apply should be studied until their contents ar~ understood. Then, for the proper abscissa value, select the appropriate orrtinate a~ount and enter it on th@ form. Note that all curves have logarithmic scales, not arithmetic.
~ention of certain adjustment factors has been omitted from the curve narratives in order to avoid duplication. These factors include the various cost indexes. labor rate conversion methods, POWf~ cost, and the more subtle v~riables such as rock hardness, floatability of various ores, etc. They are covered in this section, but it remajns for the user to properly apply these factors.
The data obtained from the curves and equations within the limits shown is reliable and ihg ___y~~___ §hQY1~ __ -n2t e!t£~~Ql~!g
___ QY~§1gg __ 1hg§~ __ 11m1~ __ ~
~~§Yl1§_~aY_Qs~~I211Ahl~~
The ran~e of the curves €ncompasses normal production with values beyond tendino to be outside the accuracy required due to the large variance cf milling and mining practices. Tn equations shown for the various curves in this handbOOk. the value of "X" is for the horizontal scale and the value of My" is in dollars. The My" subscripts "L", "SM. and "E" indicate lator, supplies and equipment operation respectively.
All labor rates (costs) use~ in the preparation of curves are based on the Denver, Colo., area as of July 1975, and include an approximate allowance of 35~ to cover all applicable payroll burdens. ~ll labor curves includ~ an appropriate allowance for equipment repair labor. Area and/or incentive bonus premiums are not inclUded and thp- user's judgment should be used in applying factors for these items. Two methods may be used to adjust the labor cost curves. Method one, the more accurate of the two, is to use the prevailing labor rates for the area under co~sideration, apply the appropriate payroll burdens and premiums, then use these costs 1n comparison to those Qiven in the narratives. Py dividing one hy the other a laber adjustment multiplier is obtained. rare should be taken in the use of labor rates as a large variance can occur within r.elativelY small geoqraphic dreas. The second methoj is to use a factor obtained by use of
After the dollar amounts for a particular item have been entered on the wort. sheets, the next step is to determine the proper adjustment factors (data will seldom require no adjustment). ~ost of the curves, particularly supplies and equipment operation, are composed of more than one it~m. Tn these cases, it will be necessary to apply a compound adjustment factor hased on the percentage occuring in each item multiplied by its appropriate cost index adjustment.
4
2.4. BATES - LABOR, POWER liD VATER
When the cost and all factors have been determined, multiplication will field the total cost. By a like manner, all applicable items are totaled and sum.ed, yie11ino a bottom line oroup total amount. These group amounts are then transferred to she~ts where total operatino costs per ton and total capital costs per ton per day are summarized for total estimated cost.
Labor costs have heen adjusted to a Denver base for July 1975 and include payroll burden. Burden includes such items as sick leave, vacation, holidays, insurance (medical, dental, disability, life & accident), payroll taxes (FICA, SOl & SUT) and retirement funds. Burden varies from 25~ to 65~ with an average used in this handbook of 35~. No production bonuses have been included in the labor costs.
-
None of the curves or equations i n this handbook have allowances for property general and/or inventory taxes, insurance or depreciation.
2.3. DITI
BEQUIRE~EITS
Cost of electrical power used throughout this handbook is constant at 25 mils ($0.025) per kW-h. Any variance from this rate should be applied as a supplies factor using the percentage of the supplie~ curve as noted in the curve text.
FOB 1M ESTI"ITE
Pefore using this handbook for preparation of an estimate covering any phase of mining or beneficiation, the user should first compile certain basic data that may be requlrpd. There are five basiC areas of interest to be covered:
Cost of water used throughout this handbook is constant at $0.10 per m3 • Any variance from this rate should be applied as a supplies factor usinq the percentaqe of the supplies curve as noted in the curve text.
2.3.1. GENERAL Location Topography Climate Access to facilities and labor market frevailing labor costs (including payroll burden) Daily or annual tonnage Prevailing cost indexes Electric power costs Transportation availability
2.5. TTPES OF RINING AND BENEFICIATION IICLUDED. The user ~hould refer to the Table of Contents in the front of this handbook for a com~lete list of the various minino and beneficiation methods that may be estimated. Mining and heneficiaticn of fossil fuels and teneficiaticn of mercury, tungsten and lauxite hav~ not been included. Aerial tramways have not been included in this handbook du~ to the specialized way in which they are desinned for each mine or plant.
2.3.2. SURFACE AND UNDEBGROUID RINEB Fock type and hardness Support or Qround conditions Cverburden (surface mines) Extraction and/or mining method
2.6. E"'IRONMENTAL IMPACT STATEMENTS
2.3.3. BENEFICATION
The cost of preparation of impact statements for the development of new mines and mills or ex~ansion of existino properties may introduce a significant cost item both directly for the statement ~reparation and from the time related expenses incurred in the approval process. It is virtually impOSSible to tie this phase of the estimate to mine or mill tonnRqe or other measurable units that couli be formulized and plotted on a curve for
Crushability and/or Qrindability Extraction wet hod (flowchart is useful)
2.3.4. EXPLORATION ~~thods to ~e used Area (coverage)
2.3.5. CAPITAL COST Extent and methods of preproduction 1evelopment Ireight rates Taxes
standard estimation.
To help the user estimate the projected cost of environ~ent~l iwpact statements, 5
outlined an1 tabulated is an environmental impact team approach used in assessing various mine properties. The time input by each specialist and the range cf laboratory analysis varies widely from location to location dependinq on such basic elements as the mine's proximity to population centers; the ranQe of weather extremes for heat and cold and air currents in smog controls: the availability of pover in v~rious en~rqy forms; water supply; and land reclamation possibilities. The following items will have to be investigated to some degree: Geology Demography Hydrology Archaeology CI1m'ate Air Quality Ecology AesthetiCS Socio-Econo~ics Physiography The envirunmental impact study ~ay require the expertise of specialists in some or all of the ahove areas. The cost of specialists may be estimated to range from S100 to $500 per day plus field expenses at about $50 per day per person plus field transportation expenses frem $5 to $30 per day plus the transportation cost to and from the field location. The team size can vary from one veIl-qualified person for smaller impact studies to perhaps ten specialists and four or five laboratory analysts. A specialjst may be required for from one day to a year. The team is usually headed by a principal or senior engineer or geologist who controls and edits the production of the impact statement data and schedules the various speCialists as required. Tim~ and workforce. as well as technical ilJlPut, should be allowed for presentation to qovernmental bodies and public meetinQs. Follovinq the agency Quidelines that exist for a specific area and mineral. the user must use his judgment plus local historical records for a realistic estimate of the cost of an environmental impact statement. The user should remember that multiple impact statements may be required for the various stages of mine and/or mill development and operation.
2.8. COST INDEXES The following cost indexes should be used to adjust cost data in this handbook. They are based on, "Employment and Earnings" and "Wholesale Prices and Price Indexes", both published by the U.S. Department of. Labor, Bureau of Lahor Statisti~s (B.L.S.). and on Fnqineerinq News Record (E.N.R.). ~he base year for all but tvo indexes is 1967 = 100. Construction labor (Index No.2) has a base year of 1913 100 and Transportation (Index No. 11) has a base year of 1969 = 100.
=
Since the manual is based on July 1975 costs. updat€s shoul~ use the July 1975 indexes as denominators and the annual cost ind~xes given in th~ accompanying table as numerators. Annual averages are included for space saving purposes, and are acceptable for updatioQ this type of estimate. Monthly indexes can be used if desired and are available from the original sources. No.
Item
Source
Cost Index
Value in July 1975
1. Mine end plant labor·
Mining labor Tabla C·l
oLS
$S.89/Iv
2. Conatruetion labor
Skillad iabor lOCI
ENR
1998.7
3. Equipment and rapair parta
Equipmant and Tabia 4 Code 11·2
oLS
184.9
4. BiU and ralat6d atoel
Iron and Steel Tabla 4 Coda 10·1
oLS
197.3
Lumber
oLS
196.8
5, nmber and lumber
Tabla 4 Coda DB·l 8. Fual
Petroleum Tabla 4 Coda 05·7
BLS
258.8
7. Powder and blasting agents
Explosives Tabla 6 Coda 067902
oLS
177.2
8. nraa
nra Table 6 Code 07120105
oLS
158.8
9. Construction matarial_
Materials {Denver)
ENR
185.0
10. Industrial materiais··
Industrial Commodities Tabla 2
oLS
1712
Rail-MatalUe Ore
oLS
185.7
11. Transportation···
Table 14 Code 28 • Rate does not Include burdon. •• U•• for Itema not oth.rw'ile covered. Reporting in Table 2 w.. dlacontlnued by B.L.S. In Mllfch. 1978. Values given at beglnnlng of Table 8 me, be used theroftftar. · · · 1 . wu year of origin. Index.. prior to 1989 have been extrapoleted. Use for an tranaportation items.
2.7. DEFINITION OF TEBRS This handbook is based on the use of metric units. Where the terms "US tons". "cubic yards". and "inches" are used. they designate manufacturers' sizing in the United States system.
11
171.6
178.4
t • .9 215.9 233.0 27'"
187.2 172.8 2115.5
l1Z.4
lt7.8
ue&.1
2117 230.3 278.5 30U
11l.1
1'1.6 m.7
tl6.1
211.1
2.406.0
232.8 2&3.6
321.0 208.7 192.0 247.7
209.4
227.3
238.2
284.4
tUO 1,913.1
111&.2 200.9
tl78
".42
....
2.132.8
1978
f7.87
1'78
".48
2.&64.0
266.8 283.4 354.2 444.5 225.7 219.4 289.J
1m
6
10 192.5 2&7.5 178.0 1&6.4 1• .3
1m
322.1
3. RIlE OPERATING COST ESTIRATIOI
•
II, ..
3.1. SURFACE RIIIIG - OPERATIIG COSTS 3.1.1. PRODUCTION DEVELOP"E.r ",'"
3.1.1.1. CLEARIIG ~o"'"
The curve for clearing production is based on costs fcir medium liQht growth on terrain with a side slope of 20~ to 50~. Estimate one tree, 0.33 m in diameter, per 40· m2 • The rate of clearing is determined by the surface mine production rate. For light clearing trees, reduce the by 75~. In heavy increased 75~ over
1 ••••
i i!
of brush and small medium clearing costs clearing, costs are the curves.
",,,,,,,
10
PARTS
30~
33%
637.
~"
~'
'"
'" ,,'
'"
, '" ,,"
,st,.......... ,
. ,," ,
",,,,,"
,," ",'"
YL •
."."ex,·''''
Ys •
90 .6JCX)'· 922
Ye: • 211. S6(X)··II'
r-t--
0.1 .! X .! 10
10 HeCTARES CLEARIN; PER DAY
3.1.1.1. CLEARINC
3.1.1.2. DRILL AID BLAST - OVERBURDEN UD
WASTE
The curves have been developed in two parts. The following distribution applies to all equipment in this section: FOUIP~ENT
TIRES
& WBE
70~
'"
1/
'.1
EQUIPMENT OFERATING COST DISTRIBUTION
Crawler DOZErs Trucks
~,-I-
",'"
Supplies consist of 657. for fuel oil and 351. for tools, cable~, and chokers.
FUEL
",'"
'"
10".
Labor costs are based on an average labor rate cf $7.30 per worker-hour.
REPAIR
~
~"~-i'"
~~'" ",'"
","
'"
'"
",'"
~.,.""
","
'" 1"
,,'
",'"
:\ 0",
",'" "''''
100
For clearing on terrain level to 20~ side slope, reduce costs by 20r. from those shown. For clearing on terrain with side slopes from 50r. to 100~, increase costs 20%. On rocky slopes and slopes over 1007., costs could double or triple and the user should use his own judgment.
DESCRIPTION
,-,,,,,,,
.. S
"''''
'"
'"
,,'"'"
",'"
OFERATING COST DISTRIBUTION
T>ESCRIPTION 4"
I'ri1l Equipment Trucks
Equipwent o~erating costs are based on a spread consisting of 75~ dozers and 257. trucks, pickups, and chainsaws.
REPAIR PARTS 501. 32~
FUEL
TIRES
(; LUBE 50" 62n
6"-
For mines excavating from 1,000 to 10,000 tid of overburden and waste, the curves reflect costs for drilling 6 m high benches with crawler type percussion drills. Spacing of 2.5 inch hol~s is on a pattern of 1.5 m x , m to a depth of 7 m. The powder factor is 0.30 kg/t. For mines excavating fro~ A,OOO to 300,000 tId of overburden. and waste, drillinq is performed with rotary drills havino a down pressure of from 13,600 to 40,900 kg. The powder factor varies from 0.11 to 0.20 kg/t with an average of 0.14 k~/t of waste. Holes drilled
7
average 12-1/4 inch diameter from a range of 6 to 13-3/4 inch jiameter. Bench heichts are 12 to 18 m averaging 15 m. Drilling patterns and overdrilling ranoe from 100 to 300 t of tlasted material per m of drill hole. Secondary ~rilling and blasting range from O~ to 101. of blast~d material.
Itt,ttO
ROTARY DRI LLS YL·O.096(X)O •• 61 ", • O.1\'(X)··917
CRAWLER TYP! PERCUSSION DRI LLS
Y! • o.073eX)O.1I1
II,OfO
.,000 .!
YL • 1.7,.eX)0.lIl -
The curves indicate average costs for a wide ran~e of materials as can be noted abov~ by drill sizes, bit sizes, powder factors, and drill pattern. To determine drilling and blasting costs, consideraticn must be given to material hardness, abrasiveness, natural fractures and jointing, and maximum size fragments that can be loaded, hauled and processed. Where the above conditions are unfavorable, the costs shown on the curves can 1e increased up to 100~. For ~avorable ccnditions, the costs can be reduced up to 40~.
x
.!
~
JOo,ooo
L ~
Y, • l.l.,'(X)··n,
i
~
Y! ••• Io'(X)o •• 1J
or
r
~.
~L' ,... 17 "~/l.£1~ ...~ ... .;:fI;' ... V .• v" .... l' ~ j,' " ~"; ~ R,;f2.K'cI' ~ ~~... ¢" ... ~.,.,.. . 1,000 .!
1,000
,
x .!
10,000
1/ ~
~J
~,,~~(~
~
....... I ....
...~~~+,,0 v'" v:~~ toO:
~
.'\.~;, ..., ~'\." v to;;" ......
100
I
10
100
1,000
HETRIC TONS PER DAY X 10'
The labor cost for a typical rotary drill operation is based on an average labor rate for drill and blast creW ~f S€.OO ppr wcrker-hour including rotary drill operators at SR.34. The labor cost for a typical p~rcussion drill operation is based on an average labor rat~ for drill and blast crew of S7.91 per worker-hour including percussion rtrjl1 operators at S8.17.
3.1.1.2. DRILL AND BLAST
3.1.1.3. EXCAVATION, LOAD AND HAUL OVERBURDEN AND VASTE The curves show the cost per day for loading and hauling, both common earth and shot rock. For common earth excavation, one bank m3 equals 2.08 t: for shot rock, one bank m3 equals 2.61 t. The following distribution applies to all equipment in this section:
The supply costs for hoth curves include drill bits and steel related items at 2470 of the total with the remaining 767for blastinQ supplies.
EQUIPMENT OrERATING COST DISTkIBUTION DESClUPTION
rquipment orerating costs include drills and supporting equipment 25~.
75~
REPAIR PARTS
Shovels, E] €ctric Shovels, DiE'sel Draglines, riesel Rear Dump TrUCks Crawler Dozf'rs J.ocomoti ves • Electric Locomotives, Diesel Muck Cars Other rquipment
94";
84"-
60"
FUEL
r. LUBF. 6 r.* 16Y. 4O';
18",1;
37~
70~
95~
30r. 11%* 54r. 5';
33"
32"
89% 46r.
TIRES
45r.
351.
* Where electric powered equipment is used, supply curve is for electric power only. The curves have heen developed in five parts coverin9 a Variety of excavation
8
methods and encompassing 1,000 to 300,000 tId.
a range from
Equipment Operation F = 0.0546(P)o.O_T(L)o.3~3
Curve 3.1.1.3.1. covers from 1,000 to 10,000 tId of overburden and vaste excavation and is based on mines uslno front-end loaders and trucks. The loaders range in size from 1 to 6 cubic lards and the trucks range from 10 to 3S US tons. The curves reflect an average haul of 750 m one way on an 81, grade from a pit 60 m in depth. To determine costs for hauls of varying length or depth of pit, multiply the costs obtained from the curves by the followino factors:
Where: F Factor R Depth of Pit in m (- or P=1.0) L Lenqth of Haul in m
= =
For a typical electric shovel and truck operation the labor cost is based on a composite crew having an average rate of $6.12 per worker-hour with a shovel operator at $8.30 and truck driver at S8.05. Fquipment operating cost distribution for shovel and truck operation: 8.5~ Shovels 70.0% Rear Dump Trucks 11.0"; Crawler Doz~rs Rubber Tired Support 10.5"
=
Equipment Operation Factor. F 0.080(R)o.o_T(L)o.3s3
=
=
orade.
=
Labor Factor. r 0.155(R)o.o30(L)o.263
Where: F Factor F = Depth of Pit in m (R=·1.0) L Length of Haul in m
O~
101,000
or
O~
EL~CTRI
grade.
C SHOVELS AND TRUCKS
TL ...... 'oooG ... g
=
'5
I:
l/l//
.,.l1ex)··967
Y•• 0 •• 25(X)··916 ',.11 .! X .! JOO,OOO _
For a typical front-end loader and truck operation, the labor cost is based on a composite crew havinq an average rate of $8.15 per worker-hour with a loader operator at $8.19 and truck driver at $7.65.
10,000
I o~~"// ,f-
~~:N~RUL~KA~~RS
:t-~ 1/
~0'" ~Vv~ ~
i •f
Fquipment cperating cost distrihution for loader and truck operation: 15.8r. I.oaders 41.8~ Rear Dump Trucks 22.71. Crawler Dozers 19.7% Rubber Tired Support
~
'L • 1J.60(X)··,n
Y• •
..... ex)··'..
1,'0' .! x !
I,D'D
It,OO~
~
~/
100
1
/
/
o/V
~ 'l-t-""O~ V
v'"
R~
~~o.f; f.~'" t.o."~.'"
.,'1/
/
1/ II'
Curve 3.1.1.3.1. covers mines excavating fro~ 8,000 to 300,000 tid of overburden and waste. The loading units are electric shovels and diesel front-end loaders ranqinq in size from 5 to 15 cubic yards with an average of 10 cubic yards. Rear dump trucks from 35 to 170 US tons are the main hauling units, with the average size of all trucks at 85 US tons. The ratio of trucks to loading units averages 6 to 1. The curves reflect an averaqe haul of 2,000 m one way on an 8~ grade from a pit 120 m in depth on wide, well maintained roads. To determine costs for hauls of varying length or depth of pit, multiply the costs obtained from the curves by the following factors: labor Factor. F 0.1173(F)o.o30(L)o.z63
,o+-
/
10
100
1,000
METRIC TONS PER DAY X 10 3
3.1.1.3.1. EXCAVATION, LOAD AND HAUL TRUCK HAULJ\GE
Curve 3.1.1.3.2. covers mines excavatinq 20,000 to 100,000 tid of overburden and waste usinq electric shovels for loading and trains for hauling. The electric shovels range in size from 5 to 15 cubic Y8rds with an average of 10 cubic yards. Locomotives range in size from 85 to 140 US tons and handle seven to eleven eo-us ton rail cars on hauls averaoino 8 km. Grades are limited to a maximum of +3~ for loaded trains and a m8ximum of +4% for empties. For this operation there
=
9
is 8 ratio of 3.2 trains for each shovel. The curves reflect a one-way haul of 8,800 m on a +3~ grade from 8 pit 240 m in depth. To determine costs for hauls of varyinq length or grade, multiply the costs obtained from the curves by the following factors: .
are based on a one-way haul of 900 m on a level orade and include a 6~ rolling resistance in the pit area. To determine costs for varyinq haul lengths and grades, multiply the costs obtained from the curves by the following factors:
Labor Factor, F 0.0058(L)OoS59(G)2.?50
Labor Factor, F O.OS65(l)o.359(G)1.S30
Equipment Operation Factor, F O.0017(L)Oo?OO(G)S.300
Equipment OpQration Factor, F O.0641(l)o •• 03(G)I.620
Where: F = Factor L = Length cf Haul in m G = Grade, defined as 1.0t(~orade/100)
Where: F Factor L = Lenoth of Haul in m G = Grade, defined as 1.0t(~qrade/100)
=
=
=
= =
Scraper prOduction in tid is based on an assumed material having a wei9ht of 2.2 t/m 3 and requiring ripping. If no ripping is required, reduce curve values by 15%.
100,"0
ELECTRIC SHOVELS AND TRAINS
TL • 1.216(X)0.125
Vs • 0.203(X,O.793 'I • a,1S1(X)o.IlS '20,000
.! x .! 100,000
10,000
......
I
.........
r•
~
..
,,"'"
v.t!!.'"...... T .,,1\0"... ",1 0!!,
...... -.... ........ ... ...
For a typical scraper operation, the labor cost is based on a compositp crew having an average rate of SS.24 per worker-hour with both scraper and dozer operators at $8.24.
l--
Equipment operating costs are 27~ for dozers, rippers and push Cats and 73% for rubber-tired scrapers, graders and water trucks.
tQ.>J}!'!!'"
......... .......
8
!.>J"~ ~
1,000
V
----
.....- i-'"'"
111,001
,j;~/ ~-:;. 01}" 1.-" +. . 7' ~~ .
.
10,001
100 10
100
i r•
METRIC TONS PER DAY X 10'
3.1.1.3.2. EXCAVATION, LOAD AND HAUL RAIL HAULAGE
~,
!l>0"
"t'#'l
..... ~/.. "
F,quipment operating cost 1istrlbution for shovel and rail operation: Shove-Is 19.9r. Locomotives 34.5~ Muck Cars 13 .6% Rubber Tire~ Support 32.0~
"..
V"
~~
1,000
...' " ~"
"
V
YL
= .... J05(X)O.6 .. S
Y
z:
f
O.299(X)··908
2~OOD !
Curve 3.1.1.3.3. covers mines excavating 2,000 to 300,000 tid of overburden and waste usino whe~l tractor scrapers ranqing in size and type from 13 US ton self-loadinr. elevating scrapers to 64 US ton twin pngine scrapers. The curves
x .!
'oo~ooo
101 1
110
10
1,000
METRIC TONS PER DAY X 10'
3.1.1.3.3. EXCAVATION, LOAD AND HAUL SCR~PF.RS
10
3.1.1.4. CORE DRILLING
Curve 3.1.1.3.4. covers diesel powered draglines excavating and casting 8 medium digning overburden and waste material from a dry pit into a spoil pile. The material is assumed to weigh 2.0 t/m 3 • The curve is in two parts. From 2,000 to 15,000 tId, crawler draglines range in size from 1.5 to 15 cubic yard capacity. Above 15,000 tId, the curve is based on 25 cubic yard walking draalines. ~ dozer is provided with each draQline for cleanup and support. For a typical dragline operation, the labor cost is based on a composite crew havina an av~rage labor rate of $8.21 per worker-hour with draglin~ operators at $8.30, oilers at $7.65, and dozer operators at $8.24.
Core drilling varies from nonexistent to extensive depending on many unknown factors. Cere drilling is performed on centers varying from 30 m to 245 m and to varying depths. Core drilling can be expected tc cost from $50 to $65 per m with average progress of 15 m per drill shift for NX (3") holes depending on the hardness of the rock, quantity and depth to be drilled, and location, access, and weather conditions. Logging of cores and testing of samples indicate subcontract prices for bore hole 1099ing are between $3 and $6 per m for 150 m holes. For additional details see Section 4.1.1. (Exploration). Note that ther~ is not always a direct relationship between core drilling during mine operation and core drilling for preproduction exploration.
Equipment cperating cost tiistribution for draglin~ operation: 70 .O~ Draqlines 28.01. Crawler Dozers 2.0% Rubber Tired Support
3.1.2. "IMING OF ORE 3.1.2.1. DRILL AND BLAST - ORE
To determine the cost of a dragline operation loading to trucks, use the values obtained from the second curve (Electric Shovels and Trucks). Adjust the values by increasing each curve component 257. and combine equipment operation and supplies curves to account for substitution of diesel fuel for electric pcwer. (Note: supplies values include only electric power.)
The curves have been developed in two parts. Th~ following ~istribution applies to all equipment in this section:
FQUIPMENT OFF-RATING COST DISTRIBUTION DESCRIPTION
REPHR
PARTS Drill Equiplllent Trucks
100,000
,
a~~ ....':/,'
~l
TIRES 6~
For mines producing from 100 to 10,000 tId of ore, the curves reflect costs for drilling 6 m high benches with crawler type percussion drills. Spacing of 2.5 inch holes is on a pattern of 1.5 • x 2 m to a depth of 7 m. The powder factor is 0.30 kg/t.
WALKING DRA.. LINE
11,000
50~ 32~
FUEL c.. LUBF 5076 2r.
Y'
a9~"'~'"
'!I-
,.,~ "/ "tJ'a
CRAWLER DRAGLINE
,:
8 1,000
.....
r-
t~~Jk:/ l"'t-..
_I--..... a~
V
~~
,.~\
CRAWLER DRAGLINI! 1.' tu TD TO 1~ CU YD
TL 'I!
~'tot.~~ ,.\~
= 21t.,1(X)··171 = •• DUCX)··"·
2,000 .:5. X.! 15,000
t.C>:
WALKIN' DRAGLINI! YL TE
= o. UIt
f15.000
lDO
1
For mines producing 8,000 to 100,000 tId of ore, drillino is performed with rotary drills having a down pressure ranoing fro~ 13,600 kg to 40,900 kg. The powder factor varies from 0.11 to 0.21 kg/t of ore. Holes drilled average 12-1/4 inch diameter from a range of 6 to 13-3/4 inch diameter. Bench heiohts are 12 to 18 m, aVeraging 15 m.
lD
~ X .:5. JO~"DO~
lOl
Drilling patterns and overdrilling range from 80 to 184 t of blasted material per m of drill hole. Secondary drilling and blasting range from O~ to 10~ of blasted material.
1,000
HETR I C TONS PER DAY X 10'
3.1.1.3.4. EXCAVATION LOAD AND HAUL
D'RAGLINES
11
The curves indicate average costs for a wide range of materials as can be noted above by drill sizes, bit sizes, powder factors, and drill patterns and therefore do not lend themselves to factorinQ for different hardness of rock. To determine drilling and ~lastin9 costs, consideration must be given to material hardness, abrasiveness, natural fractures and joints, maximum size fragments that can he loaded and hauled, and maximum or optimum size fragments to be crushed or procf>ssed.
3.1.2.2. EXCAVATION, LOAD AND HAUL ORE The curves are presented in three parts covering a variety of excavation methods and encompassing a range from 100 to 100,000 tid. The following distrihution applies to all equipment in this section: EQUIPMENT OPERATING COST DISTRIBUTION nESCRIPTIOH Shovels, ElectriC Shovels, Diesel Rear Dump Trucks Crawler Dozers Locomoti ves, Elect. Locomoti ves, Diesel Other Equipnlent
The labor cost for a typical rotary drill operation is ~ased on an average labor rate for a rotary drill and blest crew of $8.00 per worker-hour including rotary drill operators at $8.34. The labor cost for a typical percussion drill operation is based on an average labor rate for drill and ~last crew ~f S7.91 per worker-hour including percussion drill operators at $8.17.
f-
YL
at
1.798CX)O,821
"'s
II'
LlftgeX)O.719
Y
= O.60J(X,O.8B
f
100! x ! lO~DDO
1,000
.' ,,'" '"
",'
,,'" ,,' ,,' "";'" '" ,,' ,,' .'" ?i'" 1/ "';",' 'V~. ," ,,' .1, ","" rI:.
....
to'> "
100
,,' '"
" .,~,. . '" ~
" o~"i.·'
~It-.~"" ,," ,~...':,'" '--~
" "'"
","'" ,Y' .,.;§'~'V'/ " ;'
~'"
~
..~~" I.~"",
0.1
1",-
:
O.OJ)(X)O.972
:II'
o.on(x)O.lJ87
vf:
:r
O,Olt6(X)O.860
L
=
32"
35~
0.155(R)o.030(L)o.Z~3
Wh ere: = Factor R = Depth of Pit in ~ (- or R=1.0) L = Length of Haul in m
r
-
or.
grade,
front-end loader and truck the labor cost is based on a composite crew having an average labor rate of $8.15 per worker-hour with a loadpr operator at SP.19 and truck driver at $7.65. For a
typic~l
oper~tion.
-
x !. 100,DOO
10
1 U~* 54~
Equipment Operation Factor, F = 0.080(R)o.O~7(L)o.3S3
0,'~~'"
"'5
45"
Labor Factor,
ROTARY DRI LLS
Y
r.
377-
F
~,
1
307.
'"
~ ~~".r. '"
:.)"'1;
L'
'"
'"
1,000 ~
10
-~
.I'
'"
~~'" '"
18770'7. 89'7.
'"
bRILLS
1/"-
16r.
3.1.2.1.1. covers from 100 to tid of ore using front-end loaders and trucks. Th~ loaders range in si7.p from 1 cubic yard for the small mines to 6 cubic yards for the larger mines. The truck size varies from 10 to 35 US tons. The curves reflect an average one-way haul of 750 m on an B~ grade from a pit 60 m in ~epth. To determine costs for varying length haul or depth of pit, multiply the costs obtained fro~ the curves by the following factors:
10, DOO
T~PE ~EJcJSS!ON
84"-
10,000
Fquipment oreratinq costs include drills 75% and supporting equipment 257. .•
.-
67.*
947-
46 3n
TIRES
Curvp
both curves include drill bits and steel related items at 247, of the total with the remaining 76~ for blastino supplies.
r--=~
FUEL f. LUBE
* Where electric powered equipment is used. supply curve is for electric power only.
The supply costs for
r--cRLLER
REPAIR PARTS
11.
METRIC TONS PER DAY X 10 3
Fquipment oreratinq costs for loader and t ru cr. oper a tJon: 15.8~ load€·rs 41.8'Y Pear rump Trucks
3.1.2.1. DRILL AND BLAST
12
Crawler Dozers Rubber Tired Support
22. 7~
,
1",0"
19.7'7.
ELECTRI C SHOVELS AND TRUCKS
" I
'L • o''',O(X)O.II.
Curve 3.1.2.2.1. covers mines produclnQ fro~ 8,000 to 100,000 tId of are. The loading units are electric shovels ranQinq in size from 5 to 15 cubic yar~s and average 10 cubic yards. Rear dump trucks from 35 to 100 US tons are the main haulin9 units, with the average size of all trucks at 85 US tons. The ratio of trucks to loading units averaoes 6 to 1. The curves are based on an average one-way haul of 2.000 m on an 81< grade from a pit 120 m in depth. To determine costs for varying lengths of haul or depth of pit, multiply the costs obtained from the curves by the following factors:
Vs • t.Ot/(.)o.n7
v••
FRONT
r-
~ND
;:."'/
..q~
LOADERS AJlD TRUCKS
./
Ih v~04 ",
TL • n.60eX)O.S03
~ 'feLOO ~
.... oex)O.599
x,j to,ooo
I
1,000
V~ ./
'"
./
:/
V
/ ' ./
vi'"~ t.
~,
./
~q
",<$
,,0
+-t.",/
V
!r
/
","'/
r. """"0"/ ./ ~t."'i-"
100
I-V
~~.~~~
10,000
Labor Factor, F = 0.1173(R)o.030(L)o.Z63
I
!
0.22SC.)0,,,6
',IOO! x.! 100,000
.: §
~.
/
0.1
V 10
100
METRIC TONS PER. DAY X 10 3
Equipment Operation Factor, F = 0.0546(P)o.O_7(L)o.353
3.1.2.2.1. EXCAVATION, LOAD AND HAUL TRUCK HAULAGE
Where: F = Fa.ctor R = Depth of Pit in m (- or 07. grade, R=1.0) L Length of Haul in m
Curv~ 3.1.2.2.2. is for mines producing from 20.000 to 100,000 tId usi09 electric shovels with trains for hauling. 7he electric shovels range in size from 6 to 10 cubic yards. Locomotives range in size from from 85 to 140 OS tons and handle seven to eleven 60 to 80 US ton rail cars on hauls avera~ing 8.BOO m on a +3l grade from a pit 240 m in depth. To determin~ costs for varyinQ lengths of haul or depth of pit. multiply the costs obtained from the curves by the following factors:
=
For a typical electric shovel and truck operation the labor cost is based on a composite crew having an average rate of $8.10 'per worker-hour with 8 shovel operator at S8.30 and truck driver at $8.05. Equipment operating costs truck operation: Shovels Rear Dump Trucks Crawler DozFrs Rubber Tired Support
for shovel and 8.5% 70.0" 11.0% 10.5%
Labor Factor. F : 0.005S(1)o.s59(G)z.75o Equipment Operation Factor, F = 0.0017(1)o.700(G)1.300
To determine the cost of a drag line operation loading to trucks. use the values obtained from the second curve (Electric Shovels and Trucks). .Adjust the values by increasing each curve component 25r. and combine equipment operation and supplies curves to account for substitution of diesel fuel for electric power. (Note: supplies values are for 100~ electric power.)
Where: F = FActor L = Length cf Haul in m G : Grade. defined as 1.0±(r.grade/100) For a typical electric shovel and train operation, the labor cost is based on a composite crew set up accordinq to the size and nature of the operation with a locomotive operator at $8.20 and brakeman at $7.80 per worker-hour. The train operation is based on thp use of diesel locomotives. When electric locomotives are used. reduce equip~ent
For draqlines excavating and casting ore. use data and values obtained from Section 3.1.1.3. (Excavation. Load and Haul - Overburden and Waste).
13
operation cost by 197 and increase supplies by the same dollar amount.
For cutter head dredaino, increase the supply curve by 357. and increase equipment operation 100~.
fquipment o~erating costs for shovel and rail operation: 19.9f. Shovels 34.57 tocomotives 13.67Muck Cars 32.0'; Rubber Tirec Support
",.n
I
10,0"
I
ELeCTRI C SHOVELS AND TRAINS
YL
11
1,216()()··125
Ys
1:
0.203(X)0.791
Y
•
O.I51(X)',·15
f
20,000 .!
1•• 00.
--- ----
~O~_-
----.""..,....,...",.
.:
-
--
8 I ••••
S
c;IJ':!.\..\t. ........
-
~-
10-"
/'"
-~-
---
.--
." ",'>
V
f~+
,
~~~ .... ~qq",~~~.,.
"'''':~
"'
,,/ /.~,
L
.
~ ...... ",
...
..........
:11/o~ +....
.. .: . 8
v-~\Ol' - ."" --T o,t..""
~'ll'-"",,~ F-
...
1,000
x ! 100.GOO
""...
"0"'",,
1--'"
.........
'" ","'",0:
",'"
",'"
Yl. =- 16,58(X)0.522
v'" ",,,,,,,'" ",'"'"
Ys
= O.'ltl(X)O.I7J
Y E
IE
O. U2(X)O •• 56
1,,000 .! x.! 20,,000
100
I
10
II'
CUBIC METERS PER DAY X 10 3
3.1.2.3. DREDGING 3.1.3. RESTORATION DURING PRODUCTION
100
I.
Permits are generally required prior to disturbing the qround surface. Typically, the permit specifies that the area must ~e restored, hectare for hectare, to approyimately the original contours and planted with native plants and trees. On large open pit mines where restoration to the original contours would not be practical, topsoil and plantin~ g~nerally woulrl be required on the slcpes. It is estimated that a restoration proQrarn for an open pit operation would range from $5,000 to ~12,500 per surface hectare depending on the requirements.
110 NETRIC TONS PER DAY X la'
3.1.2.2.2.
EXC~VATION,
LOAD AND HAUL
RAIL HAULAGE
3.1.2.3. DREDGING The curves for dredging cover bucket line dredges which are excavating and processing free gold and platinu •• These operations normally work 24 hours per day with cleanup of metals and repair performed 00 one or two shifts of the week.
3.1.4. GENERAL OPERATIOHS
The labor cost for a typical dredging operation js based on an average labor rate of $7.47 per worker-hour with winchmen at $8.10, mechanics $7.95 and laborers $6.91. The supply power only.
curve
3.1.4.1. GENERAL ITE"S COBBUNIC1TIONS, SANITATION, HOUSEKEEPING, FIRE PROTECTION AID ELECTRICAL This set of curves covers the cost for the general operations custo.arily reQuired in surface mining operations. Examples of services provirled are plumbing, miscellaneous repairs, rough and finish carpentry, incidental jobs,
consists of electric
Equipment operation costs consist of repair parts aort 570 lubrication.
95~
14
fire protection, electrical maintenance and qeneral housekeepinq. They are plotted for la~or, supplies and equipment cperation on the basis of
1....
/
V //
handled
total quantity of ore and waste
L/
per day. The averag€ labor cost is $7.54 per worker-hour with general laborers at $6.91. Th~ size of the workforce required will vary from a small crew of one or two persons working a fractional day to possibly thrEfe shift.s of from 12 to 24 persons per day.
,," / 100
,-,"t/ "
i
.. .:.. 8
~~"
".:J
y"
L
Rquipment operation consists of repair parts 307., tires 107. and fu~l and lube 60';.
JI
/'
l/ 10
"
-.
"
"
1/
.
10,00 0
.....
Vs • a.221(X)'·'''·
1,.-........ 'L • o.200eX)t.o
1,1100
........
Ys :. o.021(X)l.D
....
,,/
Ye: • O.DUCx,1 •• 0 _ 100 .!
x .!
l,DOD
~o" -~
-
....
~....
....
.:
8
........ ....
"
ltO
"
,,""
...~ ' o~~.,..""di'"
"....
,,"
3.1.4.2. WATER SUPPLY
....
..0:
.
,/
" " ""
YL • S.1S2(X)D.SJO
""" ,,"
YS·D,lJ)(X,··n\ VI! • O.1211CX)··660
,,"
1,000.!
10
1 ••0 0
SYSTE~
3.1.4.3. DRAIIAGE AID DISPOSIL SISTEK
"
~,,~
,.." e,;'
ItOO,OOO
H~TRI C TONS PER DAY X 10:5, TOTAL ORE AND WASTE
-.)~~"
.
x .i
III
11
0.10
........
,.."....
........
"'0 .!
I
x .:!
ltO
1100,000
1.000
The curve shows the. daily cost associated with pumping and disposinq of a given quantity of water against a specific hea~. The user mnst determine the quantity of water to be handled and the associated head loss including friction, elevation and minor losses. The product of these values, expressed in m-m 3 /d, will enable a determination of daily COEt.
METRIC TONS PER OAY X 10 3 • TOTAL ORE AND IIASTE
The labor curve is based on $8.65 per worker-hour.
3.1.4.1. GENERAL ITEMS
3.1.4.2. WATER SUPPLY SISTER The water supply system curve represents a cost allowance which may be provided for furn~shing and supplyinQ the limited quantity of water typically required in connection . with surface mining operations for such functions as dust cont~ol, equip~ent operation and cooling.
a
cost
of
The supply curve is made up of 9011070 miscellaneous electric pewer and supplies .. tquipment operation· repair par~s 85% and
The cost allowance is based on the total quantity of ore and waste handled per day. If water i~ available from other sources at no cost, this curve should not be used.
16
is
composed
l~brication
1S~.
of
/
Note that from an economic standpoint, the lower limit is $150 per day (for 10 persons) and the limit above a daily workforce of 1,800 persons is equivalent to $8.50 per person per day. If the camp is to be operated on a seasonal basis due to inclement weather, increase the cost by 25l •
.IV
.IV 1...-
11.
/
",
./
~'
...-
./
",'"~Y
.,.)'I.~
...-
,
/'
.'
j
."
./
i
:•
..
V
~JL+- ,o~
../'V.;:- <1Ji.9
/
.1 10
/
'/
'"
'" " "
/
10,000
"q~
~~,
.,,,V
:•
,,-
Ys. l.25XlO- It CX,l,O Te: • ,.2ltXlO- 6 (X)l.O
/'
D
~
...;I".
V
YL z l.25XlO- S(X)t.O
/
1,'1'
100
1,000
11,0"
l7
3.1.4.3. DFAINAGE AND DISPOSAL SYSTEM
100
V
/
II ,! • .1 1,. •••
-
' •• I.SCx,I •• .,. ... .! • .!
I 10
.. I TOTAL DAILY
3.1.4.4. CAftP OPERATION
I I 1,010
I,'"
!
!
I
I 11,,000
_~R
3.1.4.4. CAMP OPERATION
Where conditions such as a remote location or seasonal operation rpquir~ that camp housing (i.e. room and board) be made available to mine workers, the daily cost obtained from the curve should be U~Qd. The user must determine the average daily workforce using the camp in the overall operation under C'onsideraticn.
3.1.4.5. LONG DISTAICE TRAISPORTATIOJ 3.1.4.5.1. RAIL TRANSPORTATION The following table Qives the cost in t/t-km to ship materials by rail in various se~tions of the United States based on a 100 km haul and Denver rates in July 1975. To adjust this cost for any haUl l~nQth multiply by the factor obtained from the following equation:
This is a daily operational cost and is in addition to townsite capital cost, ~ection 4.2.3. Of the daily cost ohtained from the curve, 307. is for housinq and 70~ for food and mess facilities. The following example serves to illustrate the use of this curve.
Factor
= 5.361(dist.,km.)-o.36.6 Ar•• hetot
Assume a surface mine operation requires an average daily workforce of 500 persons. Enter the curve with 500 persons and determine a daily cost of $4,902. If 60~ of the workforce require room and board and 40% require only room (i.e. units have kitchens), then:
= 4,Q02[(.3)+(.7)(.6)]
-
-
,_ • 1I.SlCI)··1t1
METER - CUBIC METERS PER DAY X 10 3
Cost per day
-
CNf1 OPIRATlON DAILY COlT
/
10,000 .! X .! 6,000,000
/'
V--.O.06
/
V
..
...-
./
"" ,,' 1/ 1/"
111,011
./
"v/ /'"
I"V 11
V V
Mal.rialto ba shipped
Denver
Rat.
Mtn-Pac. Factor
Minaralore Iron or.
1.665 1.B96 1.046 3.170 2.253 3.260 2.356 2.643 2.445
1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
2.972 3.021 1.112 2.954
1.0 1.0 1.0 1.0
Copper"ore
Lead-zinc or. Bauxite Matallic or•• Nonmetallic are. Flulling lime.tone Sand or gt'8vel Industrial .and and
gravel Ceramic or clay Phosphat. rock
Rock ..I,
=
W ••tern FlICtOf
1.4 1.4
NA 1.1 1.2
NA 1.0
NA .8
S. We.ter" Factor 1.3 .7 2.3 1.1 I.B 1.4 7 .6 .9
1.1 .9
NA 8 1.0 .7 .8 1.5 .7
1.2 1.1
.9 1.2
I."
NA
15
.9
4
.6
The foUowing map Indicat•• the . . . .nat.tt f.ctor . . . .
16
Factor
NA
NA Not available
$3,529
Southern
.8
Official factor
1.6 1,6 1.0 1.2 1.8 .9 1.1 1.3 1.1 12 1.8 .8 .8
Class 70
F
= 16.08(X)-0.710
To adjust values for competitive haul areas use 8 factor of 0.68; to adjust for nonmountainous areas use a factor of 0.95; and, to adjust for loads of 23 t or more use a factor of 0.95. txample: For a Class 35 haul of 1S km in a competitive area with a load of 25 t: Factor = 14.41(15)-0.68P 2.273 Rate = 14.76xO.68xO.95x7..273 21.67 t/t-km. Total Cost = 21.67x25x15/100 $S1.26
=
= =
3.1.'.5.3. VATER TRANSPORTATION
F.xample:
Barge shipment is significantly affected by the following variables:
To estimate the cost per t-km for moving 800 t of iron ore 200 km through the Official area: Denver rate = 1.896 Area factor = 1.6 Distance factor 0.78 (from equation), Therefore: Rate = 1.896x1.6xO.78 = 2.366 t/t-km. Total Cost = 2.366x800x200/100 = $3,786
Access to a commercial waterway at both shipping and receiving points, duration of shipping season, adequacy of dockage and facilities for transfer of cargo, and tonnage to be moved by waterway.
The data" and classifications used for rail transpcrtation are based on U. S. Oepart.ent of Transportation, Federal Railroad Administration, ·Carload Waybill Statistics, Territorial Distribution, Traffic and Revenue by Commodity Classes."
Amount of cbrgo to be mov~d (size of tow), covered or open hatches, special or standard holds, and the possibility of barge carrying cargo on back haul instead of making return trip in ballast.
=
The
The following gives the rates per t-km for contract truck transportation in mountainous areas. Three classes have been designated to cover the value of various materials to be shipped:
Class 35 Class 50 Class 70
3.1.4.5.4. PIPELINE TRANSPORTATIOI Pip~line costs are appreciably affected by vertical alignment (i.e. number of lifts or pumping stations required and type of material). Typical rates for well lubricated nonviscous materials are:
less than SO.S8/kg from SO.S8/kg to S2.20/kg greater than S2.20/kg
The noncompetitive 50 km haUl based on Denver in July 1975 are:
rates
Few lifts - $O.004/t-km f-everal - SO.OOS/t-km
14.76 tlt-km 17.61 t/t-km 20.84 tlt-km
3.2. SURFACE IIIIRG - ADIINISTRATIVE COSTS 3.2.1. GENERAL EXPENSE
To adjust these rates for other haul distance in km: distances where X
=
Class 35
F
Class 50
F
cost variables are:
Typical rate is SO.006/t-km and if cargo is availabl~ for return trip reduce cost by 407..
3.1.4.5.2. TRucr TRANSPORTaTION
Class 35 Class 50 Class 70
~ajor
3.2.1.1. IDIIRISTRITIVE SALARIES AND WAGES
= 14.41(X)-0.682 = 15.89(X)-0.707
The general expense curve for surface mines administrative salaries and wages
17
drilling, leading, blasting, mucking and hauling plus track, vent line and utilities installation.
1,"1 . , - - - - - - - , - - - - - - - - , - - - . . . . . , . - - - , . . - - - .
The average labor cost is ~8.12 per worker-hour with miners at $8.29. Supplies are compose~ of steel items 671 (track, drill bits and steel, pipe, fan line, etc.), explosives 307. and electric power 3%.
100
\"~2~
+-------+------...+.:::..._...-.::-=-:-::::-~...;..-==F:.:........j
.-
The equipment operation curve is based on the use of battery locomotives and is composed of repair parts 89~ and fuel and lube 11X. If diesel locomotives are used, increase the equipment operation value by 201 and decrease the supplies
...-
......
27..
EQUIPMENT OPERATING COST DISTRIBUTION DESCRIP'TJON Locomotives, Battery Locomotives, Diesel Other Equipment
REPAIR PARTS
......
....;opp~',!!.--
' l :; 28.7ltCX,··UIt
Ys :; It6. ]lex)··"06
FUEL t LUBE
89'Y.
11~
46r.
541.
907.
107.
Y
f
•
t.726(X)O.725
J~X~lO
10 sqUAll! Ml!TER PACE AREA
3.3.1.1.1. SMALL DF.VELOPMENT DRIFTS
Factors: Add for tOUGh, abrasive rock drilling: 8~ steel. Add for difficult breaking rock: 8.57. explosives. Add for regular pattern roc~ bolting: 10~ steel and 7~ labor.
RA
n.
HAUl.AGE
3.3.1.1.2. S"ALL DRIFTS FOB ROBBER TIBED HAULAGE
Drift sizes on this curve vary from 4 to 20 m~ face area with advances varying from 1.7 to 2.0 m ppr shift and are normally used for LHD haulage. The curve components are based on a medium hard rock requiring no support and include drilling, loading, blasting, mucking and hauling plus vent line and utilities installation.
For timber set support: Add 33r. labor. Add 30¥. supplies.
The average labor cost is S~.27 worker-hour with miners at $8.29.
per
Supplies are composed of steel items 58~ (drill hits pipe, fan line, etc.), explosives 38~ and electric power 47.. The equipment operation curve composed of repair parts 72%, tires and fuel and lube 197.. Factors: Add for tough, abrasive rock drilling: 8% steel. Add for difficult breaking rock: 8.5')( explosives. Add for regular pattern rock bolting: 10% steel and 7~ labor.
19
is 9~
1,DO 0
I, ••
•
_.
.......... "'~;;;
."...,...,.,-
10D
....
~~
... ....W ... :
100
'"
Qq
f
o
~'"
~o:
,~
........
Y L 's
lI:
56.07(X)o.Jft2
lI:
\J.DJ(X)O.JU
toll\!..
e! . r
J. JOJ(X)o. II'
"'"
~\~.........
\,,.t.";'.~
'II!: •
",,,,,,, 10
..----.,;
~";
,c/",/' ~'" ~
u
...... ~ ............ ....... 'I..\t~_ ..
1.,,' 01'-.... .. . -1'''''\t.!t~''''
V"
It .! X .! JO
10
'l'L • 10. ,'eX)O .1"
100
"s •
SQUARE METER FACE AREA
-
Jl.lOeX)O.'57
Yr .... 'I66(X)a.tol
3.3.1.1.2. SMALL DEVELOPMENT DRIFTS RUBBER TIRED HAULAGE
10 ! X ! 50
I.
'0
100
SQUARE METU fACE AREA
3.3.1.1.3. LARGE DRIFTS FOR ROBBER TIRED HAULAGE
3.3.1.1.3. LARGE DEVELOPMENT DRIFTS RIIBBER TIRED HAULAGE
rrift sizes on this curve vary from 20 to 50 mZ facp area with ddvances varying from 2.1 to 2.4 m per shift and are normally used for truck haulage. The curve components are hased on a medium hard rock requiring no support and include drilling, loading, blasting, mucking and hauling plus vent line and utilities instdllation. The average labor cost is se.28 workpr-hour with miners at $A.29.
10
3.3.1.2. SINKING SHAFTS Shaft sinking curves cover a range of face areas from 4 to 40 m2 with average advances of 0.76 ~ per shift to 1.22 m per shift in the smaller shafts and 1.02 rn per shift overall in the laroer shafts.
per
The smaller shafts are based on using miners at $8.29 per worker-hour and a hoistman at $8.14 for an average labor cost of $8.15. In the larger shafts the crew siZe increases considerably iith the average hourly cost at $8.21 per worker-hour. Applicable hourly costs include: shaft miner S8.64, foreman $9.09, miner helpers $8.02, mucker operator and ca~ers $7.88, electrician $8.20. and holst men S8.14.
~upplies
arf composed of steel items 52~ (drill bits and steel, pipe, fan line, etc.), explcsives 45~ and electric power 3L
The equipment operation curve is composed of rppair parts 71V" tires 10r. and fuel and luhe 19%. Factors: Add for tou~h. abrasive rock drillino: A~ steel. Add for difficult breaking rock rock: 8.5 for explosives. Add for r9Quiar pattern rock bolting: 101. steel and 7~ labor.
~upplies are composed of explosives 8r., timber 14~, power 67., steel related items 62~ (pipe and fittings, guides and manways, reck and hanger bolts, etc.) and miscellaneous items 10~.
The equipment operation curve is composed of repair parts 887., fuel and lune 7~ and tires 5~ (tlr~s used OP
20
topside cranes and loaders servicinq the shaft sinkinq).
Supplies are cOMposed of steel 1teas 33" (drill bits and steel. pipe, etc.), explosives 38~, timber 28" and pover 1".
Factors:
When
concretino
a
large
shaft
concurrently with sinking, reduce labor 12~, add 18' to supply curve for concrete and foras, and reduce equipMent operation 3.5". If shafts are to be laqqed with tiaber, increase labor 9~, increase tiMber ~ortion of supply curve 38~. and increase equipment operation 13~. Services installed in shaft include guides, .aDways, air, vater and vent lines, and all electrical cables. signal lines, and lighting. Sinking i5 considered to be done with a sinking headframe. Costs for permanent hoisting facilities ~re included in Section 4.3.2.2. (Hoisting Facilities).
The equiP"ent operation curve composed cf repair parts 911. lubrication
9".
Is and
If a simple chute with steel bottom lip and steel door at the bottom of a raise is used, add $265 to the total labor cost and $750 to the total supply cost for each raise. If grizzly chains and air cylinders are to be included also, add an additional $265 to the total labor cost and $1.500 to the total supply cost for each raise. If the raises are Dot tiMber lined deduct 28" from supply curve and 30X from labor curve. I .....
1.....
V'
V V
tI
V
~ ~
",..0/ ~~
i .;
II
)1. ~'\)/
•
i•
~~~ V v~
r
~
~£...lloM £QUlpMfllT~P-
~
"L •
"I.
V
i
'L • U,IHCX)""'
_st.n(a)··'" sa.'7(X)···
'I. ,... no),·IIt"
'.. .,.,J(X)··"'
11
1
_
'E • '.712(K)·· .. "
.. .! I .! "
II.
~
e I
........-::
--
SUI'·Lll[S
Itl
1 1. .
1
,
,.!X.!, 10
SqUARE MEUR RAts! AREA
SQIWIE METER SIW'T AREA
3.3.1.3. DRIVING RAISES 3.3.1.2. SINKING SHAFTS
3.3.1.4. PBEPABIIG STOPES
3.3.1.3. DRIYING RAISES The curves for driving raises are for tvo-compartment timber lined raises varying in face area from 2 to 6 mZ • Advance rates in m per worker-shift Ianqe from 1.25 for a 2 m2 raise to 0.7 for a 6 raise.
.2
The averaqe labor cost is $8.20 per worJter-hour with !!liners at $8.29 and motormen at $7.53.
Stope preparation varies widely from one mine to another dependlnq upon the individual mine system of extraction. Stope development is generally considered to be that work necessary to develop and prepare a stope or body of ore for full scale extraction of the ore contained therein and includes such items as sutlevel drifts. minor raises within the stope, finger raises. slusher station cutcuts, scram drifts, pocket
21
cutouts, chute installations ~nd box or mill holes. In block caving, all of the draw raises, undercut drifts, mill holes, and scrams if used, would be considered as stope devp.lopment.
miscellaneous supplies.
The costs given below are averaQes from several mines. Should the user desire, stope preparation costs may also be determined usin9 the applicable cost curves (drifting, raising, haulage, etc.) that fit the particular situation.
For EX core drilling (1-1/2" reduce labor cost 9~ per m.
F.quipment operation cost is $0.75 per m and is composed of 88" repair parts and 12% luhrication.
The amount of core drilling required will vary for different types of operations and is not based on dally mine production. Therefore, the user must rletermine the quantity and type of cores thftt will be needed.
Overhand stopes (flat back, rill, vertical face and square set stopes), shrinkage stopes, room and pillar and block cavinQ are in the lower cost range, frOM $1.00 to $2.48 per t of mine production. Cut and fill, stopes are in from $2.34 to production.
3.3.2. ftINIRG OF aBE The curves in this section reflect costs associated with mining of ore by various methods and are taken through the loadinQ operation. Haulage, hoisting and transporting of materials, are covered in ~ection 3.3.3. (Haulage of Ore).
longhole or sublevel the median cost range, $3.89 per t of mine
Combination methods or nonuniform ore bodies will he in the upper cost range. from $3.75 to $5.23 per t of aine production. Labor is 66~ of the total cost miners at S8.29 per worker-hour.
3.3.2.1. SHRIRKAGE STOPES The curves for shrinkage stope minino cover a range of overall production varying from 18 to 36 t per worker-shift and average 28 t per worker-shift.
using
The supplies cost is 30~ of the total cost and is composed of steel items 40l, explosives 35~, timber 12~ and misceilaneous items 13~.
The average labor cost is based on a miner's rate of $8.29 per worker-hour. Supplies consist of steel related items 31~, explosives 53r., timber 6~ and miscellaneous items 10r..
Equipment operation expenses compose the remaining 4~ of the total cost and consist of repair parts 91~ and lubrication 97.. Equipment O~eration Factor: If slushers are required add t.
$0.15
Equipment operation repair part~ and 10~
Supplies Factor: For very abrasive rock add 8~ for steel. For very tough breaking rock add 8.5% for explosives. For timber sets add SO.53 per t.
Factor
of
90~
=
1.50(W)-O.350
Where: W = Width in m
3.3.1.5. CORE DRILLIRG
Labor cost is $13.00 per m usinQ at $8.29 p~r worker-hour.
consists
lu~rication.
Stopes are considered to be free running and curves are based on stopes 3.2 m wide with varying lengths. For stopes from 1 to 4.3 m wide, multiply each curve value by the following factor:
per
The core drill size used for these costs is AX (1-7/R" holes).
hole),
"For widths Qreater than ~.3 ro, the factor will remain constant at 0.90.
alners
Supplies cost Is $8.02 per m composed of .drill rods and bits and SY.
95~
22
factor will remain constant at 0.95.
10,000
"-
1>-_0,"
......
I,DOO
_ .....
......
...
...;;....
...
,/"
","
100
""
""
V ......
......
"
....,,"' " ,,'"
'"
,,",,"
"",,,,,,,
" 10,00'
,.,.",,;... '",,"
............ ,," ~"
O,t:~......
...
\'f:;';"
1,0"
t.~11
YI! .... 072(X)··501
1--'"
"," ./
./'
",,,,,,
1-'",
'"
""", ",'
" ,,",,"
,,' ,,/
..~ t.'" " ~'\ ...,....
,/
o~
"
t.~~"''''
lOO
100 ! X .! ".000
100
"
,t." ",,'" c,\)':"''/'
",,,' " ,,'
-
"
",'
r
Ys • O."7CX)···ftS
-,,' '"
,,"
i
... ...... YL • 75. "(X)·· .. "
10
~/
",,,,,,/ '
...,,;t\O! ........
,;.
-----
......
"
,,-,'I.';,'"
",""
, ..... ..........
--_ .
......
",,,,'
J,OOO
'"
" YL • t.,71CX)O.9U
METRI C TONS PER DAY
fS • 2.1"eX)0."8
3.3.2.1. SHRINKAGE STOPES
YI! ••• SUCX)··' 110 .!
10 1 I
3.3.2.2. COT AND FILL STOPES
x .!
1.000
1, •••
10, II
METRIC TONS PER DAY
The curves for cut and fill stope mining are for overall production, includin~ placement of backfill, ranging from 10 to 13 t per worker-shift and averaging 12 t per worker-shift. The average labor cost is based on a miner's rate of $8.29 per woiker-hour.
Supplies consist of steel related items 14V" explosives 28~, timber 42l, power c% and cement 107..
3.3.2.2. CUT AND FILL STOPES
3.3.2.3. O'EBHAID STOPES Overhand stopes are defined as flat tack, rill, vertical face and square set stopes in which constant timbering Is required. The curves for overhand stope mining are for overall production ranging from 5 to 8 t per Yorker-shift and averaging 7.3 t per worker-shift.
90~
The average labor cost is based on a miner"s rate of $8,29 per worker-hour.
The curves include excavation of the chutes and sand are, slushing to backfill operations including chute and manway extensions.
Supplies consist of steel related items 15%, explosives 15~, timber 607., power 5~ and misc~llaneous items 5~.
Equipment operation consists of repair parts and 10r. lubrication.
The curves are based on stopes 5.25 m wide with varying lengths. For stopes from 1 to 6.5 m wide, multiply each curve value by the following factor:
widths
greater
than
6.5
ro,
89~
The curves are based on stopes 7.2 m wide with varying lengths. For stopes from 1 to 7.2 m wide, multiply each curve value by the following factor: Factor
Where: W = Width in m For
Fquipment operatibn consists of repair parts and 11~ lubrication.
the
23
=
1.50(W)-O.Z05
~'here:
It,'"
W = Width in m
t,,-
For widths greater than 7.2 m, factor will remain constant at 1.0.
the
,,'
V
",,/ $I , es, ~'
1,'"
,/
~'; ,.
I,."
~l ~....
,," '"
...," ",""
V ,,,,§:- V'
"
, ....
!
~
V
II.
.:
,,/ ....
...~. o'~'
........
......
~,.,.
....
10
'L . . . . IJ(X),·-'I
8
TS. tl.77(X)··'" 'I • , ..... (X) •• Ut
I'!.X.!." II
I 10
I
II.
I
.,;,'
I,".
SI.oo
"
YL •
o. 7I'(X)·· . .,
"S ••• .,' ..
~"
ex)···..
TI! • 0 •• 'I(X)··tt7
III.! X .! 11.000
I,ll. MET" C TONS PeR DAY
11,,'
..
3.3.2.5. ROOK AND PILLAR 3.3.2.5.1. ROOB AND PILLAR
3.3.2.3. OVERHAND STaPES
KEDIUK TO HARD ROCK
S~OPES
In MPdium tc hard rock and ores very little oround support is required. The overall production of room and pillar minino in this media ranges from 34 t per worker-shift in the very hard rock to 171 t per worker-shift in the medium rock. The curves reflect an average production of 163 t per worker-shift.
The curves for longhole stope mininQ are for overall production ranging from 70 to 110 t per worker-shift and averagino 90 t per worker-shift. The averagE labor cost is $8.15 per workpr-hour with miners at $8.29 and helpers at ~8.02.
The averaqe labor cost is $8.15 per vorkpr-hour with miners at $8.29, loader operators S8.17 and laborers $7.65.
Supplies consist of steel related items 48%, explosives 42% and miscellaneous Hems 10"!:. Fquipment operation consists of repair parts and 10r. fuel and lube.
10.
........ ....
V
.... "....
3.3.2.4. LONGHOLF. STaPES
MET. . C TONS PER DAY
3.3.2.4. LO"GHOLE
/
...."
~
V. .
... (t)".
.:
~...
V
~,,~;
:\
~~~
l,.-'
<1"'" . . . . ......
/
/'
....'
IL'/
to ........
"....
V'
~"
,,'
........
...........
III
V"
" ,$/."""~ ....
1-0'
,,"
Supplies consist of steel related items 4570 and explosives 55r..
90~
Equipment operation consists of repair parts 7470, fuel and lubp 19r. and tires 7%.
The curves reflect costs associated with mining in a minimum stope width of 6 m and have no upper width limit. If this minin9 method is to be applied to widths less than 6 m, the explosives portion of the supply curve must be increased 25% and the la~or curve values increased 10"'.
24
"
1.....
~ V' ~
~ ...... "t"
1....
~..."
h ....... . .
~
!:". .7
i
r
rJI' .,..4.......
10-......
1.....
........./
/'"
~r
i
r
/'
",'"
,p""''''
",'V'"
...
I, •••
......t.Cl!..........
L
...."''''.. '5.
.. .
"'L
V
,,~
~
'L • ,.,I7(X) •• I" Ys • I.U'(X)··IU
-
' I . . . . . 7(X)··n7
1.U'CX)··tOJ
' I ' .! x.! JO, . . .
't: • O.UseX)I ••
".
.,........~ <§~
....:J
",
YL ••• 110(X)'· UI
t,"
tf",?;r '"
1-''''
......
.........
,.,
1-"
~"',.)'I.~
1..-......
tIt; ......
':''I.,~""",
.........
/: V ......
...
......
......
~
.....
1••
1,000 ! X .! 10,.0'
1..
I"."
11, •••
METRIC TONS PER DAY
1....
'.'"
1'."1
HETRIC TONS PER DAY
3.3.2.5.2. ROOM AND PILLAR ~OFT ROCK (NONMETALLIC)
3.3.2.5.1. ROOM AND PILLAR MEDIUM TO HARD
3.3.2.6. BLOCK CAVING
3.3.2.5.2. ROO" AND PILLAR SOFT ROCK (NON"ETALLIC)
3.3.2.6.1. BLOCK CAVING LOAD-HAUL-DURP RETHOD
In soft ores and rock (nonmetallic) the production averages 67 t per worker-shift. Labor costs generally are higher than for medium to hard rock room and pillar mining due to the extra labor needed for continuous close pattern rock bolt support.
The load -ha ul-d ump (tHD) method of excavation in ~lock cave mines covers a production draw ranging from 270 to 900 t per worker-shift and averaQinQ 500 t per worker-shift. The trammino distance is limited to 150 m for LHD haulage. The following section (3.3.2.6.2.) will cost typical slusher and gravity lIIethods.
The average lahor cost is $8.14 per worker-hour with miners at $8.29, loader operators SA.17 and laborers $7.65.
The average labor cost is $8.44 per worker-hour with LHD operators at S8.17. h~nqup persons SP..76 and grader operators $8.21.
Supplies consist of steel related items 23';, 3~, explosi ves power 40" equip.ent), powered (electrically miscellaneous items 1% and rock bolts, 33%.
Supplies consist of explosives (used for secondary blasting) 98~ and miscellaneous items 2~.
fquipment operation consists of repair parts 74", fuel and lube 19~ and tires
Equipment operation consists of repair ~arts 50:, fuel and lube 26~ and tires 24".
7';.
25
100 ....
10.000
7
",'P "
-..l
~~ £V
1.000
l/
v
"'"-~'" '" '........
.,/
~.....
ID,DOO
/'
....
" '" ""1 ,,' "'~!.
./ '7
7
............
. p [7
~
q
a
'P
1,000
t,~
IDD
V 1,000
Vs
II
/'
\f(,".,
~
\.0
'"
t,o..~"~'"
",'"
",'"
o.3IS(X)1.0
/'
'! • O.159CX,··872
-
'"
YL .. U.03(X)··511
2,000 .! X .! 20,000
10,000
",."
'"
/'
/'
'"
YL ••. 1t29CX}··517
."."
-l..--......... ~q"", ."~r· ""~ -~ I. ",,"'i-"'/'o'~'" /'"
'"
/'
,q
~
'5 .. O.319(X,l.D VI! .. O,"19(X)D.172
100,000
2,000 .!
METR I C TONS PER DAY
-
x .! 60,000
100 1,000
3.3.2.6.1. BLOCK CAVING LO~D-HAUL-DU"P
10,000
100,000
METRIC TONS PER DAY
METHOD 3.3.2.6.2. PLOCK CAVING
3.3.2.6.2. BLOCK CA'ING SLOSHER AID GRA'ITY "ETHODS
SLUSHER AND GRAVITY METHODS
The slusher method of excav~tion in block cave mines covers a production draw ranQinQ from 100 to 450 t per worker-shift with an averaae used in the curves of 200 t per worker-shift. The precedinQ section (3.3.2.6.1.) presented costs for typical LHO excavation methods. The averaQe labor cost is $8.52 per worker-hour with slusher operators at $8.29 and hangup persons at S8.76. Supplies consist of explosives (used for secondary blasting) 837., power 12~ and miscellan~ous items 51..
3.3.3. HAULAGE OF ORE 3.3.3.1. HOISTING ~he costs associated with hoisting ar~ based on tId of material hoisted a given distance expressed in m. The curve is applicable to sublevel as well as ~urface hOistioq. Costs includp all personnel directly conn~cted with hoisting.
The average labor cost is $8.23 per worker-hour with hoist men at $8.14. skip tenders S8.34. cagers $1.88 and oilers $1.53.
repair
Supplies ccnsist of power 50~ and steel related items, such as rope and materials for cage repairs, 50~.
For straight gravity ca~ing. apply the followinQ factors to the curve values:
Fquipment cperation consists of repair parts 91% and lubrication 9%.
Delete equirment operation costs. Reduce the labor values 10%.
25r..
Fquipment operation consists of parts 90~ and lubrication 10 ...
For friction hoisting.
26
reduce
supplies
1",'00
10,011
/~
3
,.."
1/
...'" ......
",'"
,'"
.......
-'"
./
..........
",'"
"!f"~'"
.:
8
V
10,000
'" ---, .... --- /'" ....
-';!'!f! ~-
-- -- -
E 100
10
'"
",'"
1,001
~
t..,.. \a;,
-
•r
... I k"~""
..S.
n\l\!,.
; ...
r- 0"
~ ......
/
,/
'L • "."(X)·· 17.
...
1#'"
1.-.......
3.3.3.1. HOISTING
~+
;.'
11.1.1
METRIC TON METER PER DAY X 10'
fI" "'~'"
toeS: '"
10 100
"
.;:"."
~~
)/
1 .... .1 X.! lO ........
",'"
0+,,-
,/
'I ••• 1710)··\72
10
,,'"~
~~~
-'"
", ••.•"CX),·,"
.'" V
-:,...
lOa
v
/
V
/
'"
-'"
'L • '5
3.3.3.2. RAIL HAULAGE
10
=
J.,u(X)·· 197 0.671(X)0.117
' I :::r 0.112(X)0.799
,/ I
V
V
L
1,000
J
V
V
20 ~ X ~ 100.000
100
1,010
10,000
100,000
METRI C TON KJ LOHETERS PER DAY
~hp
costs associated with rail haulao~ are based O~ tId of ~aterial hauled a 9iv~n distance expressed in km. The curve is applicable to main line as well as spur line haulage and is based on batt~ry locomotive operation.
3.3.3.2. RAIL HAULAGE
3.3.3.3. CONVEYOR HAULAGE Thp. use cf conveyors is much more prevalent in the softer nonmetallic mines than in the hard rock mines, and their us~ is generally associated with room and pillar operations. The costs associated with conveyor haulage are hased on the tid of material conveyed a giVen distance expressed in km. The curves are applicable to conveyor systems of any length so long as the product (in t-km/d) does not exceed the curve limits.
The average labor cost is $7.52 per worker-hour with motormen at $7.88 and swampers at $7.16. Supplies consist of miscellaneous 90~, steel it~ms 6% and power 4X.
items
Equipment operation consists of repair parts 91~ and lubrication 9~. If trolley locomotives are to be reduce ~quipment operation 10%.
used, Conveyor operation consists of maintenance labor, power, repair parts an~ lube. Conveyor costs are based on conveyors rangin9 in width from 760 to 1,829 mm having lengths of ~O to 1,000 m.
If diesel locomotives are to be used, equipment operation cost should be increased 1.8 times. Total supplies cost should be reduced 3% due to reduced power requirements.
The supply curve pover only.
Equipment operation With. diesel locomotives consists of repair parts 461and fuel and lube 54%.
consists
of
electric
Equipment operation consists of repair parts 95~ and lubrication 5~. the Factors to be multipliev by other values for inclines horizontal are as follows:
27
curve than
Labor Factor,
The labor curve is based on a cost of $7.97 per worker-hour for drivers of Qreater than 20 US ton trucks. For drivers of 20 US ton or slaller trucks, a cost of $7.65 per Worker-hour may be used to adjust the labor curve.
F = 1+0. 0 II 17 ( R )
Supplies Factor, F = 1+0.3750(R} Fquip~~nt
Orerating Factor,
F :: 1+0.091HR)
~guipment
Where: F :: Factor F = Conveyor incline in degrees
39o.t.
cperation consists of repair parts 297.. fuel and lube 32" and' tires
~he
curves are valid for orades froa level to 2~. To determine daily costs for Qrades Qreater than 2~. multiply the costs obtained from the curve by the followinq factors:
In th~ case of a decline conveyor, use the horizontal costs without adjustment. I ....
Laber Factor. F = O.98(GP·S30
1--.
Eguipmp-nt Operation Factor, F = O.9B(G)S.620
.,-
lot
/'
./
I' r•
V
/
~~ .,-1
~
~here:
F G
iF
lL
= Factor = Grade.
defined as 1.0±C"grade/100l
/ a., •••
f7
,,,/
/
",
:/
/V
.:
"
""~
V
~+'" ~
8 V
1,,1
,,'
,,/
,,'"
. ,;,
~... «~
t.~
cI'.
,,~,
;to'" 'L'
,;to?,
v
'-
k~".,
/'
/
"L.
V
a.n,cx)··'·l
"5.
t.IU(K)··'··
'I. •
l.t",(x)··7)1
I".! • .! 0.10
It.
.,
if"
1.008
I .....
II,,'"
METR I C TON U LOIIETERS PEl DAY
, ","
/
.: §
3.3.3.3. CONVEYOR HAULAGE
",/"
~,.
"'~
i
r 1 ......
.," '."'" ,,'
,
I ..
.,.,,,""" " .1'';' 0;,,'" ","
I.
,,"
3.3.3.4. TRUCr HIULAGE
, 'L ••• 2n
//"
The costs associated with truck haulage are hased on tid of material hauled a given distance expressed in km. The curves are applicable to any haul len9th so long as the product (in t-km/d) does not exceed the curve limits.
's
'I! •
"",,,,,,, I
lO.
'.SUO)··1)1t
I ....
1. . . . .
3.3.3.4. TRUCK HAULAGE
28
-
tol ~ X ~ to.I"
METRIC TON KILOMETERS PER DAY
The supplies and equipment operation curves are not dependent on truck size. The labor curve, however, is dependent on the labor cost selected.
-
= •.• 10eK)I.1
1. . . . . .
3.3.'. CEIlBlt OPERATIOIS
3.3.3.5. tOAD-BAUt-DU!P HAUtAGE
3.3.'.1. CIIERlt ITERS COBIUIICATIOIS, SIIITATIOI, BOUSIKIEPIIG, FIRE PROTICTIOI liD ELECTRICAL
The costs associated with load-haul-dump (tHD) haulage are based on tId of material hauled a given distance expressed in k.. The curve is applicable to anr haul length so long as the product (in t-k./d) does not exceed the curve limits. None of the curves are dependent on the size of unit being used.
This item is intended to cover those work tasks not directly attributable to a specific mine operation. Included are deliverr of aaterials and supplies, maintenance of roads, service and aaintenance of communications, electrical maintenance, sanitation and housekeepinq facilities, and other miscellaneous work.
The labor curve is based on the cost of an LHD cperator at SS.17 per worker-hour. Equipment operation consists of repair parts 43~, fuel and lube 24l and tires
The average labor cost is $7.60 per worker-hour with general laborers at $6.91. The size of the workforce required viII vary from a saal1 crew of one or two persons vorking a fractional dar to possibly three shifts of from 50 to 60 persons per day.
33~.
The curves are valid for grades from level to 2~. To deter.ine daily costs for orades greater than 2~, aultiplr the costs obtained fro. the curve br the following factors:
Miscellaneous SO.10/t.
Labor Factor, F = 0.9S(G)Ie!530
=
Where: = Factor = Grade, defined as
are
priced
-f--
II
1.0±(~grade/100)
I
.........
I I
I
.,....; V
I II
l'L • 1.'ll(X)I.1
II ....
I,,". ~ t-
~
,,'i
,/
.•i .8 L
'/
1....
. « L
L...
...' 8
v. . .,..../
1••
..... ~~ C7 ,,~ .. '" l!-
'I: •
""'CX)'"
.I.!. x.!
,It
!/1
110
/
....
/'
....
1.-"
...
...
I
~,
~ o'''!! ~ ~~.... ~; "ftI'"
....
I......
,--
,.
f-
/
TL • t.tU(lC)o.n,
1// II
1,/'"
Tt
:I"
1 0.111':0 ••
TE
Ii:
l.tUCX)··-'"
SIG.! x.! ......
I •
I 100
10 00.
10 0 .f.t
METRIC rOMS "Elt DAY
YL • It • .,(X),·I7·
Vf: • I. luex)' .1S1t
11 11
.... I,....
1/ /;Iv
,,'/
II
V ........
1/. . V
~
./
1""~" ~,
II
"'''~~ L.....~
V //
Ys • , •• II(X)I.I
,:
i
is 12~
11."0
~...
at
The eguip~ent operation curv~ composed of repair parts 42r., tires and fuel and lube 46~.
Equipment Operation Factor, F 0.98(G)1.620 F G
supplies
III
.!. x ~
I,'"
1....
3.3.4.1. GENERAL ITEMS I .....
3.3.4.2.
METRIC TON KILOMETERS PER DAY
YEITILATIOI SISTE"
Mine ventilatinq syste~s Bnd are dependent upon
3.3.3.5. LOAD-HAUL-DUMP HAULAGE
29
vary qreatly the size and
shape of the ore body, the system of mining, depth of operations, workforce requirements and type of equipment to be used under9round. As a result of the many variables encountered, there is no standard or ideal system of mine ventilation.
11....
./
Ventilation require.ents mBY range from 1 to 6 m3 /min of air per t of material mined depending upon the factors set forth above, as well as the MESA (now ~SHA) ventilation regulations. The curves shown are based on m3 /min of venilation air at a total pressure of 6" W.~. (15.24 em). The user must determine what quantity of air is required for the type of mining operation selected and the total pressure to be expected. Since, for a given volume of air the total pressure will affect the horsepower requirements, an adjustment must be made to the supply curve for pressure variances. Therefore, for changes in total pressure the following a~ount must be added to or subtracted from the supply curve: Dollar Amount
=~
4.33x10- 3 (Q)(DeltaP)
Where: Q = Air Volume in m3 /min DeltaP = TotAl Pressure in inches minus 6" This ~urVe covers only the operation of the main ventilation and exhaust systems. ~he smaller mine fans in the drifts, stopes, etc., are included in the particular mine operation. The only laLar involved is for repair and maintenance and is based on the cost of mechanicF at $8.02 per worker-hour~ The ~upply cu~ve is for fan operation with electriC po~er composing 95~ and miscellaneous costs Sr.. Equipment operation consists 71~ and lube 291.
of
'I
I ....
/
i
,. k'
",'~
or
r
/
.,.;s~q
III
./
,:
V '"
8
V
II
~~~-'"
,~~
.,a." ,.
~,.
~.
~~~ /'
,.
./
TL
/
",'
,,101
'E
O.02S(X)O.67S
=
0.0100),·111
15 • .!
V
K $I."
=
TS • o.OI7(X)l.l
~'
",,'
J/
,.
1,000
10,000
x .! 110,000
100,000
1,000,000
CUBIC METERS PER MINUTE
3.3.4.2. VPNTILATION SYSTEM
3.3.'.3. COftPRESSED AIR PLART The following factors will assist the user in determining quantities of compressed air necessary to maintain ore production and development work. The curves are based on total compressor capacity includin9 line losses, leaks and drilling diversity factor for a plant installed at an elevation of 1,600 m. The user must apply applicable correction factors to the volumetric compressor capacity. For shrink, cut and fill, underhand and flat vein stope mining, air requirements range from 0.165 to 0.265 m3/min per t per shift and average 0.20 m3/ min installed capacity per t mined per shift • For room and pillar mining, air requirement£ range from 0.02 to 0.15 mJ/min per t per shift and average 0.085 m3/min installed capacity per t mined per shift.
repair
part~
For longhole drilling and sublevel and caVE mining, air requirements range from 0.05 to 0.093 m3 /min per t per shift and average 0.07 m3 /min installed capaCity per t mined per shi ft. ~lock
For open stope mining, air requirements range from 0.17 to 0.26 m3 /min per t per
30
shift and average 0.20 m3 /min installed capacity per t mined per shift. The labor curve is based on the cost of compressor operators at $7.65 per worker-hour. The supply curve power only.
consiFts
of
electric
mine's water reqUirements are at least partially met by the availability of subsurface drainaQe. Should this be the case, an appropriate reduction can be made from the curve values. $I
I,DlD
1/
Fqulpment cperation consists of repair parts 73~ and lubrication 27~. 11,000
...
,.,y
~v"
'
i
...• ..
,.,"
.. ~v".?1
/
S
",'"
L~-
-
100
-'"
10
'"
o~I
-'"
/I-.~""
~q"
,.,'t'" ~'"
/
",'"
-~-
Vs • o.ouex)l.O
'"
20 .:!
0.10
~""
o~~'"
'" ".
10
I.~~t-
---
V
",'
.:;~",'"
'L • U.9](X)··2I2
'5 • 0.1"(X)1.0 YE • a,'39(X)o •• Ol
1,000
10
1 0
I, 00
x
~ 61,000
10,000
100,'10
METRI C TONS PER DAY
-
3.3.4.4. WATER SUPPLY
-
SYSTE~
3.3.'.5. DBAINAGE AID DISPOSAL SISTER
n.! x.! 2,,000
100
-
/
u
'"
1,000
/
..'!-
10
0
,/
/
II
101
i .,.."
OlD
10 ,DO
The drainage and disposal system curves give the daily cost associated with pumpinq and disposinq of a qiven quantity of water aqainst a specific head. The user must determine the Quantity of water to be handled and the associated head loss including friction, elevation and minor losses. The product of these values. expressed in m-m 3 /d, will enable a determination of daily cost.
CUBIC METERS PER MINUTE INSTALLED CAPACITY
3.3.4.3. COMPRF.SSED AIR PLANT
3.3.4.4. VATER SUPPLY SISTER The vater supply system curve includes costs for furnishing of vater for orills. dust and fume suppression, cleanup and fire control. The components of this curve are: purchased water 75%, miscellaneous supplies 151., and equipment operation 10%. For factoring of equipment operation, see Section 2.8.
The labor curve is based on a cost of $8.65 per worker-hour. Suppl.ies consist of electric and miscellaneous items 10~.
quantity of water required for underqround mines (measured in m3 /d) has been estimated as the tId mined multiplied by 0.135. While this quantity will not cover all types of mining operations, it provides a basis for factoring from the curve once a definite amount has been determined. The user should be aware that often a
The
power
90%
Fguipment operation consists of repair parts 85~ and lubrication 15~.
31
.. ,.S~
•
/
-,V /'
.0•
,.... .... "'.
. ;,
L. .
i •
V'
",'
/.
~
r
/~
'I
"'.... 10-.....
.........
V/
1_.. ....
.....
/
........
.........
....
......../
.........
." /'
'"
./
.,./ '"
"',00 0
.,-
..o.~'i...
/
'
...... 10,000
...-
.r
.........
....
IL'
,<:./
,: YL • 1. 15K1. -5 ex)I.' If
101,000
!
1,000
-
Yr • ,.nX1O-'ex)1 ••
V
§
-
TS -= 1.25XlO- 'X)1.0
1.1' 1 0
/
......
~
........
Note that from an economic standpoint the lover limit is $150 per day (for 10 persons) and the limit above a dally workforce of 1,800 persons is equivalent to $8.50 per person per day. If the camp is to be operated on a seasonal basis due to inclement weather, increase the cost by 25%.
.....'"
....~I-.",~ dI~"'/ +'\ .... ,-II> ....
V.... ....
/
/
..../'"
~.
= ~,090(.3)+(.7)(.6)J =
Cost per day $6,545
;'
...-
CAMP OP'I!ItATION DAILY COST
......
X ! 10,000,000
1, 00
~
/
METER - CUBIC METERS PER DAY X 10 3
'5 • 11. )I(X)····l
/
10 , 0 0
1.
V
3.3.4.5. DrAINAGE AND DISPOSAL SYSTEM
This is a daily operational cost and is in addition to townsite capital cost. Section ij.3.3. Of the daily cost oht~ined from the curve. 30r. is for housing and 70~ for food and mess facilities. The following example serves to illustrate the use of this curve. Assume an underground min~ operati~n requires an averaqe d~ily workforce of 1.000 persons. Enter the curve with 1,000 ~ersons and determine ~ daily cost of $9,090. If 60~ of the workforce require room and board and 40~ require only room (i.e. units have ~itchens). then:
x
.!. 1,100
1, ... .! x.! &,10'
I
I I I
100
10
I
I
10,000
1,DOO
110
TOTAL DAILY MANPOWER
3.3.4.6. CA"P OPERATION Where conditions such as a remote location or seasonal operation require that camp housing (i.e. room and board) be made available to mine workers. the daily ~ost obtained from the curve should ~e used. The user must determine the aver~ge daily workforce using the camp in the overall oper~tion under consideration.
~
", ••. sex)'··
3.3.4.6. CAMP OPERATION
3.3.4.7. LONG DISTANCE tRANSPORtAtION 3.3.4.7.1. RAIL TRANSPORTATION The following table Qives the cost in '/t-km to ship materials by rail in various sections of the United States based on a 100 km haul and Denver rates in July 1975. To adjust this cost for any haul lenQth, multiply by the factor obtained from the following equation: Factor
=
5.361(dist.,km.)-O.36.6 Area Factor
be shipped
Denve, Rate
Mtn-Pac. Factor
Westem Factor
Miner.lore Iron ore Copper or. Lead-,Inc ore Bauxite Metallic ore. Nonmetallic ore. Ruxing flmeatone Ceramic or clay Phosphate rock Rock salt
1.1185 1.896 1.046 3.170 2.253 3.210 2.356 2.643 3.021 1.112 2.954
1,0 1.0 1.0 1.0 1,0 1,0 1.0 1.0
1,4 1.4
Matarial to
NA 1.1 1.2
NA 1.0
S. Western Factor 1.3 .7 2.3 1.1 1.B 1.4 .7
NA
.6
1.0
1.1
1.2
1.0 1.0
NA
NA
.9
.4
NA Not available The following hlap Indicates the designated factor areas
32
-
Southern Factor
Offlci8l
1.1
1.1 1.1
,I
NA .B 1.0 .7 .8 1.6 1.0 1.5 .6
1.0 1.2
'".,
1.1 1.3 1.8
.. .8
To adjust values for competitive haul areas use a factor of 0.68; to adjust for nonmountainous areas use a factor of 0.95J and, to adjust for loads of 23 t or more use a factor of 0.95. Example: For a Class 35 haul of 15 kill in competitive area with a load of 25 t: Factor 14.41(15)-0.682 2.273 Rate: 14.76xO.68xO.95x2.273 = 21.67 t/t-Iun. Total Cost 21.67x25x15/100 = $81.26
=
8
=
=
3.3.4.7.3. YATER TRAISPORTATIOI Example: To estimate the cost per t-km for moving 800 t of iron ore 200 km through the Official area: 1.896 Equation)
=
Rate 1.896x1.6xO.78 = 2.366 t/t-km. Total Cost ~ 2.366x800x200/100 = S3,786 The data and classifications used for rail transport.ation are based on U. s. Department of Transportation, Federal Railroad Administration, "Carload Waybill Statistics, Territorial Distribution, Traffic and Revenue by Commodity Classes."
3.3.'.7.2. TRUCK TRANSPORTATION The followinq gives the rates per t-klll for contract truck transrortation in mountainous areas. Three classes have been designated to cover the value of various mat~rials to be shipped: Class 35 Class 50 Class 70
less than SO.BS/kg SO.88/kq to S2.20/kq ryreater than $2.20/k.o fro~
The noncompetitive 50 kill haul tased on Denver in July 1975 are: Class 35 Class 50 Class 70 ~o
rates
Barge shipment is significantly affected by the folleving variables: Access to a commercial waterway at both shipping and receiving points, duration of shipping season, adequacy of dockage and facilities for transfer of cargo. and tonnage to be moved by waterway. The major cost variables are: Amount of cargo to be moved (size of tow). covered or open hatches, special or standard holds, and the possibility of barge carrying carqo on back haul instead of making return trip in ballast. Typical rat~ is SO.006/t-km and if cargo is available for return trip reduce cost by 407..
3.3.4.7.'. PIPELINE TRANSPORTATION Pipeline costs are appreciably affected by vertical alinement (i.e. number of lifts or rumping stations required and type of material). Typical rates for well lubricated nonviscous materials a.re: Few lifts - $0.004/t-km Several - SO.008/t-klll
14.16 '/t-km 17.61 Ot-k.m 20.84 f!/t-km
~djust
these distances where X
3.4. OIDERGROUID RIlING ADRIIISTRATIYE COSTS 3.'.1. GENERAL EXPEISE
rates for other haul = distance in km:
3.4.1.1. ADRIIISTRATIYE SALARIES AND
VAGES Class 50
F
Class 70
F
= =
15.R9(X)-O.707 16.08(X)-O.710
Th~ Qenerel expense curve for underground mlnino administrative salaries and waqes is intended to cover
33
the supervision and various other administrative functions required for underground mines of varying sizes. The number of administrative (salarie~) employees varies from 3 to 4 persons working a single shift in the smaller ~ines to as many as 80 or more in tbe larger (8,000 US tons and up) mines. ~he breakdcwn of personnel into various classifications together with th£ average percentage of cost attr ibutable to each is as follows:
3.4.1.3. AD"IIISTRATIVE EQUIP"!NT OPERATION This curve includes ad~inistrative equipment operation expensp for vehicles such as se1ans, pickups and flatbed trucks. The approximate curve components are: tires 2X, repair parts 40~, fuel and lube 37r.. and repair labor 21~ assuminQ the equipment is used 50~ of its available time. u,ooo I
Percent
Classification Supervision Clerical Engineering Assaying & ~etallurgical Purchasing t Warehousing Safety & Fir~t Aid Security
t'I'.,~
50 5
29 7
~edian
«"....
4 3 2
[....0- j...
monthly salaries are as
i
U
",~), ,..."\\
\
.....f-~"~..
o~t.'"
...
",.
:;,.'
~\"t"'''' .,,,-,,",,,
..,
.......
....
_.
~\
.., t-Sl't.'-
'\."
, .... 1.1. YL:: 12.121(X)D.600 ' .... 1.2. Ys ~
J .... 1. J. YE 20 .!
x .i
1.,lt7(X)a.69S
= D. 3nCX)" 515
60,000
I
10
100
1,000
10,000
METRIC TONS PER DAY
3.4.1. GENERAL EXPENSE
The curve fer administrative purchases covers office. engineering, safety and first aid sllPplies, and ~penses such as telephone, telegraph and postaQe. travel and entertainment, miscellaneous fees, dues and donations and professional and computt"r services when applicable. Also included are small tool and supply allowances assumed at 7% of the direct mine labor. 351,
t.'"
J.~..;~
.............
3.4.1.2. IDRIIISTRITIYE PURCHASES
657.
'"
II
'"
",'"
'. ~c.+...,,,,.
t.Q.\1
'" '"
,
","
1.1. \~~~\I",
",'" ",'"
!
~.t"--"
....
...
NOTE: The above monthly salaries do not include an allowance for burden. If these personnel are covered by the same fringe benefits as the mine workers add 35~ to the ~dministrative Salaries and Wages curve. However, if they are not covered, add only 2~~.
The curve is apportioned administrative purchases and sroall tools and supplies.
",. .""J'
..,....'!.:-
i
•f
$2,300 1,550 1.200 1,500 1,800 2,200 1.400 1,900 1.600 1,850
¥f
~'t-\"'"
~\~ I I
..,....
follows: Mine Superintendent Gen~ral Mine Foreman Mine Shift Foss ~eneral Maintenance Foreman Chief Electrician Chief En';Jineer Geologist Chief Accountant Safety Director Director of Purchases
~\~
1,000
100
~elected
./
I! .....t.':,?
to to
34
100,000
,. RINE CAPITAL COST ESTIRATIOR costs for the various exploration methods are given in a following table. It is estimated that a regional appraisal will cost approxl~atelJ $q per km 2 •
4.1. EXPLOBATIOR ARD ACCESS BOADS 4.1.1. EXPLORATION Fxploration can b~ defined as all the activities and evaluations performed in order to locate and define mineral deposits for the purpose of extraction now or in the future.
~tage 2 Detailed Favorable Areas
of
Pesults of the regional appraisal might indicate that within the 2,600 to 260,000 km 2 regions, there are favorable areas ranging from 26 to 260 km2 which would warrant further detailed investigation. The detailed reconnaissance would include geologic, geochemical, and airborne and ground geophysical surveys in more detail than was used in Stage 1. Methods or techniques used in this stage would probably include photo-geologic study, aerial examination, outcrop examination, geologic mapping, boulder tracking, stream sediment sampling, water sampling, rock sampling, aeromagnetic surveys, airborne electromagnetic surveys, radiometric surveys, and other remote sensing. Ground surveys would also be made and would include gravity, magnetic, radiometric, seismic, resistiVity, self potential and induced polarization studies. Estimated unit costs for the various exploration methods arc given in a following table. It is ~stiwated that the cost of 8 detailed reconnaissance survey would range from ~1,400 to $3,900 per km 2 •
Exploration covers a wide r~noe of activities from an individual prospector searching for mineral outcrops to the use of sophisticated equipment in ground or airborne surveys attempting to detect hidden mineral deposits followed by extensive sampling and 10Qging of excavations or drilling programs. For escalation, use F.NR Construction Labor Index, Item 2 in Section 2.8. In organized exploration pro~ram consists of the four following principal stages: Stage 1 Regional Appraisal. Stage 2 Detailed Reconnaissance of Favorable Areas. Stage 3 Detailed Surface Appraisal of Target Areas. Stage 4 Detailed Three-Dimensional Sampling and Preliminary Evaluation. It has been noted that exploration programs startinq with regions ranging from 2,600 to 260,000 km2 being reduced to an ore body of approximately 1 km 2 have cost $190,000 to $2,700,000. Costs are dep£ndent on location, accessibility, qround cover, terrain, weather and geologic complexity. Stage 1
Reconnaissance
Stage 3 Detailed Surface Appraisal Target Areas
of
If the results of the detailed reconnaissance are favorable, they may indicate areas ranging in size from 3 to 130 km~ where more detailed inve~tigaticn is warranted. This stage of investigation would include all of the ground survey techniques or methods that were used in Stage 2, but with more refinement, closer intervals and greater detail. The methods or techniques used miQht include additional outcrop examination, geologic mapping, boulder tracking, reck and specialized sampling, and possibly assaying. In addition, the various ground geophysical studies including gravity, magnetic, radiometric. seiSMic, resistivity, self potential, and induced polarization would be made. Possibly this stage would also warrant some trench excavation and drillino plus field Bod
Regional Appraisal
A regional appraisal might cover an area of 2,600 to more than 260,000 km 2 and would consist of a compilation and geologic study of all available data of importance to the area such as geologic information, geologic maps, aerial ~hotographs, etc. In addition, the appr~isal might include one or all of the following: an aerial examination, field inspection, outcrop examination, qeoloqic mapping and investigation, stream sediment sampling, water sampling, reck sampling. The appraisal also might include a limited airborne geophysical survey including remote sensing and possibly some ground geophysical studies. The esti.ated unit
35
4.1.2. ICCESS BOADS
laboratory tests. Unit costs for the various techniques or methods are given in a followino table. The estiaated cost of this stage of exploration would range fro. S9,700 to $29,000 per k.~.
The curves for clearing for access roads yield the cost per k. for roads varyino in width fro. 3 • to 30 a. The curves are based on estimated costs for clearing medium qrowth on terrain with a side slope of 251.. "edium growth varies froa heavy brush to one tree, 0.33 a in diameter, per 40 m2.
Stage 4 Detailed Three-Dimensional Sampling and Preliminary EValuation
A detailed three-d1.ensional surveyor sampling of a target area ranging in size from 1 to 25 km2 or more would be made 1f it appeared that an economical ore body existed. The sampling or survey would be made to determine boundaries cr limits and depth, size, shape, mineralization and grade. This stage of exploration would probably include an extensive drilling program together with borehole logging and geologic mapping. Excavation of test trenches, shafts and adits might also be included. ~amples would be taken, field and laboratory tests would be conducted, and assays would be qade to permit economic evaluations. The cost of the stage 4 exploration could vary greatly depending on location, accessibility, ~round cover, type of deposit. and the pxtent of a drilling or excavation prog~am. Pnit costs for various techniques cr methods are given in a following table.
For light cl~arin9, consisting mainly of brush and small trees, the costs should b~ reduced by 75~ of the base curve values. For heavy clearing, defined as a dense growth of trees exceeding 0.33 • in diameter. the costs should be increased by 75~ to 100~ of the base curve. On terrain where the side slopes are Qenerally level, the costs can be reduced by 20~ fro. the base curve. The costs for clearing on 50~ side slopes should be increased by 80~ to 1COl of the bas~ curve. On steep slopes in the range of 100~, the clearing costs viII increase in the range of 200~ to 300r. of the base curve. The av~rage labor cost for a typical clearing crew is $7.91 per worker-hour with a common laborer at $7.21 and dOzer operator at $9.56. Of the labor cost shown, 10~ is for equipment repair labor and the remaining 90% for the clearing crew. Of the clearing crew cost. 55~ for common laborers and 45~ for equipment operators. Equipment cperation costs are 73~ for dozers and wheel loaders and the remaining 27~ for trucks. pickups, etc. The combined dozer and wheel loader costs can he divided into 13~ for tires. 57~ for repair parts, and 30~ for fuel and lubrication. Costs for trucks, pickups, etc., are made UP of 4~ for tires, 33~ for repair parts and 63% for fuel and lute. Supplies have not been consider~d in the access roads clearin9 costs. It 1s assumed that brush or timber would be buried under the excavation waste: thus no fuel oil is required for burning. to purchase Where it 1s necessa~y or have a subcontractor equipment rerform the work, multiply the equip.ent value by the followino operation
36
4.1.1. EXPLORATION DESCB!PrIO. iIQLQil~AL
IIA1POWE!
IIAIHOORS PER OIIT
OIIT COST
IEIIAlXS
aEXKQAi
SUBFACE GEOLOGICAL IIAPPIIG
2-_
BEl
3-12 I SQ. XB.
._0 -
.,50 I SQ. XI.
• ,50 - '_00 I DAY
CEOLOGICAL IIFEBEICE
RUE or PlODOCTIOI liD COS~ IS DEPIIDEIT 01 TIIIAI •• CIOVID CO'II. CORPLE!ITY or GIOLOGY. DIT1IL REQOIRED AID SCALE or IIAPPIIC • A QUALIFIID GEOLOGIST IITEIPIETS DATA SHOVI O. lAPS. PHOTOGIIPHS 01 FIILD I.VISTIGATIOIS.
ilWIma.LUtIlllU CIA'ITATIOIAL SOI'EY
1 GIOPHISICIST 2-' U. SUIYEI
CREW
12-50 I PIorILI XB • • 200 -'.600 I PIorILI XI.
PIODUCTIOI VAlliS rlOI I FIW TO 50 IEADI.CS PII DAY DIPIIDI.C 01 TIPI OF EQUIPB •• T. PIOOUCTIOI IS ALSO DIPIIDIIT 01 STITIOI SPICII; liD TEIIAII. SUI'EYI.G IS THI COSTLY PHASE OF THE SOI'EY.
IAGllfIC SOIYEY
~
AIIIOIiE
1-' IIEI
GIOOIO
2-3 lEI
,-e I
0-150 BETElS D'PTH
2-7 lEI
1-_
O'EI 150 BETER DEPTH
15-20 BEl
5-10 I DEPTH DET.
PIOFILE XI.
.,0 - .30 I PBorILI XI.
BACKETIC. ILECTIOBIGII~IC liD IADIOACTI'ITY SUIVEYS. ITC., 111 USUALLI TAXII COICUlal.TLI rlOI Oil AIICIAFT AT _00 TO aoo LIII XB. PII DAY. PIODUCTIOI AIO COS~ DEPIIOIIT O. THE TIPE OF IIICIlrT IQUIPNIIT ETC.
.eo -
PIODUCTION IS DEPEIDEIT 01 PIECISIOI AID SPACIIG OF 111DIIGS, TIPE OF IQUIPB'IT, VEITHII, TIIIIII AID BODE OF TIAVEL.
"00 I PIOFILE XB.
SEIsnc SUIYEY I DEPTH DET.
.20 - .60 I DEPTH DET.
PORTAILE EQUIPIEIT VITH 5 TO 15 DEPTH DETEIBIIATIOIS PII DAY.
.,00 - "50 I DEPTH DET.
VIIIOSEIS EQUIPBEIT VITH 3 TO 15 DEPTH DETEIIIIIATIOIS PEl DAY.
.,0 - .30 I LIIE XB.
OSUALLY TAXEI CO.CUIIEITLY VITH IIACNETIC AND ELECTIO!ACIITIC SURVEYS FRO! DIE AIICIAFT AT 400-800 LINE XB. FER DAY. PRODOCTION AND COST AlE DIPEIDEIT ON THE TYPE OF AIRCRAFT AND EQUIPK!NT, ETC.
IADIOACTIVITY SOIVEY AlIIOIBE
4.1.1. EXPLORATION IIUPOWER
DESCRIPTIOII GROUID
1
RESISTIVITY SURVEY
IIAN
IIANHOURS PER UNIT
UNIT COST
1-2 I LINE XII.
$10 - $20 I LIIE '".
2-3 I DEPTH DET.
$30 - $60 I DEPTH DET.
RE!ARXS DEPEIDENT ON TERRAIII AND GROUIID 1'0 BE COVERED. SURVEY IS RUN AS FAST AS TERRAIN CAN BE COVERED.
1 GEOPHYSICIST
1-4 ASSISTANTS
ELECTBO!AGIETIC SURVEY UnOUE
1-4 liEN
GROUID
~
INDUCED POLARIZATION SUBVEY
1-6 I LIIIE X!.
$;0 - $30 I LIIIE X!.
USUALLY rAXEI CONCURREIITLY VITH IIAGIIETIC AID RADIOACTIVITY SUBVEYS FRO! ONE AIRCRAFT AT 400 LINE XII. OB 80 SQUARE XII. PER DAY.
$50 - $100 I LIIIE X!.
BEADIIIGS ARE TAXEII AT 25 TO 50 !ETER INrERVALS COVERIIIG 5 TO 10 X!. PER DAI AIID ARE DEPEIIDEIIT 011 rIPE OF EQUIP!ENT, TERRAIII 1110 II0DE OF TRAVEL.
$20 - $40 I SQ. XII.
AEBIAL PHOTOGBAPHY
sncx
UD WHITE
PHOTOGBAPHY
$20 - $40 I SQ. XII.
PHOTOGEOLOGIC INTERPRETATIOI
$1,500 - $2,500 I PRINT
PHOTOGRAPHS COVER 40 SQUIBE XII. EACH AT 1:6000. IIANY AREAS ABE ALREADY PHOTOGRAPHED. FLYING lCCOUNTS FOR 15-30~ AIID GROUIID VOBX FOR 70-85~ OF SUBVEY COST.
COLOR PHOrOGBAPHY
$40 - $60 I SQ. XII.
PHOTOGEOLOGIC INTEBPRETATION
$1,500 - $2,500 I PRIIIT
PHOrOGRAPHS COVER 40 SQUIRE XII. EACH AT 1:6000. FLYING ACCOUIITS FOR 15-30% AIID GROUND WORX FOR 70-85~ OF SURVEY COST.
INFRARED COLOB OB BLACX AND WHITE
$40 - $60 / SQ. KII.
PHOTOGRAPHS COVER 40 SQUABE XII. EACH.
THER!AL INFRARED I!AGE2Y
$100 - $300 I SQ. XII.
IIIAGE COVEP.S 40 SQUARE X!. ABEA.
$2 - $4 / SQ. KII.
USED FOR 13,000 OR II0RE SQUABE X!.
AERIAL BADAB IIIAGERY SIDE LOOKIIIG RADAR (SLAR)
4.1.1. EXPLORATION DESCBIPTION
ftANPOWEB
ftANHOURS PER UNIT
UNIT COST $30 - $75 I PRINT
SATELLITE SURVEY
OTHER REftOTE SENSING RETHODS
REIIARIS 23 I 23 Cft. PRINTS AT 26,000 SQUARE Kft. EACH ARE AVAILABLE FROR U.S.G.s. REftOTE SENSING DATA ACQUISITION CAl COVER SEVERAL HUIDRED SQUARE KII. PER DAY. COST OF INTERPRETATIOI REDUCTION OR INTEPRETA~OI EOUAL TO OR GREATER THAI COST OF ACOUISITIOI.
GEOCHEftICAL ftETHOD§ STEAft SEDIftERT SAftPLING
1 liAR
RECORNAISAICE SOIL SAIIPLIIG
1 IIAN
DETAILED SOIL SAlfPLIIG
fg
2 IIEI
$10 - $20 I SQ. Kft. 0.05-0.20 / SAftPLE
1-2 / SAIIPLE
$3 - $15 / SAIIPLE $600 - $3.000 / SO. KII.
DEPENDEIT 01 SAIIPLIIG IITERVAL, TERRAIN, ACCESS AND RODE OF TRAVEL. 50 TO 200 SAftPLES PER DAY DEPEIDEIT 01 ACCESS. TERRA1I. GROUND COVER AID GEOLOGIC COIIPLEXITY.
$15 - S30 / SAIIPLE
HUIlUS SABPLIIG
$15 - $30 I SAlfPLE
BIOLOGICAL SAftPLIRG
S15 - $30 / SAlfPLE
WATER SAlfPLES
$25 - $50 I SAIIPLE
IUULLU!¥ _I1U.ll2RS CORE DRILLING EARTH
0.8-3.3 / IIETER
$15 - $50 / IIETER
VARIES AS TO ACCESS, QUAITIT! AID DEPTH OF HOLES. VARIES AS TO ACCESS QUAITITY AID DEPTH OF HOLES.
SOFT ROCK NI 3- HOLE
2 liEN
1.6-3.3 / IIETER
$25 - $50 / IIETER
HARD ROCK NI 3- HOLE
211E1
3.3-6.6 / IlETER
$50 - S100 / RETER $15 - S80./ ftETER
CHURR DRILL 6- HOLE PERCUSSION DRILLING
1-3 ftEN
0.1 / IIETER
$5 - $15 / IIETER SO.65 / DIA. CIf. / IfETER
AUGER ROTARY DRILLIIG SOFT ROCK 5- HOLE
2 !EI
0.8-2.0 / IlETER
$20 - S40 / IIETER
HARD ROCK 5- HOLE
211E1
2.0-3.3 / IfETER
$40 - $65 / IIETER
VARIES AS TO ACCESS, QUAITIT! AID DEPTH OF HOLE.
applicable factor in order to obtain the total valup of equipment expense for ownership and operationl Shi fts per Day Factor
.. o
2 1.68
1 1.91
3
1.61
If a subcontractor Is used, multiply. labor by 1.50 and equipment expense by 1.20 to compensate for sUbcontractor's Ir.arkup.
..
III
Ie
.
C
III
lot
10,10'
,- '" ,,"
",'"
",'
'"
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.... ..
... ... .. .... .. .... -..: ...... ....., . ...
w w
III W
II:
z
u
1/1
0
~
a:
w
.....
I:>
.......
0
..J Q..
X
I&J
...
... ~
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0 .,..
....
III N
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...
..
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U
...
... ...
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..... . .
#
III
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100
· · .... · ....· · ·
I:>
U
W
~
....
1/1
0
I:> 0 :0:
N
I
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oC
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0
W :II
. 0
~
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. E .... ..... .... • ..... . ... ...... . ....
4.1.2.1.
III
lot
lot II:
....
\II
\II'
~
~ ~
H
U 1/1 14
A
\II \II 0
~
W
\II
... ... ... ... '" Q
.. lot D:
0
~
0 II: W
0
III
III W
0
C
Q
l1li
W
III oC
~
0
~
ROADS - CLEARING
33~.
~
1/1 W
~CCESS
The curves for excavation of access roads yiel~ the cost per km for roads varyinq in width from 3 m to 30 m. The curves are based on a dozer excavation operation on level terrain, side-castino frOM cuts or ditches to a 30 ca fill or to waste. The m~terial to be excavated is either hlasted rock or a common type conolomerate presentino some difficulty in cutting and drifting. Jf the .aterials are found to be easy cuttino and driftinQ, the costs obtained from the base curves should be reduced 25~. Tf the material is extremely wet and sticky, costs should be increased by
\II
II:
100
4.1.2.2. EXCAYATIOI
III
0
x .! Jt
10
U
....I .,..
II:
C
I
-
ROADIIAY WIOT" METERS
. .
III
",.S(X)··107
I:>
III
II:
II
T£ '= 215.It(X)··70 •
W
III
I:>
YL
§..'
W
0
'"
.",'"
..... . W
Q
~~
0'
I
.,..
0 .,..
... ... III
I:>
....
cI' ",'"
~,
II:
I:>
U
W
0
1,'00
· ·
W
1/1
./'" "'~... :\" ~~",,,,
w
W
"""
'" ,",'" '"
;
. . .... ...
On terrain where there is a side slope the costs can be determined by aultiplying each of the curve values by the factor obtained from one of the following equations:
\II H
:0:
W
W
:0: U
oC
a.:
U
0
III
40
For
side
slopes
oreater than 0" up to
II, ...
25": Factor For
=
side
(G)O.600
slopes oreater than 25% up to
100":
/
I, ...
Where: Grade, defined as 1.0t(%Qrade/100) W = Roadway Width in m
G
=
If
v....
100
~'"
o~
l/..(Y /
/
Y • S6.II(W,O.'1t1 l
V
'IE
' ! W .! '0 I
I
-
= ItD,U(W'O.", I
ID
I 100
ROADNAT WIDTH METERS
4.1.2.2. ACCESS ROADS - EXCAVATION
4.1.2.3. DRILL AND BLAST The curves for drilling and bl~sting of access roads yield the cost per km for roads varying in width from 3 m to 30 m. The curves are based on drilling and hlasting a cut contnining 50~ rock. on a 251. side slcpe with a sinqle ditch.
Where it is necessary to purchase equipment or have a subcontractor perform the work, multiply the equipment operation value by the followino applicable factor in order to obt~in the total value of equipment expense for ownership and operation: 2 1.71
" ~~
~
w
Equipment operation can be divided 70% for crawler dozers and rippers and 30~ for rubber tired motor qraders, water trucks and pickups. The crawler dozer and ripper costs are. 711. for repair parts and 29~ for fuel and lUbe. The rub~er tirerl equipment costs include 24% for tires, 40~ for repair parts, and 36~ for fuel and lube.
1 1.94
L..L v
=
The avera9~ labor cost for a dozer operation is $9.48 per worker-hour with a dozer operator at $9.56. Of the labor cost shown, 28~ Is for equipment repair labor. The remainino 72~ is for the excavation crew, of which dozer operators comprise 50r..
Shifts per Day Factor
L /
For cuts containing 100~ rock, the costs should be increased to 1407. of the base curves. On terrain where there is no side slope but drilling and blasting ~re required for two ditches and to provide borrow for a minimum fill, use the costs 3S shown with no adjustment.
3
1.63
subcontractor is used, multiply by 1.50 and equipment expense by 1.20 to com~ensate for SUbcontractor's markup. 8
On terrain where the side slopes average 50~, costs will be 1507. of the base curves.
labor
100~, !.;here the side slopes avp.rage costs will be 300ro of the base curve costs.
percussion The averli'Je labor cost for a operation is $7.85 per drillinQ $7.95 and worl\.E'r-hour with drillers at $7.28. Of the labor chucktenders at cost shown, 7% is for equipment repair labor. ~upply
powder,
41
costs cars
are and
in two catagorles: accessorlE's, 67% and
33~.
drill steel, bits, etc.,
0.20
compacting surfacing to a depth of
m. Equipment o~eration costs are 55% for portable diesel compressors, 22% for percussion drills and 23r. for trucks. The compressor and drill equipment costs are 5070 for repair parts and 50r. for fuel and lube. Truck costs are 32~ for repair parts, 627. for fuel and lube, and 67. for tires. Where
The averaqe labor cost for a six person crew placing surfacing 1s $8.96 per worker-hour with rootor grader ud roller operators at $9.56. ~upply costs include only Qravel surfacing delivered and dumped on the roadbed by suppliers trucks at a cost of $3.31 per t.
it
is necessary to purchase cr have a subcontractor perform the work, multiply the equipm~nt operation value by the following applicable factor in order to obtain the total value of equipment expense for ownership ard operation: ~quipment
Shifts per Day Factor
2 1.84
1
2.12
Equipment operation cost covers a grader. rubber tired roller. water and pickup. Equipment operation are 23~ for tires, 41~ for repair and 361. for fuel and lube.
Where it is necessary to purchase equipment cr have a subcontractor perform the work, multiply the equipment operation value by the following applicable factor in orrler to o~tain the total value of equipment expense for ownership and operation:
3 1.75
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for subcontractor's markup.
Shifts per Da y Factor
100,000
1
2
2.05
3
1.79
1.70
If a subcontractor is used, mul tiply 1.20 and labor by 1.50, supplies by equipment expense by 1.20 to compensate for subcontractor's markup •
,,,.
;
motor truck costs parts
..;,..
...
0
. -:.,,;~/'"
100 ,00
...
~
ID,DDD
...."' ~ ::; ....
:.,.,....
...
~
....:;v
~;
,....,t.), "
;
"~,,
.....
,
~;
,,(\o"i'.".'
~1:"
>l\',.e; ... ", ..
PI
...
t.""
.,.
...
t.O: .........
It"
Vs .. 1562(X)D.715
1/
",'
ID,OO YL • "'3t(X)D.
'"
-
'"
.,"
'"
Ye • I1J7CX)·· .. 9J
, .! x .1 50
.... .......
.,000
10
IDD
.:
S
ROADWAY WIDTH METERS
1 .. 00 0
4.1.2.3. ACCESS ROADS - DRILL AND BLAST
.. ....
4.1.2.4. GRAVEL SURFACING
.....,,0" .. ' \.~
.....~\~
~
;,I-.~
.... ..
The curves for gravel surfacing of access roads yield the cost per km for roads varying in width from 3 m to 30 m. The curves are based on costs for preparing a subbase. receivinq surfac1nQ material delivered to the jobsite in suppliers trucks, and spreading and
t.o.~~~o~ ~""
.. .....
.
o,~
Y L
=
Ys
=
e ~
Y
181.l(X)O.663 1597(X)1.0
6&.26(X)O.661t
), ! x
-
~ )0
100 I
10
!DD
ROADWAY WIDTH METERS
4.1.2.4. ACCESS ROADS - GRAVEL SURFACING
42
4.2. SURFACE "IlliG - CAPITAL COSTS
Where it i . necessary to purchase equipment or have a subcontractor perform the work, multiply the equipment operation value by the following applicable factor in order to obtain the total v81u~ of equipment expense for ownership and operation:
4.2.1. PREPBODUCTIOI DEVELOP"EIT
4.2.1.1. CLEARIIG The curve for clearinq during preproduction development is based on estimated costs for medium light growth on terrain with a side slope of 20~ to 50V,. ~stimate one tree, 0.33 m in
diameter.
p~r
Shi fts per Day Factor
40 m2.
1.56
1.50
If
8 subcontractor is used. multiply labor by 1.50. supplies by 1.20 and equipment expense.by 1.20 to compensate for subcontractor's markup.
large scale The cleariD9 rate for during occurring operations pr eprod uction development is based on the equation:
Y:
123
1.75
10,000
0.153(X)O.6 7 8
Where: Y = Clearina Rate (ha/d) X = Total Clearing Area (ha)
---
1,000
The above equation is valid between the X limits of 1 to 500 ha. Above 500 ha the costs are expected to remain constant.
!
- ---
u
I!
..•.
1---
.: §
For light clearing consistinq mainly of brush and small trees. the costs should be reduced by 75~ from those shown on the curves. For heavy clearing. costs should be increased 75~ over those shown for medium clearing.
--- -
1-- ~- ~---
-I-. -=!I'.!.':'!.H.!..!!~f!AT!..ON
--- --- - -
--- --- - - ---
SUPPLIES
100
L".O_
lIltex)-0.107
YL •
"s • 1I1.,(X)~O.O,. Yr
=
)25.)eX).. O.... ,
1 !. x !. 500
For terrain on level to 20r. side slopes, costs should be reduced by 20~ from those shown. For terrain over 50'7. up to 100% side slope. costs should be increased 70~. On rocky slopes and slopes over 100% the costs should ~e increased 2 to 3 times.
10 1
HeCTARE:S
~he curves have been developed in two parts. Th~ following distribution applies to all equipment in this section.
F.QUIPMENT OFERATING COST DISTRIBUTION
Equipment orerating costs are 751 for dozers and 257. for trucks. pickups and saws.
DESCRIPTION Drill Equipment Trucks
r.OUIPMENT OFERATING COST DISTRIBUTION
Crawler D07.ers Othf'r equipment
1,000
'.2.1.2. DRILL AND BLAST - OlERBUBDEN AID WASTE
are 65% fuel oil for 35% for tools. cable.
nJ:;SCRIPTION
I I
4.2.1.1. CLEARING
The average labor cost for a composite clearing crew is $7.30 per worker-hour with laborers at $6.91. Supply costs hurning a no chokers. etc.
"
I
100
10
REPAIR PARTS 70" 33%
FUEL
(. LUBE 30f. 63%
TIRES 4%
43
REPAIR PARTS
FUEL (. LUBF
50%
507-
32~
62'!'1:.
TIRES 6~
I.'• I- PER~-:SLIe:. r::1~LS
--
For mines excavating fro~ 1,000 to 10,000 t/d of overburd~n and waste, the curves reflect costs for drilling 6 m high benches with crawler type percussion drills. Spacing of 2.5 inch holps is on a pattern of 1.5 m x 2 m to a depth of 7 m. The powder factor is 0.30 kg/to
~~",L
'L • 1.7910)-1.11'
's ••.• ',ex)"·· In ' . . . . . .I(X)-1.1I7
£OU/~ ~I-
~~E~"'" ~~1IIf
! '.U
I I I. 1
I I
~~
I .... .1
x .1
1••• 01
1
pun
su
u
2
For mines excavatinq from 8,COO to 300,000 t/d of overburden an~ vaste, drillinq is performed with rotary drills having a dovn pressure of from 13,600 kg to 40,900 ~q. The powder factor varies from 0.11 to 0.20 kg/t with an average of 0.14 kg/t of waste. Holes drilled average 12-1/4 inch diameter from 8 range of 6 to 13-3/4 inch diameter. Bench heights are 12 to 18 m averaging 15 m. Drilling patterns and overdrilling range fro~ 100 to 300 t of blasted material per m of drill hole. Secondary drilling and blasting range from O~ to lOr. of blasted material.
r-
I
-
""'t--- _LUoR
"'" t----~IPII!L
~
~
u
'.11
I_
OPE '"t-.
I
I
I
ROTAllY DRILLS
I-
t-
~
'L . . . . .,(1)- •. 11t
's ••. I .. '(X)-I .•" '! • '.'7)(X)-I.II.
" , " • .1
.... 1 I
" 1
.1
".0i"j'
10
II.
METRIC TONS PER OAT
1 ••••
x It'
4.2.1.2. DRILL AND BLAST OVF.FBURDEN AND WASTE
The curves indicate average costs for a widp range of ~aterials as can be noted above by drill sizes, bit siZes, powder factors. and drill patterns. In determining drilling and blasting costs consideration must be given to material hardness. abrasiveness. natural fractures and jointin9. and maxi~um size fr~gments that can be loaded, hauled and processed. Where the above conditions dre unfavorable. the costs shown on the curves can be increased up to 100~. For favorable conditions, the costs can be renuced up to 40~.
Equipment operating costs inclUde drills and supporting ~quip.ent 20r..
80~
Where it is necessary to purchase equipment or have a subcontractor perform the work. multiply the equipment operation value by the following applicable factor in order to obtain the total value of equipment expense for ownership and operation: Crawler Type
~ercussion
Shifts per I)a y Factor
The labor cost for a typical rotary drjll op~ration is based on an average labor rate for drill and blast crew of S8.00 p~r worker-hour including rotary drill operators at $8.34. The labor cost for a typical p~rcussion drill operation is based on an average labor rate for drill and ~last crew of $7.91 per wor~er-hour including percussion drill operators at S8.17.
1
2.05
Drills:
2 1.79
3 1.70
2 2.65
3 2.47
Rotary Drills: Shifts per Day Factor
1
3.20
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for subcontractor's markup.
The supply co~ts for both curves include drill bits and steel related items at 241, of the total with the remaininQ 76~ for blastinq supplies.
'.2.1.3. IXC1'ITIOI, LOID liD HIOL 0'IR808D11 lID VISTI The curves show the cost per t for excavatin9, loadin~ and hauling of both co •• on earth and shot rock. For com.on earth excavation, one bank ~3 equals 2.08 t~ for shot rock, one bank equals 2.61 t. The following distribution applies to all equipment in
.3
44
this section:
EQUIPftENT OPERATING COST DISTRIBUTION J'lESCRIPTION
FUEL
REPAIR
*
Where
electric
TIRES
(. LURE
PARTS Electric Shovels Diesel ShOH-ls Dragline, Diesel Rear Dump Trucks Dozers, 'Rippers Scrapers OthE'r EquipJl!ent
or have a subcontract~r perform the york, multiply the equipment opp.ration value by the followinQ applicable factor in order to obtain the total valu£ of equipment expense for ownership and operation:
equip~ent
94~
6'-·
84" 60% 18770" 35"1. 33q,
16~
~hifts
40~
Factor
37r. 30%-
45~
30r.
35~
32~
35';
per !'ay
1 2.05
2 1.79
3 1.70
If a subccntractor is used, multiply labor by 1.50 and equipment expense by 1.20 to compensate for subcontractor's markup.
powered equipment 1s
used, supply curve 1s for electric pover
Curve 4.2.1.3.2. covers mines excavating
only.
from 8,000 to 300,000 tId of overburden and waste. "'he loading units are electric shovels and diesel front-end loaders ranoing in size from 5 to 15 cubic yards with an averaQe of 10 cubic yards. Rear dump trucks from 35 to 170 US tons arp. the main hauling units, with the average size of all trUCKS at 85 US tons. The ratio of trucks to loajing units averaQes 6 to 1. The curves reflect an average haul of 2,000 m one way on an b~ grade from a pit 120 m in depth on wide, well maintained rOads. To determine costs for hauls of varyinq length or depth of pit, ~ultiply the costs obtained from the curves by the folloving factors:
The curves have ~een developed in four parts covering a variety of excavation methods and encoapassing a range from 1,000 to 300,000 tId. Curv~
4.2.1.3.1. covers from 1,000 to 10,000 tId of overburden and wa.ste excavation and is based on mines using front-end loaders and trucks. The loaders ranee in size from 1 to 6 cubic yards and the trucks range from 10 to 35 US tons. The curves reflect an average haul of 750 m one way OD an 8% grade from a pit 60 m in depth. To determine costs for hauls of varying length or d€pth of pit, multiply the costs obtained from the curves by the follo~inQ factors:
Labor Factor. F = 0.1173(R)o.030(L)o.~63
Labor Factor, F = 0.155(R)o.030(L)o.Z63
Equipment Operation Factor, F O.0546(F)o.O_7(L)o.353
Equipment Operation Factor, F = O.080(R)o.O_7{L)o.353
Where: F = Factor R = Depth of Pit in m (- or F=1.0) L = Length cf Haul in m
Where: F = Factor R = Depth of Pit in m (R=1.0) L = Length cf Haul in m
=
or
Or.
O~
grade,
grade,
For a typical front-end loader and truck operation, the labor cost is based on a composite crew having an average rate of $8.15 per worker-hour with a loader operator at $8.19 and truck driver at $7.65. Equipment operating cost distribution for loader and truck operation: 15.81Loa.ders 41.8~ Rear Dump Trucks 22.7r. Cravler Dozers 19.7'1. Rubber Tired Support purchase to Where it is necessary
For a typical electric shovel and truck operation the labor cost is based on a composite crew having an avera\1e rate of $8.12 per worker-hour vith a shovel operator at $8.30 and truck driver at S8.05. Equipment operating cost distribution for shovel and truck operation: 8.51, Shovels 70.0~ Rear Dump Trucks era wIer Dozers 11.0" 10.5~ Rubber Tired Support Where it is necessary to purchase equipment or have a subcontractor perform the work, multiply the equip~ent
46
F.quipment Operation Factor. F = 0.0641(1)o •• 03(G)1.620
operation value by the following applicable factor in order to obtain the total value of equipment expense for ownership and operation: Shifts per ray Factor
1
2
2.55
2.16
Where: F ::- Factor L = Length of Haul in m G Grade, defined as 1.0t(%Qrade/100)
3 2.0.3
=
Production in tid is based on a material havino a weight of 2.2 t/m 3 and requiring ripping. If no rippiD9 is r~quired, reduce curve values by 157..
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for subcontractor's markup.
The average labor cost for a composite crew is $8.24 per worker-hour with both scraper and dozer operators at $8.24.
I." ~
'~
~~
~"~~
' ! • l.tUex)-t.ll ..
o,,~~
1,,000 ! X!
~il"::-"f', 0..,,,
'RONT END LLJRS AND TRUCKS
I
0.10
I
Equipment operating costs are 27~ for rtozers, rippers and push cats and 73% for rubher-tir~d scrapers, graders, water trucks.
'L • 8."oex,-0.111 "s • a.ln(Xl-a.on JOo,ooo
Where it is necessary to purchase equipment or have a subcontractor perform the work, multiply the equipment operation value by the followino applicable factor in orrler to obtain the total value of equipment expense for own~rship and operation:
EQUIPMENT OPERATION
.I t--- ~~
~
I
I-- t--
~ 'L • u.60eX)-·· .. U
'I. • ... oex)-··'Ol
t-
1,'"
~ X.!. 10,,000
u
!LECTRI C SHOVELS AND TRUCKS
2
Shifts per Day Factor
I
.r
I
SUPPLIES
. u HETRIC TONS PER DAY
2
1.79
3
1.70
a subcontractor is used, multiply labor by 1.50 and equipment expense by 1.20 to compensate for subcontractor's markup • If
'.01
.
1
2.05
100
x
1,'"
10 3
4.2.1.3.1. EXCAVATION, LOAD AND HAUL TRUCK HAULAGE Curve 4.2.1.3.2. covers mines excavatino from 2,000 tId with 13 US ton self-loadinQ scrapers to 300,000 tId with a spread of 64 US ton twin-engine scrapers. The curves are based on an average level haul length of 900 m and include a 6~ rolling resistance in the excavation area. A change in haul length or grade viII result in a change in unit cost. To determine the unit costs for varying haul lenoths and grades, multiply the costs obtained fro. the curves hy the following factors: Labor Factor, F 0.0865(L)o.359(G)1.530
=
46
combine equipment operation and supplies curVeS to account for substitution of diesel fuel for electric power. (Note: supplies values include only electric power. )
1.0 0
",
.~
-- -
' ....
,-
u
:;
~O..
EQUIPi:iE~
.,
0.10
. ,
~-
,
::.6p
-.
R~" ION '-.I,
Shifts per Day Factor
,
"
I
I..
Wh€re it is necessary to purchas~ equipment or h~ve a subcontractor perform the work, multiply the equipment operation value by th~ following applicable factor 1n order to o~tain the total value of equipment expense for ownership and operation: 2
3
2.16
2.03
If a subcontractor is used, multiply labor by 1.50 and equipmpnt expense by 1.20 to compe.nsate for subcontractor's markup.
-t
..
1
2.55
L
YL • ft.3DS(X)-O.JU
YE
= O.299(X)-O.092
2,000
I
0.01 I
10
100
.s.
I
1.00
X :!. )00,000
CRAII~R dRA~LINE
I I I 1,000
METRIC TONS PER DAY X 10 3
\
4.2.1.3.2. EXCAVATION, LOAD AND HAUL SCRAPERS
-~~
Curve 4.2.1.3.3. covers diesel powered dr~qlines exc.vating and casting overburden and waste material from a dry pit into a spoil pile. The material is assumed to weiQh 2.0 t/m 3 • The curve 1s in two parts. From 2,000 to 15,000 tId, crawler draalines range in size from 1.5 to 15 cubic yard capacity. Above 15,000 tId, the curve is based on 25 cubic yard walking draglines. A dozer is provided with each dragline for cleanup and support.
"'i+.I'
1\ ~.pof.l''''''~
0,0
"'Ij;
0.10
"\
WALKING DRAGL[NE
--
EQUJ.:l..NJ OJ:LTJON LABOR
ClAW\.!a DlACLINI! 1.1 tu YD TO 11 CU YO
YL • •",.I(X)-0.129 YI! •••• UCl)-O ... "
..
I .... .! x .! U.IDO
'
WAUIHI OIAGLiNI
8
For a typical dragline operation, the labor cost is based on a composite crew having an average labor rate of $8.21 per worker-hour with a dragline operator at S8.30, oiler at S7.65 and dozer operator at $8.24.
'0
TL • UftCX)-o.Uft YI •••• 95(X)-0.020
lS.OOO .i
x i JOD,OOO
0.01 1
10
I 0
1 , 00 0
HETRIC TONS PER DAY X 10 3
4.2.1.3.3.
F.XC~VATION
DRAGLINES
4.2.2. RINE PLANT AND BUILDINGS
Equipment operating cost distribution for draglin€ operation: 70.0~ Draglines 28 • O~; Crawler dozers 2 .• 0"(. Rubber tired support
In this section if a subcontractor is used, multiply labor portion by 1.50, materials portion by 1.20 anrt equipment operation portion by 1.20 to compensate for subcontractor's markup except 1n the case of Communications System.
To determine the cost of a draQline operation loading to trucks, use Curve Shovels and 4.2.1.3.1. (Electric the values by Trucks). Adjust increasing each curve component 25K and 47
4.2.2.1. RAILROAD COISTBUCTIOM This curve covers the cost of buildinO unballasted standard gage railroad in an open pit mine. For mainline trackage or installations where ballast may be required, increase curve value by 9~.
steel 70~, and purchased equipment the remaining 10~. The installation is based on a three-shift aining operation. 1, ...
For unballasted trackage, distribute cost 25~ to labor, 12~ to equipment operation and 63~ to track materials. For ballasted trackage, ~lstribute cost 20ft to labor, 11~ to equipment operation and 697. to track materials.
. ...
"' l/
==
V 10
L
"'" ""'"
~
/'
V
!D.OO
/ 1,00
/
V
/
~
COST • IS. 51t(X)I. 1S1
/
I, ... .!. x.!. ...., ...
1
'"::
" ~
OIl
V
/
V
/
COST. U.SlXlO'CX)1.1
Construction labor accounts for 27~, purchased equipment 40~ and construction materials 33% of the cost.
I.! X.! U
10
1
•
The user must evaluate the mininQ situation and determine the m3 of water to he pumped and the total pumping head.
4.2.2.1. RAILROAD CONSTRUCTION 4.2.2.2. VATER AID DRAINAGE SISTERS 4.2.2.2.1. VATER SISTE" The cost of water supply for a surface mine includes purchase and installation of pumps, storage tanks, electrical hookup, piping and distrihution to surface buildings and a nominal amount of extra heavy duty pipe with pressure reducers and chec~ valves installed to service the mine workings. for
20~
1....
This curVe covers ditches, culVerts, sumps and drains needed to drain the surface area around the mine. It is based on m-m 3 /d where the term m represents the total pumping head. Power supply equipment for the pumps is included in Section 4.2.2.5. (Electrical System).
~
accounts
10.
4.2.2.2.2. DBAI.AGE SISTER
KJ~OMETUS
Labor
10
4.2.2.2.1. WATER SYSTEM
V V
1
1
METRIC TONS PER DAY X IO J • TOTAL OIl! AND IIAST!
/
10 0
V
1/
....
Where it is necessary to purchase equipment cr have a subcontractor. perform the work, multiply the equipment operation portion of thp. curve by 1.7 in order to compensate for ownership or subcontractor's rental of equipment.
B
L
of
the cost,
48
I,'"
I,ll'
/
..::
/
10.
/ .,+- 1.1
..of.
...-i",
uo
~.~
V
8
,:
8
~/
11
~~
./
"
'.1.1.'. _ICATI_ "S_ COST. 1\7.1(10·· ..· '
1.... .! • .1 , ••••••
/
COST.
'.1.2.'. PUILI . . SYITD
o.tnex)O.'"
COlT •
10,'00 .!. X .!. 6,01','00
I I 10
..'i~
/'
--
11
./
1
I
£. ~\~ I "¢' L~.\'·~
IC
,/
,:
/
~ ,,~" V ~'"
/
./
IC
/
no
I
1,'00
I
I I
:'.~. ~ x 1 '~.'...
1
lO,IO'
n. &I ex)··'1S
1
11
I
1. .
I
I 1 ....
METRIC TONS PER DAY X lO', TOTAL ORr AND IIASTe
METeR - CUBIC METERS PU DAY X 10'
4.2.2.2.2. DRAINAGE SYSTEM
4.2.2.3. COMMUNICATIONS SYSTEM 4.2.2.4. FUELING SY5T["
The communications system curve is based on installed costs for a radio network and surface telephone service. The radio system contains mobile and base units with one or more repeaters dependinq on the size of the mine. Telephone service costs are based on a complete telephone system with installation by an outside agency. The costs are based nn a three-shift mining operation. For escalation, distribute 80~ of the cost to purchased equipment and 20~ to labor.
4.2.2.5. ELECTRICAL SISTER This curve is based on the assumption that commercial power is delivered to the main sUhstation at the mine. The electrical system includes .ain substation, overhead power lines, trailing cables, and portable substations and is for a mine using electric shovels as the primary loading unit. The costs include purchased equipment and installation. Capital electrical costs for small surface mines us1ng front-end loaders are represented hy lower tonnage ranges of the curve.
4.2.2.4. FUELIIG SISTER This curve is representative of the cost of fueling systems for diesel, gasoline, lubricants, coolants and waste oil. It is based on one stationary fueling point and one or more mobile units. The cost is composed of equipment purchases 75~ and installation 25%. Any building required for fueling facilities is covered in Section 4.2.2.8. (Surface Buildings). The costs are based on a three-shift mining operation.
The cost ottained from the curve is based on a three- shift min1ng operation and is composed of 80r. electrical equipment and structural support and 20~ installation labor.
49
The following distribution gives the percentage allocation of total cost applicable to surface mine repair shops and warehouse facilities:
10,'" eLECTRIC SHOWL MIMU
[7
1,100
BuUding & Fixtures Erection & In stalla tion Excavation & Concrete Equipment
/
V 1.....
/
'"
1-'
V
Warehouses
33~
6~
16%
2%
17%
7r.
1B~
1,,{
u, •• o
V
/
100
Shops
Cost Components
NONELECTRI C SHOYl!L MIN!!
== >C
Il'
"
.:
,,/
I..........
8
,,"
I;......... 11
./
V
../
HONILI!CTlIC SHOY!L HIHI!S
-
COST • 7I.lI(X)·· . . 1
-
x .!
-
1,000 .i IL~CTRIC
eOST •
10,'"
IHOYI!L MINES
ss.esex)O .....
"
~" ,," ,,"
1,010
-
/'
".
',000 .! x.i IfU, •••
I I
10
""
no
1,"0
,,'
'"
. ..S.
METRIC TONS PER GAY X IOJ, TOTAL ORE AND WAST!
==
4.2.2.5. ELECTRICAL SYSTF."
•• 2.2.6. REPAIR SHOPS AND WAREHOUSES
,,"
"
"
"
~,
,,"" " ~,," COST
Repair shops include buildinqs, equipment, floors, foundations and aprons. Building costs are based on step.l building construction including all applicable equipment and cover all types of surface mining operations and haulage. J( rail haulage~s required, the user should remember to include trackage 'cost for yard and shop facilities under Section 4.2.2.1. (Railroad Construction). The buildings are based on weather requirements for the Denve~ area and the cost may be reduced 5~ for more moderate areas or increased 5~ for more severe areas.
= JDlO(X)'·S76
1,000 .! X.:! ltoo,OOO
100
I
10
10'
1,000
METRIC TONS PER DAY X 10 3 • TOTAL ORE AND WASTE
4.2.2.6. SHOPS
~ND
WARFHOUSES
•• 2.2.7. OFFICES liD LABORATORIES cost curve for offices and laboratories includes construction of general offices, engineering and safety offices, and laboratories, including furnishinQs as well as all necessary assay and metallurgical equipment. The cost is based on steel building construction. The buildings are based on weather requirements for the Denver area, and the cost may be reduced sr. for more moderate areas or increased 5% for more severe areas. The installation is based on a three-shift mining operation.
The
The cost ~btained from this ·curve assumes that these facilities will be used only for mining operations. If the mine and teneficiation pl~nt are to share the same facilities the user must determine, using a knowledge of t"he requirements, what can be jointly used and how much. if any. increase to the cost must be made for joint usage. The costs are based on a three-shift mining operation.
curve The cost obtained from this assumes that these facilities will be used only for mining operations. I f the mine and beneficiation plant are to
50
share the saMe facilities the user must determine, using a knowledge of the requirements, what can be jointly USlo!! and how much, if any, increase to the cost must be made for joint usage.
I."
I
,/
Thl" followinq distribution gives the percentage allocation of total costs applicable to surface mine offices and laboratory facilities: Cost Components
Offices
Ruildings and Fixtures Erection & Installation Excavation and Concrete F.quipment
,p~VV
~;.o
.. I
'\.
....
.... ";'1
14~
157.
........".
~
~r.c,
~...,,9'
f....c,
37713~
~/ ~
Lab's
t. • -#t"C;
c,
:....1 ...
/: .. . ~
.y
"'::
q.2.2.8. SURFACE BUILDINGS
'
".t.I.7.
il
The cost curve for surface huildinQs covers the general support facilities for the mininQ operation, including change house, powder magazine, tool sheds, Quard houses, fencing, etc. Buildings are furnished and of st~el construction. The buildings are based on weather requirements for the Denver area, and the cost may he re~uced 57. for more moderate a~eas or intreased 5~ for more severe areas. The installation Is based on a three-shift mining operation.
o"tce:s •
LAaOu,TORns
COST • " ... 90:)"'"
I...... !
0
x .:!.
"'0.'"
... t.2.'. SUR'ACe: BUILDI.S COST. U72(X)··)7S
.,0"
~
x.! .... ,000
II
I ....
110
I METRIC TONS PER DAY X 10 3 ,
TOTAL ORE AND WASTE
4.2.2.7. OFFICES AND LABORATOPJF.S 4.2.2.8. SURFACE BUILDINGS
.4.2.3. TOIlISITE
cost obtained from this curve assumes that these facilities will be used only for mining operations. If the mine and beneficiation plant are to share the same facilities the user must determine, using a knowledge of the requirements, what can be jointly used and how ~uch, if any, increase to the cost must be made for joint usaQe.
The following housing costs are based on using trailers in a fairly level and accessible site containing between 75 and 125 units. (For 40 to 60 units, increase costs hy 10~; for 150 to 250 units decrease costs by 10~). These costs are quoted per individual trailer and may be factored by the ~LS Industrial Materials Cost Injex.
The cost
Site costs for family or bachelor unit:
·~he
ottained from the curve is on construction labor 2370, purchased buildinq and materials 57~ and construction materials 20~.
~ased
Site preparation (typical ar.a 250 m2
)
$(00.00 Streets (5.5 - 7.3 m wide 5 cm 3srhalt or 7.5 cm gravel, lill'ited curhing) $270.00 Patios and
wal~s
$250.(,)0 ~ewers
- connected to trailer $210.00
Water - connected to trailer S240.00
51
Electrical - yard lighting and 80 aMp service connection to trailer $460.00 Laundry and recreation buildin~
$110.00 Total TYrical Site Coet
In ~ay
$2,800.00
addition, the following accessories also'be required:
Skirting at base of trailer
'.2.5. III. EQUIPI.IT '.2.5.1. SUIFaCE IIIIIG
EQUIPIEIT
The follovinQ cost curves are for ~he purchase of surface aine capital equip.ent and are based on .ines operatino three shifts per day. Preproduction develop~ent work can be done usino the equipMent purchased for operatiDQ the aine; however, no reduction in the capital cost should be made if a subcontractor brings in his own equip.ent.
$200.00 landinos and steps $150.00 Canopies OVEr landings $150.00 !lr conditicninq - using ~xistino heater $600.00 Housing Units Faaily units with living, dining, kitchen, bath and sleeping facilities for 2 adult~ and 2 to 4 children: $17,000.00 Type A bachelor units with living, dining, kitchen, bath and sleepinq facilities for 2 persons: $7,000.00 Type R bach£lor units with bath and facilities for 6 persons: $14,000.00
sle~ping
For type B bachelor units, add for each 1 to 6 units, $50,000.00 for caap living, dining and kitchen facilities. For each additional type B bach~lor unit add $3,500 to the $50,000 amount.
Q.2._.
RESTORATIOI DURIIG COISTIUCTIOI
Permits are generally required prior to disturbing the ground surface. Typically, the per_it specifies that the area must he restored hectare for hectare to approximately the original contours and planted with native plants and trees in areas which are not to be mined. For areas where restoration to the ori?inal contour would not be practical, topsoil and plantino oenerally will be required on the slopes. It is estimated that a restoration prograM for these could ranoe frOM $5,000 to $12,500 per surface hectare depEnding on the requirements.
These costs are predicated upon the equipment being delivered and made fully operable at an appropriate site in the Denver area. They also include provision for standby eqUiPMent, spare parts, administrative and maintenance units and an allowance for miscellaneous items. Fscalation for purchased equipment should be factored by BLS F.quipaent Cost Index. Cost curves are presented for four reouiarly found conditions or types of surface minino operations defined by loadino and hauling methods as follows: Using wheel loaders and trucks (production range from 1,000 to 20,000 tid) Usino shovels and trucks (production range fro. 8,000 to 400,000 tid) Using shovels and haul trains (production range from 20,000 to 200,000 tid) Using scrapers (production 2,000 to 300,000 tid)
range frOM
The types of equipment covered in these cost curves are all classes of mobile and stationary machinery reoularly found in surface minino, including compressors, drills, powder trucks, hydrocranes, wheel loaders, shovels, crawler dozers and rippers, on and off hiohway trucks, freight locomotives, railroad cars and administratiVe and maintenance equipment. The percentaoe of cost fro. the curves applicable to haulino eguipment or scrapers should be adjusted by the same equipment factors as were used in Section 4.2.1.3. (ExcaVation, Load and Haul Overburden and Waste). This factoring will take into account varying haul lengths. orades and pit depths. The cost for
fixed supporting items such as railroad track or electric power transmission lines has been covered where specifically noted in other itels. Draol1ne costs IU Y be' used interchangeably with olectric shovels.
generalized cost can not be applied. For the user's guidance, the followino cost of dredges, ready for shipment at the manufacturer'~ site, are given. YEAR H.P. REACK BUCKET COST, $ BUILT (ft) (cu ft)
Capital costs for various hauling methods are distributed as follows:
1966 1952 1937
Using electric shovels and trucks: 36r. Loadino 57'; HauliDg equipment Drill and blast equipment 71 Using electric shovels and trains: equipment 34" Haulino equipment 59~ Drill and blast equipment 7"
....... /'
.,..... ~;, ~
~~~
~~,
W
.
L
I. I ....
~ .....
~~ 1"
4:"'~\
./
~ iI""
./ ".
V-- ~~L'~
IIMII ... UII:I COlT • R,III(..,I.,,. 1, ... ! • .! II, •••
/
GWU. COl' • IIII(X)··1I' I, ••• .! x .!. J •• ,,'"
./ ~
IIIIDL MIl I . . .
/
COl' •
',1"
7". I(X)' ,."
.1 • .! .... " •• HlDL _ lUllil COlT • II"(X)I. I.,
• 11
•
8,000,000 1,109,000 600,000
The curves are based on percentage of net constructed cost and the complexity of the project. Over the years, engineering experience has established some approximate correlations between engineering and construction costs and these correlations have resulted in the costs, presented herein. The curves for design and engineering services fees are hased on ASCE - Manuals and Reports on Engineering Practice No. 45. Construction management fees are not as veIl established, but have been based on the practices of several firms engaged in this type of construction management.
64'1: 28" 8".
V
18 18 8
'.2.6. ENGINEERING AND CONSTRDCTION IIAIIGEIIEI! FEES
Using Wheel loaders and trucks: 32'1: Loading equipment Hauling equipment 42~ Drill and blast equipment 25"
JIo"
82 107 60
Additional data regardino cost of dredges may be obtained from U.S. Bureau of Mines Information Circular aQ62, Gold Placer Minino, Placer Evaluation and Dredge Selection, by C. K. Romanovltz, H. J. Bennett, and W. L. Dare (1970, 56 pp.).
Loadin~
UsinQ scrapers Scrapers Pit equipment Road equipmt'nt
3,600 2,500 1,300
...
I','" .! • .! 10','"
METRIC TONS PER DAY X 10', TOTAL Oil! AND WA~TI
.....
4.2.5.1. MINE EQUIPMENT
'.2.5.2. DREDGES
The net construction cost is th~ sum of the group cost for Sections 4.1.2. (Access Roads), 4.2.1. (Preproduction Development),. 4.2.2. (Kine Plant and Buildings), 4.2.3. (Townsite), 4.2.4. (Restoration During Construction) and 4.2.5. ("ine Equipment). Factors for escalation, locat.ion, etc., should not be applied to the design and engineering fee, and only a factor for remote and/or inclement locations should be applied to the construction management fee • The total design, engineering and construction management fe~ curve is based on a sinole firm performing both tasks. The other tvo curves are ~ased on different firms performing each task.
Dredges are generally designed and configured for a specific minino application. For this reason a
53
II, It.
/
v
",,1/"II
If'
.......' " ~" rJ<~" L /
"V
1,000
~
The average labor cost is $8.12 per worker-hour with miners at $8.29 •
/
~~'~1~; .." ""#
~~~ ~i ..
Supplies 8re composed of steel items 67~ (track, drill bits and steel, pipe, fan line, etc.), explosives 30r. and electric power 3~ •
~#,'
.:: .
.. W
,,~~ "ri: .,+~~.. ~-, ~ ..~, ~'"<;
..,'at'
II.
"lL
,,' V V / " " V"/'
The equipment operation curve is based on the use of battery locomotives and is composed of repair parts 89r. and fuel and lube 11%. If diesel locomotives are used, increase the equipment operation value by 20~ and decrease the supplies
~o
~" /
10
-"
10 m2 face area with advances varying from 1.7 to 2.0 m per shift. The curve components are based on a medium hard rock requiring no support and include drilling, lcadinq, blasting, muckinq and hauling plus track, vent line and utilities installation.
L
2" •
/
V
CONSTRUCTION MAHAClMENT FEE
• D,GnU)"''''
KliCH AND ENCIN!!RING '11
• •• 215(X)··105
TOTAL DlSIC", ENCINE!!IINC AND CONSTRUCTION HANACEMENT PU.
• •. tt,
EQUIPMENT OPERATING COST DISTRIBUTION DESCRIPTION
lDO,,'" ~ X .! 10D.ooo,00a
I
I
100
I
1,000
I Ii
I
I I
I
10,100
100,000
NET CONSTRUCTION COST X 10'
4.2.6. ENGINEERING AND CONSTRUCTION f'lANAGEI'IENT FEES
4.2.7. WORIING CAPITAL Workinq capital needed for a surface operation is a variable factor that cannot be tied to mine production and cost only. Pasically, it is the capital required to meet payrolls and pay bills for material inventory and to carry accounts receivable until ore sales produce revenue to pay for these items. ~ine
Working capital is estimated as 60 days of operatinQ and administrative cost. For surface mines, capital demand is higher on mining equipment and repair parts, while labor is lower, and support materials and utility costs are minimal.
'.3. UIDERGROUND "IlliG - CAPITAL COSTS
REPAIR PARTS
FUEL
r. LURE
Locomotives, BatterY Locomotives, Diesel OthE'r equipment
TIRES
89r.
11~
4M>;,
54~
907.
10%
Factors: Add for tough, abrasive rock drilling 8% steel. Add for difficult breaking rock 8.5~ explosives. Add for regular pattern rock bolting 1070 steel and 7~ labor. For timber set support: Md 33% labor. Add 30~ supplies. Where it is necessary to purchase equipment or have a subcontract~r perform the work, multiply the equipment operation value by the followinq applicable factor in order to obtain the total value of equipment expense for ownersh~p 8nd operation: Shifts per Vay Factor
4.3.1. PREPRODUCTION DEVELOP"EIT 4.3.1.1. DEfELOP"ERT DRIFTS 4.3.1.1.1. SKILL DRIFTS FOR RAIL HAULAGE Drift sizes on this curve vary from 3 to
54
1
1.74
2 1.56
3
1.49
If a subcontractor 1s u••4, ault1plr laJ)oZ' )71.50, supplies by 1.20 and eqUip •• Dt expeD.e !If 1.20 to co.p.naate for subcontractor- ••• rkap_
Add
for
regular pattern rock boltino -
10% steel and 7% labor.
1,00 0
1---
_...V"
,.,...... s 1.1'.0': SUpp\.IE . :,....... ...
100
".-
'"
----
... ~-----
Where it is necessary to purchase equipment or have a subcontractor perform the work, aultiply the equipment operation value by the following applicable factor in order to obtain the total value of equipment expense for ownership and operation: Shifts per ray Factor
W I-
~
'"w":;;' o
u
10
------
.........
tI~
-
OPEV~~"'''' ...
l..--.....
123
1.70
1.53
1947
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for subcontractor"s markup.
E.Q.\l\P".:.--
1,000
VL • U. 7\CX).· In
Ys • ".71(X)O.~O'
1---
YI! • 2.726()C)0.72S J .1
f---
~
x .1
-
10
6
--
10
SQUARE METER FACE AREA
4.3.1.1.1. SMALL DRIFTS FOR RAIL HAULAGE
4.3.1.1.2. S"ALL DRIFTS FOR BUBBER TIRED HAULAGE Drift sizes on this curve vary from 4 to 20 me facF area with advances varying from 1.7 to 2.0 m per shift and are normally used for LHD haulage. The curve components are based on a medium hard rock requiring no support and include drilling, loading, blasting, mucking and hauling plus vent line and utilities installation. Thp. average work~r-hour
labor cost Is $8.27 with miners at $8.29.
per
Supplips are composed of steel items 58% (drill bits and steel, pipe, fan line, etc.), explcsivps 38~ and electric power 4~
•
The equipment 0peration curve is composed of repair parts 727., tires 9% and fuel and lube 19~. Factors: Add for tough, abrasive rock drilling 8~ steel. Add for difficult breaking rock - 8.5~ I?xplosiv£>s.
100
\.jo.I!o.!
.....
......
...
-
-"t;\.\t.'" ...... ~! ...
_ ..
i"
.f
<1:'" ......
"'' '
,§"'~'"
,o'
YL
+.... '"
q~
8
~'"
",'" 10
= 56.07CX)o.'-2
Vs • \, • .,0)°·362
-
'f! • J. JOSCX)O ... ,
4'"
If
~
x.!. 20
100
10 SQUARE METER
~ACE
AREA
4.3.1.1.2. SMALL DRIFTS FOR RUBRER TIRED HAULAGE
4.3.1.1.3. LARGE DRIFTS FOR RUBBER TIRED HAULAGE Drift sizeE on thi~ curve range from 20 to 50 m~ face area with advances normally u~e~ for truck haulage Lhat range from 2.1 to 2.4 m per shift. The curve components are based on a medium hard rock requiring no support and include drilling, 10adinQ, blasting, mucking and hauling plus vent line and utilities installation. The averao~ labor cost is $B.28 per worker-hour with miners at $8.29.
55
Suppli~s
•• 3.1.2. SINKING SHAFTS
are composed of steel items 52% (drill bits and steel, pipe, fan line, etc.), explcsives 45% and electric power
Shaft sinking curves cover a range of face areas from 4 to 40 m2 with average advances of 0.76 to 1.22 m per shift in the smaller shafts and 1.02 m per shift overall in the larger shafts.
3% •
The eguipm~nt operation curve composed of repair parts 71%, tir~s and fuel and lube 19~.
is 10%
The smaller shafts are based on using miners at $8.29 per worker-hour and a hoistlllan at $8.14 for an average labo.r cost of $8.15. Tn the larger shafts the crew size increases considerably with the average cost at $8.21 per worker-hour. Applicable hourly costs are: shaft miner $8.64, foreman $9.09, miner helpers $8.02, mucker operator and cagers $7.88, electrician $8.20, and hoistmen $8.14.
Factors: Add for touQh, abrasive rock drilling 8~ steel. Add for difficult breakino rock 8.5% explosives. Add for regular pattern rock boltlnQ 10% steel and 7~ labor. Wh~re it is necessary to purchase equipment er have a subcontractor perform the work, multiply the equipment operation value by the following applicable factor in order to obtain th~ total value of equipment expense for ownership and operation:
Shifts, per Day E'actor
1 1.52
2 1.39
Supplies are composed of explosives 8~, shaft timber 141., power 6~, steel related items 627. (pipe and fittings, Quides and manways, rock and hanger bolts, etc.) and miscellaneous items 101.
3
1.35
The equipment operation curve is composed of repair parts 88%, fuel and lube 7% and tires 5% (tires used on top~ide cranes and loaders servicing the shaft sinking).
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for subcontractor's markup.
Factors: When concreting a large shaft concurrently with sinking, reduce labor 12%, add 18% to supply curve for concrete and forms, and reduce equipment opera tion 3.51..
1,"0
~
~ 100
V
If shafts are to be la,ged wit~ timber, increase labor 9~, increase timber portion of supply curve 381., and increase equipment operation 131.
~
Services installed in shaft include guides, manways, air, water and vent lines, and all electrical cables, signal lines, and lightino. Sinkino is considered to be done with a sinkino headframe. Costs for permanent hoisting facilities are included in Section 4.3.2.2. (Heisting Facilities).
:\\~
...~ "'
~
....
Where it is necessary to purchase equipment or have a subcontractor perform the work, multiply the equipment operation value by the followino applicable factor in order to obtain the totftl value of equipment expense for ownership and operation:
'L • 1I ••'(X,··1I1 -
's •
Sl.II(I)··'57
' I • , .• II(X)··111
•• ~.~,. I 10
.. 0
10 SqUAU MeTER
~ACE
110
AREA
4.3.1.1.3. LARGE DRIFTS FOR RUBBER TIRED HAULAGE
56
Shifts per Day Factor
1
2
1.18
labor cost and $1,500 to supply cost for each raise.
3
1.14
1.12
If a subcontractor is used, multiply lahor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for suhcontractor"s markup.
the
total
If the raises are not timber lined deduct 28~ from supply curve and 30~ from labor curve. Where it is necessary to purchase equipment or have a subcontractor' perform the work, multiply the equipment operation value by the followinQ applicable factor 1n order to obtain the total value of equipment expense for ownership and operation:
10,000
/"
Shi fts per Day Factor
,
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20 and pquipment expense by 1.20 to compensate for subcontractor's markup.
..........-::: ,,~.,~../ I-"
../ v'
1,000
,-","/
~
~" ,,-;,,"
/
V
.
l/"
........
V
S
3 1. 73
1.000
~t,~<"''/
t,,,,\l\;;~
..,':?
Tl Ys
ItS9.0l
I:
•
SI.tt7(X)J·O
u.S)CX)··, ...
Y• •
" .!
lOa 1
2 1.83
<.\o'i'
t,...tc:1 "
V
0-
.-'
1
2.10
)C
.! "'
10
100
SQUARE METER FACE AREA
100
.. ; •
4.3.1.2. SINKING SHAFTS
....
SUPPLIES
I."so"
..•
4.3.1.3. DRIVIle RAISES
L
The curves for drivinq raises are for two-compartment timber lined raises varying in face are~ from 2 to 6 m~. ~dvance rates in • per worker-shift range from 1.25 for a 2 m2 raise to 0.7 for a 6 m2 raise.
.
0-
S 10
--
.."nON
E(\UIP"EtI~!!:.~-
The average' labor cost is $8.20 per worker-hour with miners at $8.29 and motormen at $7.53.
n.lft
TL •
's. ,... SICX)'·'''· 'e:
_
J.7U(X)D.'"
z
t.1x.:s.6
.
Supplies are composed of steel items 33~ (nrill bits and steel, pipe, etc.), explosives 3ar., timber 28~ and power 1l. operation curve The equipment repair parts 9'~ composed of lubrication 9~.
10
4.3.1.3. DRIVING RAISES
is and
If a simple chute with steel bottom lip and steel door at the bottom of a raise 1s used, add S265 to the total labor cost and $750 to the total supply cost for each raise. If grizzly chains and air cylinders are to be included also, add an additional $265 to the total
6
SQUARE METER FACE AREA
4.3.1.4. PREPARING STOPES Stope preparation varies wid~ly from one mine to another depending upon the individual mine system of eitraction. Stope development 1s generally considered to be that work necessary to develop and prepare a stope or body of ore for full scale extraction of the ore contained therein and includes such
57
items as sublevel drifts, minor raises within the stope, finger raises, slushe~ station cutouts, scram drifts, pocket cutouts, chute installations and box or mill holes. In block caving, all of the draw raises, undercut drifts, mill holes. and scrams if used, would be considered 8S stope development. The user must determine the total tonnage for stope preparation to be applied to arrive at capital cost.
Labor cost is $13.00 per m using miners at $8.29 per Yorker-hour. Supplies cost is $8.02 per m composed of 95~ drill rods and bits and 5% miscellaneous supplies. Equipment operation cost is $0.75 per m and is composed of 88% repair parts and 121. lubrication. For EX core drilling (1-1/2" reduce labor cost 9~ per m.
This type of work will normally be performed by the mine itself rather than by subcontractor. For this reason, no allowance should be made for equipment ownership expense or subcontractor markup. Capital equipment is included in Section 4.3.5. (Hine Equipment).
The amount of core drillinc required will vary for· different types of operations and is not based on daily mine production. Therefore, the user must determine the quantity and type of cores that will be needed.
Overhand stopes (flat back, rill, vertical face and square set stopes), shrinkage stopes, room and pillar and hlock caving are in the lower cost range, from $1.00 to $2.48 per t. CUt and fill, longhole stopes are in the median from $2.34 to $3.89 per t.
4.3.1.6. CLEARING The curVE for clearin1 during preproduction development is based on estimated costs for medium light growth on terrain with a side slope of 20~ to 50~. Estimate one tree, 0.33 m in diameter, per 40 m2 •
or sublevel cost range,
Combination methods or nonuniform ore bodies will be in the upper cost range. from $3.75 to $5.23 per t. Labor ~iners
hole).
The clearing rate for large scale operations occurring during preproduction development is based on the equation:
is 66% of the total cost using at $8.29 per worker-hour.
The supplies cost is 30~ of the total cost and is composed of steel items 40%, explosives 351.. timber 121. and miscellaneous items 13~.
Where: Y = Clearing Rate (ha/d) X Total ClearinQ Area (ha)
=
The above equation is valid between the X limits of 1 to 500 ha. Above 500 ha the costs are expected to remain constant.
Fquipmpnt operation expenses compose the remaining 4~ of the total cost and consist of repair parts 91~ and lubrication gr..
For light clearing consisting mainly of brush and small trees. the costs should he reduced by 75~ from those shown on the curves. For heavy clearing. costs should be increased 751 over those shown for medium clearing.
Fquipment Operation Factor: If slushers are required add $0.15 per t. Supplies Factor: For very abrasive rock add 81 for steel. For very tough breaking rock add 8.57. for explosives. For timber ~ets add $0.53 per t.
For terrain on level to 207. side slopes, costs should be reduc~d by 20~ from those shown. For terrain over 50% up to 100~ side slope, costs should be increased 201. On rocky slopes and slopes over 1001. the costs should be increased 2 to 3 times.
4.3.1.5. CORE DRILLING The predominant core drill size used for these costs is AX (1-7/8" holes).
The
58
average
labor cost for a composite
clearing crew is $1.30 per with .laborers at $6.91.
4.3.2. RIlE PL.IT .ID BUILDIIGS
worker-hour
Supply costs are 65~ fuel all hurnino and 25X for trucks, pickups sa liS.
In this section if a subcontractor is used. multiply labor portion by 1.50, materials portion by 1.20 and equipment operation portion by 1.20 to compensate for subcontractor's markup except in the case of Communications System.
for and
F.guip~ent cperatino costs are 15% for dozers and 25% for trucks, pickups and
4.3.2.1. CORPRESSED AIR FACILITIES
salis.
This curve is based on m3 /min of installed compressed air capacity required to meet the needs of operation and development lIork and must be used in conjunction lIith the air volume determined from Section 3.3.4.3. (Compressed ~ir Plant).
EQUIPMENT OPERATING COST DISTRIBUTION nESCRIPTTON
REPAIR PARTS
Crawler Dozers Other equipment
&
FUEL LUBE
70""
30~
337.
6n
TIRES 4%
Where it is necessary to purchase equipment or have a subcontractor perform the work, multiply the equipment operation value by the follollino applicable factor in order to ohtain the total valuf' of equip",ent expense for ownership and operation: Shifts per Day Factor
1
The cost of compressed air facilities can he distributed as follows: equipment 751, huilding and materials 11~ and installation of equipment and erection of buildip9 14"..
3
2
1.75
The cost for the compressor house is based on steel building construction and includes purchase price and erection of huilding, and installatien of compressors, piping, and wiring.
1.56
1.50
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for subcontractor"s markup.
II."•
10 .. 000
~./
"
1••••
.. I! .....•
---
I, DOD
- ---
!u
1----
.
--- - -
.:::
----
LA OR --;;;;;
--- ---
.
- - ---
fQUIPHt:NT OPfRATION
/~ ~"
--
~---
-
100
"
17
/
-- --- - - ---
SUPPLIES
"
1••
.: 8
,,'
~7
V
COST. 1S90(X)·· 98_ TL •
11l,e)()-··U7
' • • 'I1.I(X)-I .
)0 .!
.,a
'I • U5.)()()-··· .. ,
10 10
1 .i
I
10 I
100
10
x .! soo
I
a: :!.
L
uo
2,000
i
1 J
1,,000
10,000
CUBIC METUS PER MINUTE INSTALLED CAPACITY
I I 4.3.2.1. COMPRESSED AIR FACILITIES
1,"0
HECTARES
4.3.2.2. HOISTING FACILITIES
4.3.1.6. CLEARING
There are many variables involved with the selection of hoisting equipment. Pope speed, shifts worked, depth of
59
The curve shown is based on m3 /min of ventilation air at a total pressure of 6" W.G. (15.24 cm). ReferrinQ to ~ection 3.3.4.2. (Ventilation System), the user must determine what quantity of air is required for the type of mining operation selected and the total pressure to be expected. ~ince, for a given volume of air the total pressure will affect the horsepower requirements, en adjustment must be made to the capital ccst curve to account for pressure variances. The following equation should be used to determine the factor to be multiplied by the base curve value:
shafts, number of levels, type of hoisting equipment, quantity of material to be hoisted, safety factors, size of crews and balanced or unbalanced systems are some cf the variables to be considered. For the reasons above, this curve is not intended to meet all of the various situations possible, but does provide 8 cost for the average mine hoisting job. It is based on t-m/d hoisted for a two-shift mining operation. The
curve includes costs for hoist hoists, headframes, cages, skips, loading pcckets, foundations, and electrical and mechanical installation and is distributed 80~ to equipment and material purchases and 20~ to installation. hous~,
Factor
••• 0 •
,,,
..:=
.:=
,," /
I
•
I ....
,,/
.
1.017(Q)-0.03265(H)0.042
"'here: Q : Volume of Air in m3/min H = Total Pressure in inches
I .....~
10,'"
=
;-
V ./
"
,,/ 1, •••
/
....
),
V'" I
.....
"!IICX)·~ , ...
I,"'.! X.!"',,., COlT • \u.,(X)··,J7
II'
~
./
.......
",.1" .! X.! 1.,. ••• , ... 10
/'
/"" COST •
V' .. 1...-..... lit
100
V
~
./
V '"
I I II
I,'"
I
METRIC TOOf MEnRS PIA DAY x 10 3
I I
10 100
II,'"
./
~
,,/ COST • 7S1.I,(X)O.611
lSI ! X .! 100.00'
I 1,000
10,000
I I 100.0 . .
CUBIC MEHRS PER MINUTe
4.3.2.2. HOISTING FACILITIES
4.3.2.3. VENTILATION SYSTEM
4.3.2.4. VArER SYSTER
4.3.2.3. YEITILATIOW SISTER
The cost of a water supply systeM for an underground mine includes purchase and installation of pumps, storage tanks. electrical hookup, piping and distribution to surface buildings, and a no.inal amount of extra heavy ~uty pipe with pressure reducers and check valves installed tc servlee the mine workings.
This curve includes the installed cost of primary ventilation fans and their structures in addition to small fans for use in stopes, drifts, raises and underground workings. Also included are air doors and bulkheads. The cost is distributed 80~ to equipment and material purchases and 2070 to installation.
Labor accounts
60
for
20~
of
the
cost,
•
steel 70r., and equipment 10r., with all costs being based on a two-shift mining operation.
a.1I
t--
.,-
a....
~
UO
V i."
/
V
.
~
= .
v
/
V
L,. . v
.
V
~~ ,,~
/;
/
8 ~
10
/
100
v~'
COST
".677 /'
a.loo
COST
:II
20 !
x ,i
lOt
It IS'CX)'· JlI
I I 10.000
60,001
:II
....
lto,OOO .!
10
V
1-
/~ ~
~~
,:
10
V
/'
UI
.=
1/
V
Y
U(X).· IU
x .!
1,000 METER -
10,000,000
10,000
CUBIC METERS PER DAY X 10 3
4.3.2.5. DRAINAGE SYSTEM 100.0.0
4.3.2.6. COR"UIICATIONS SISTEB
METRIC TONS PER DAY
4.3.2.4. WATER SYSTEM
4.3.2.5. DRAIIAGE SISTER This curve covers capital expenditures for ditches, culverts, sumps and drains needed to drain the surface area around the mine and is based on m-m 3 /d where the term m represents the total pumping head. It does not cover the water discharge pipes in the shaft as those are included in the shaft sinking item. However, it does include the cost of pumps and installation of the various items.
This curve covers the installed cost ~f necessary phones for communication from the mine to the surface and for Int~rofflce communication. The cost allows for switchboard and phone installation by an outside aqency and is based on a two-shift mining operation. For escalation, distribute BOX of the cost to purchased equipment and 20r. to labor.
The user must evaluate the minino situation and determine the m3 of water to be pumped. The cost 1s composed of pumping equipment 57r., miscellaneous materials 16~, and installation of equipment and mis- cellaneous earthwork 27~.
If the mine has gravity flow from an adit, reduce curve value BO%.
61
I ••
I ....
/ It.
c;?
.
= .
~
..-
V ....
I.
V
.....
/
v
It
V
.
V
= "
10-........
/
/
v
1/
V
COST. JUIt(X)"O 21
.!
X
.! ItOO
COST • 211. t(x)" .... 2
"0 • .! X .! ",000
1
COST. tu,eK)··' .. 5
,
1.
u .! X !5. ",01'
III
I II
101
I .... METRIC TONS PER DAY
1..
1.,'1.
11 ....
110 ....
METRIC TONS PER DAY
'"
4.3.2.7. FUELING SYSTEM
100 ....
'.3.2.8. ELECTRICAL SISTER
4.3.2.6. COMMUNICATIONS SYSTEM
~his curve covers the purchase and installation of surface and underground substations as well as surface distribution of pover and distribution of major feeder and subfeeder lines underground. The curve cost also includes the power drops to hoists and surface ventilation fans.
4.3.2.7. FUELING SISTER Fueling systems may range from small gasoline and diesel fuel tanks at small mines to large complex storage systems in the larger mines. The cost curVe shown, allows for normal consumption of fuels for surface equipment and assumes nondiesel operations underground.
Installation labor accounts for 35~ of this cost while equipment and materials purchase is 65%. These costs are based on a tWo-shift minin? operation.
If underground operations are to be handled with diesel equipment, the curve value should be increased 2001.
If the mine is to be operated through an edit or adits rather than through a shaft, reduce the curve value by 20f. for elimination of hoisting electrical power supply system.
The cost is composed of 20r. for installation labor and 80~ for purchase of tanks and dispensing equipment. Any building required for fuelino facilities is covered in Section (Surface Buildings). The 4.3.2.11. costs are based on a two-shift mining operation.
62
associated with excavation and support of a suitarly sized chamber or chambers with all required facilities excluding equipment.
10,000
r--- 1--
/
/
1,000
Equipment and tool expenditures range from 15% of the indicated curve cost at low tonnage mines to 5% at hiQher tonnages with a weighted average of 7%.
V
1/
If an underground mine has all repair shops and warehouse facilities located above ground, the user should refer to ~ection 4.2.2.6. (Surface Mine Repair ~hops and Warehouses). The cost of repair shops and warehouses for mines with tonnages below 1,000 tId may be calculated using the equation appearing on the curve for Section 4.2.2.6. after adjustment for the number of daily operating shifts, if required.
V >C
.,: o
V
u
/
/
V
100
/
/ /~'
V / ID
V
COST
t.
/' 10
$9,IH
=
I II 100
C TONS
I
10,000
1,00' HET~ I
10111(X)0.71O
PE~
For surface facilities, the cost ohtained from the curve is based on construction labor 251., buildings and purchased materials 58% and construction materials 17",.
! X .i 60,000
I I I 100 0"
DAY
4.3.2.0. ELECTRICAL SYSTEM
For underQround facilities, the cost obtained from the curve is based on mining lahor 1B~, purchased materials 42% and construction materials 40r..
4.3.2.9. REPAIR SHOPS AID WAREHOUSES This curve includes costs for surface as well as underground repair shops and warehouses and is based on a two-shift mining operation. The costs for surface buildings range from 531 of the inrticated curve cost at low tonnage mines to 38! at higher tonnages with a weighted averaQ€ of 42~. They are based on steel huilding construction and include foundations, floors, aprons, storage facilities and mechanical and plectrical work. The buildings are based on weather requirements for the Denver area and the cost may be reduced ~~ for more moderate areas or increased ~% for more severe areas. The costs for ~urface buildings assumes that these facilities will be used only for mining operations. If the mine and heneficiation plant are to share the same facilities the user must determine, using a knowledge of the requirements, what can re jointly used and how much, if any, increase to the cost must be made for joint usage.
1,211,10/
I,OOD
/
V
V
/
/ I ..
V
/
/
..
/
~
"
V~ /
/
COST
Iii
]Dl6(X)O' , ...
to .:! x .! 60,000
10
I II 100
10
HET~IC
The cost of underground repair shops and warehouse installations range from 32~ of the indicated curve cost at low tonnage mines to 57% at hiqher tonnages with a weighted average of 51?. These installations are based on costs
TONS
I
10,010
1,000 PE~
I
100,000
DAY
4.3.2.9. SHOPS AND WAREHOUSES ~.3.2.10.
The
63
cost
OFFICES AID LABORATORIES curve
for
offices
and
laboratories includes construction of general offices. engineering and safety offices. and laboratories, including furnishings as well as all neCessary assay and metallurQical equipment. The cost is based on steel building construction. The buildinos are based on weather requirements for the Denver area and the cost may be reduced 5~ for morp moderate areas or increased 5~ for ~ore severe areas. The costs shown are based on a two-shift mining operation to 10,000 tId and three shifts thereafter.
'.3.2.11. SURFACE BUILDIIGS The cost curve for surface buildings covers the general support facilities for the mininQ operation, including change house. powder magazine, tool sheds, guard houses, fenCing, etc. Buildings are furnished and of steel construction. The buildings are based on weather requirements for the Denver area and -the cost may be reduced 5~ for more moderate areas or increased 5~ for more severe areas.
cost ohtained from this curve assumes that these facilities will be used only fer mining operations. If the mine and beneficiation plant are to share the snme facilities the user must determine, using a knowledge of the requirements, what can be jointly used and how much, if any, increase to the cost must be made for joint usage.
The c,hanQe house and its furnishings represent B2% of the cost and is based on a production rate of 16 t per worker-shift. To adjust the cost for varying production rates encountered with different minino methods. multiply the curve value by the followino factor:
The following distribution gives the percentage allocation of total costs applicable to underground mine offices and laboratery facilities:
Where: P : worker-shift
The
Cost Components
Offices
Buildings and Fixtures F.rection & Installation Excavation and Concrete Fquiprnent 1. . . .
--- -_. _.r~-
-
----
----
r-
131.
--
/
V V
-
/v
-
/
--- -
V
-f-- --
/
--
/'
-- -- -
--
/
0-
S 10
V 10
/
--- - -
COST. It .!
liD
l.toO
U2Iex)O. su
x .!
10,'"
2.973(P)-O.393
Production
Rate
in t per
The cost ottained from the curve is based on construction labor 28~, purchased materials 551. and construction Ina ter ials 177..
/
/
110
>C
14~
15~
-- --
--- --- 0-
Lab·s
---
=
The cost obtained from this curve assumes that these facilities will be used only for ~ininQ operations. If the mine and beneficiation plant are to share the same facilities the user ~ust determine, using a knowledge of the requirements, what can be jointly used and how much, if any, increase to the cost must be made for joint usage • . The costs shown are based on a two-shift mining operation.
37%
--- 0-- f- --_..-
-- - - 0-
Factor
11,1"
100,000
HETR I C TONS PER DA.Y
4.3.2.10. OFFICES AND LABORATORIES
64
1,'"
In addition, the following may also be required:
/ V
/ /
1. .
V
accessories
Skirting at base of trailer $200.00
Landings and steps $150.00
Canopies over 1andinQs
V
$150.00
Air conditioning - usino existino heater $600.00
/
..::
Housing Units
V
.
V
Family units with living, dining, kitchen. bath and sleeping facilities for 2 adults and 2 to 4 children: $17,000.00
V'"
:/
COST. 1t,,19(X)··ltltit
to .!.
11
11
1,'"
III
X
.!
10,000
le,'OO
100,'"
HETRIC TONS PER DAY I
Type A bachelor units with living, dinino. kitchen, bath and sleeping facilities for 2 persons: $7,000.00
4.3.2.11. SURFACE BUILDINGS
Type ~ bachelor units with bath and sleeping facilities for 6 persons: $14,000.00
4.3.3. TOWNSITE The following housing costs are based on using trailers in a fairly level and accessible sitp containing between 75 and 125 units. (For 40 to 60 units, increase costs by 101.; for 150 to 250 units decrease costs by 107.). These costs are quoted per in1ividual trailer and may be factored by the BLS Industrial ~aterials Cost Index.
type B bachelor units, ndj for each to 6 units, $50,000.00 for camp living, dining and kitchen facilities. For pach additional type R bachelor unit add 53,500 to the $50,000 amount. For 1
'.3.'. RESTORATION DURING CONSTRUCTION Permits
arp genprally required prior to the around surfacp, and topsoil must be rpmoved and stockpiled for reuse. Areas around the mine must he planted. It 1s estimated that restoration will cost about $5,000 per surface hectare.
Site costs for family or bachelor unit: Site preparation (typical area 250 m2
~isturbing
)
$600.00
Streets 5.5 - 7.3 m wide 5 cm asphalt or 7.5 em gravel, limited curbing) $270.00
Patios and walks
The capital cost curves inctude the purchase of underground equipment and items not previously included in other sections. These costs aTe based on two operating shifts per day for mines producin9 from 20 to 60,000 tid. The costs on these curves are predicated upon the equipment bein9 ~elivered and made fully operable at an appropriate si te in thE" Denver area. They also include prOVision for standby equipment, spar~ parts, administrative and maintenance units.
$250.00 ~ewers
- connected to trailer $210.00
Water - connected to trailer $240.00
Electrical - yard lighting and 80 amp service connection to trailer $460.00
I.aundry and recreation huilding $770.00
Total Typical Site Cost
S2,E\00.OO
The
65
curve
for
drill
and
blast
aod
Where: r Fa.ctor R = Conveyor incline or grade in degrees
miscellaneous support equipment is composed of various mixtures of equipment to be found in underground mines such as jack legs, stopers, drifters, percussion drills and jumbos. It is not the intent of this handbook to designate the type of equipment to be used vrth a specific mining method, but rather to provide an estimated cost which is directly related to the tId produced. ether source material may be used for making a more detailed estimate.
=
10,800
V
,./
""
V~ 1,,000
/
I-
:b~ /t-'"
Costs for raIl (locomotives, cars, battery chargers, etc.), conveyors, truck haulage and its normally associated loading equipment, and tHD haulage are directly related to the quantity (in t/d-km) transported. The Quantity associated with one of the curves does not necessarily imply that the other curves need use the same quantity.
~"'~
"
-
K,.'"
!h"
W~~ .,'oJ'
100
/a•..;"..,
Q"
/ DRILL. BLAST' M!2£.:..-EQUIPMENT
/
The. types of equipment contained in these cost curves consist of all classes of equipment regularly found in underground mines, including drilling equipment of all types, loading and mucking equipment, haulage equipment, surface support vehicles, cranes, trucks, dozers, and pickup trucks, as well as administrative equipment. Hoisting, ventilation, compressed air and pumping equipment have been included with other capital cost items. The cost for other fixed supporting items such as railroad trackaQe and pover transmission lines has been covered where specifically noted in other items.
20 ~
= 2.177(JOO.752 x ! 10,000
COST
=
COST
ItO,HO(X)O.lt35
10,000 !
10
10
100
1,000
x
~
60,000
I--L--.L..L.
10,000
100,000
HETR. C TONS PER DAY
4.3.5. MINE EQUIPMENT
CURVE 1 OF 2 11,11' .---,r---r--r'TT--,---r-"..,--r--r-.-,.,--r-,-,.-,n
I---t--l--l-++--+--l-H+---f----i- - -
The cost of rail haulage equipment is based on the use of battery locomotives. For other types. adjust the percentage of cost applicable to hauling ~guipment by the folleving factors: Trolley Locomotives, F = 0.833 Diesel Locomotives, F = 0.521 The values obtained from the curves are valid for horizontal conveyors and grades up to 21 for truck or LHD hauling equipment. Adjust the percentage of cost for incline conveyors or greater hauling grades by the following factors: Conveyors, F = 1+0.018(P) Trucks, F = 1+0.0159(R) LHD's, F = 1+0.0159(R)
HETRI C TON KJ LOHETERS PER DAY
4.3.5.
~INE
EOUJP~ENT
CURVE 2 OF 2
66
-----+--+--+-H
In the case of decline conveyor or haul grades less than 2~~ use curve values without adjustment. The curves are intended to be additive; that is~ the user should enter the drill and blast curve at the value corresponding to the daily mine production~ adjusted for the number of shifts operated per day. To this value should be added the cost or costs associated with a given quantity transported by any or all of the haulage methods.
The total deSign, engineering and construction management fee curve 1s based on a single firm performing both tasks. Th€ other two curves are based on different firms performing each task. 10,00 0
1/
V'
V V' ..1 ~.,.,/ / ~" ,/
~/~
~
1,000
-;s.. .,~ /
The following table gives the percentage breakdown of types of equipment inclUded in each of the capital cost curves: FQUIPMENT TYPE Loading Hauling Drill ~isc. t Blast 507. Drill t Bla st 50" 7", 43f. 50~ Rail HaulagE' 927. Conveyor Sys. 3": 75r. Truck. Haulage 2070 95." I.HD Haulage
/,,'
~....'F/ ~ ~,,'
(,~~~~~' ~",~~~/ t,~"~~~ tt9 II' II'
OPERATION
~"
II'
~~~o+/ ",~ "....:.'
100
. .0"':;,
..~......~
v' ". 0;"
'":::
..
... " " "" "." " ,,/
10
V;;" ,,',,",,"
_.3.6. ENGINEERING AND CONSTRUCTION nNAGEIIENT FEES
"
on percentage of net constructed cost and the complexity of the project. Over the years, engineering experience has established some approximate correlations between engineering and construction costs and these correlations have resulted in the curves presented herein. The curves for design and engineering services fees are based on ~SCF - Manuals and Reports on Engineering Practice No. 45. Construction management fees are not as well established~ but have been based on the practic~s of several firms engaged in this type of construction management.
= =
TOTAL DESH'H, ENGINEERING AND CONSTRUCTION HAHAGEJ«NT 'E!
= O.321(X,··911
The net construction cost is the sum of the applicable group cost for Section 4.3.1. (Preproduction Development)~ Section 4.3.2. (Mine Plant and Builrlings)~ Section 4.3.3. (Townsite), Section 4.3.4. (Restoration During Construction) and Section 4.3.5. (tUne Equipment). Factors for escalation, location, etc.~ should not te applied to the desion and ~n9ineering fee, and only a factor for remote anrl/cr inclement locations should be applied to the construction management fef>.
lOO'jOO 1 100
a.0I5(X,'·'''·
DESICH AND ENGINEI!RING I'E!
CONSTRUCTION MNtA,GEMfNT FI!!:E
The curves are based
.!
x
t lOi,OjOiOOO
1,000
10,000
I
0.251(1)" ,02
I
I , 100,000
NET CONSTRUCTION COST X 10 3
4.3.6. ENGINEERING AND CONSTRUCTION l"IANAGEMENT FEES
_.3.7.
WORKING CIPITAL
Working capital ne€ded for an underground mine operation is a variable factor that cannot be tied to mine production and cost curves only. Basically, it is the capital required to meet payrolls and pay bills for material and product inventory, and to carry accounts receivable until ore sales produce revenue to pay for these items. ~orkinq capital is estimated as 60 days of operating and administrative cost. For un~er9round mines, work.ing capital demend is shorter term since weather and environmental restrictions do not affect production as in surface mining and heneficiaticn. ~dditional pp.rsonnel are needed where mechanical methods are of limited use.
67
68
P
5. BEIErICIITIOJ OPEBITIIG COST
I
ES'Uftl'l'IOI
5.1. BEJErICIATIOJ
TYPIC~L
OPE.ATIIG COSTS
Throuqhout Section 5. the costs are associated vith three-shift operation.
table)
WORK INDEX·
MATERIAL
6 9 12 15 18 22
Barite Ferro-chrome, potash t pyrite Lead-zinc ore & manganese Taconitp. & gold ore Silver t uranium ore ~n~esite & trap rock
opera ting a basic
5.1.1. CBUSHIRG
* For 8 more complete list of work indexes for various materials, refer to Chemical Fnqineers' Handbook. McGraw-Hill Book Co •• New York. 5th ed., 1973, pp. 8-11.
This
operation covers the reduction of to a size suitable for orinding or further beneficiation operations. The crushinq may be done either in the mine or at a surface location. The curves include all costs associated with crushing, screeninq, conveying and transfer of material and are valid for as .any stages of reduction as might be required. The curves should be applied to open as vell as closed Circuit crushing. The curves are based on the reduction of a medium ore (Work Index 12.0) from _ine run size to 80~ passino 0.95 cm (3/8").
minp. run ore
n,'"
VI'
/
=
R.
I,'"
Labor costs average S7.Sij per worker-hour with key personnel beino crusher operators and utility.en averaging $7.84 and general laborers at $6.91. ChanQes in the product sizino or material work index do not affect the daily labor cost.
I?'/
~
I ..
./
V
V
n
The supply curve consists of electric power only. 80th supply and equipllent operation curves should be factored if other than the above state:! base conditions exist.
I
V l/:V
'~ ".11
~~.,..
,/"
~ ~
.-"11' ,/
V
% i.-"
/
o~~
~ .,~
,..'
~~
..oil
L
/'
The equipment operation curVe covers the daily operation cost for all crushino plant equipment and inclu~es allowances for the replftce~ent of jaws, liners, mantles. bowls. belts and miscellaneous repair parts.
/
~
/ Ys
= =
0.062(X)0.9 8 7
YE
=
o.131(X)O"'-'
YL
V
100
5.910(.)°·5 .. 5
~
x .! 100,000
I
1,000
10,000
I
I 100,00
CRUSHER '[[0. METRIC TONS PER DAY
5.1.1. CRUSHING
5.1.2. C:BIRDING This operation covers the grinding of are after reduction in the crushing operation, and is based on a grinding mill running at normal load and speed including the operation of the classifiers in th. grinding circuit. Open-circuit grinding is so seldom encountered in actual practice. factors for its USe have not been included. The curves are based on reducing a medium are (Work Index 12.0) from 0.95 em (3/8") to 100 mesh. By applying the proper factor, below. this curve can 8lso be used to determine regrind cost.
Due to wide variations in rock hardness and abrasiveness and product size required. there is a great variation in the amount of electric power and crusher wear part consumption required to Carry out crushing of the ore. Therefore, the following factor should be applied to the daily supply and equipMent operation costs obtained from the curves: F
= Product Size, cm = Work Index (see following
=
= O.0799(p)-o.a30(I)
Where: F Factor
=
I.abor costs worker-hour and
69
averaqe $7.58 include grinding
per mill
operators at S7.68, mechanics and utilitymen $1.95, and oeneral laborers $6.91. Changes in the feed or product size or the work intiex d.o not affect the daily labor cost.
voula
~hen ~o ~~sh be the product size to be used in the preceding factor equations.
screen.
Included in equipment operation are replacement of steel balls, rods, shell and head liners and scoop lips. These requirements range from about 0.6 to 0.9 kq/t ground <0.07 to 0.11 kg/kW-h).
For dry grinding, multiply the supply curve amount by 1.3 to account for increased power consumption. ConVersely, the equipment operation Curve should be multipliert by 0.7 to account for decreased metal wear (balls, rods. liners, etc.).
The supply curve is composed of electric pover only. Roth the equipment operation and supplies curves should be factored if other than the above stated base conditions exist.
For autogenous grinding, multiply the supply curve amount by 0.45 to account for reduced pover consumption. Similarly. reduce the equipment operation amount by multiplying by 0.75. 11 .....
Due to the wide variations in relative rock hardn~ss. size of feed to the grinding mill, nnd the particle size product required, there is a great variation in the amount of electric pover and grin~ing media consumption required to carry out fine grinding of the orp. Therefore, the following factor should be applied to the daily supply and equipment operation costs ohtained from the curves:
. . . 11'
11."0
/
./
v/
~ l--:;lI'
I ....
l-
v
-t=t: «
\..~Ilo,..
Grinding: F = 0.003357(I)(X)o.702(P)o.699
Vv
100
Regrinding: F = 0.003357(I)(X)oo702(A-B)
.....-
v~·
toi':: 0'1
j:::
~~ 1../
V'
~f--:~r-< r---;",~"/'
t---c ~",'1
,,~qz
l/
/~
Where: I Work Index (see table in Section 5.1.1.) F = Factor X Feed size to grinding, cm P = Product size from grinding, mesh " :. Proi1uct size from regrinding, mesh
v
=
II "l
/'
V
=
"5
V
= SO.Bl(X)O.297 = O.21S(X)t.D
YE :: 3.IJU(X)O.6lJ6
-_.
10
! x ! lOD;OUO
I I II
1
10
100
1,000
10.000
I
I I 100,000
GRINDING HILL FEED, HETRIC TONS PER DAY
B
=
(P)Oo699
5.1.2.
5.1.3. CONCENTRATING
Note: m~sh
cm
=
GRJ~DING
is USA-AST~ standard screen size 2.354(mesh)-10090
Work indeXES used for this curve are based on the assumption that BO~ of the product will pass a certain size. If the useros requirements are such that some other percentage passing a product siZe? is desired,. it viII be necessary to obtain or estimate a grain size distribution curve. For example, if it is desired to Qrind to 60~ passing a 60 mesh scr~en. the sieve analysis might show that ~O~ will pass 8 40 mesh
501.3.1. FLOTATION The operating costs from flotation plants that are incorporated into the basic cost curves include a representative cross section of the major metal ores being treated by this method. Due to th€ ~any variables to be found in the processing of various ore mineral~. the r.ost curves in this section have heen divided into thr~e s~parate parts
70
so as to more closely follow the millino characteristics of many different minerals. The reagent usage shown for the various flotation curves represents the amount used for ores with average floatability and grade. The user must make a determination as to grade and floatability of the ore under consideration and adjust the reagent cost accordingly. If the user has knowledge of the reagent consumption, then reduce the value of the supplies cost by the reagent allowance and add the actual reagent cost. Otherwise, use the curves without adjustment to obtain an acceptable cost range.
...... ,,/ /'
1....
.......
... 11.
. ~ :Y' ".. /~.. ~ ~~ 11"<>
~
R ~
./
...... ~
f'#!>#:"
o,&~
I--"
/'"
v /' /
~o.\)~
V
The processes include only the conditioning of feed, if required, operation of float cells, and the necessary pumping and launder facilities for passag~ of the pulp through the separation process. For the product flotation curves, the user shOUld enter with the tId input to the first flotation only.
/
......
'L • u. "ex)""·
V
'e·l.lueX)··It'l 100 !
11
x ! .. o~ooa
I lit
-
's • ,.DueX)··5IO
1....
I
11.100
I
I
lID. 000
Ml!TRlC TONS PElt DAY flOATED
5.1.3.1.1. SINGLE-PRODUCT FLOTATION 5.1.3.1.2. TVO-PRODUCT FLOTATIOI
5.1.3.1.1. SINGLE-PRODUCT FLOTATION
This curve covers the production of a single bulk concentrate.
This curve covers the operation of mills producing two separate and distinct concentrates.
~he average labor cost is $7.66 per worker-hour with operators at $8.34 and laborers at S6.91.
The averag~ labor cost 1s $7.76 per worker-hour with operators at $8.34 and laborers at $6.91.
Supplies consist of electric power 5370.
Supplies consist of electric power 441..
reagents
47~
and
Equipment operation consists of repair parts B9~ and lubrication 11%.
reagents
Equipment operation consists of parts 89~ and lubrication 11~.
56r. and
repair
For plants floating products other than copper-molyhdenum, use 957. of values obtained from curves.
71
".,
1.', •• '
n,'"
./
V
...
v-io'" It,'" /"
."
~,~.
'/ V'
.p
..,... i--"I-"
1/'"
1,'" [p: ;...-
~
. s '
t;?'
71
1"
~-
i--'
1-" ...........
../
v
./
.../
V
/
~df~~
....I.......... i--"i-'
......
...
./
~ ""
\,tIf. '-'~
t/
\~ Io-'f'
~o
~..... ~
"I !. . . .'
V
~
'L • 51. 79(X)·· 311
'L ..... to(JC)··,,1
's • 'e: •
's = , ... no)··'" lOa
100
I,'"
I.c'"
"
V V~~ .,r
i-"'"
'e:
10
\~~,
~,";"
~
/
V
/'
--
./
/
L
lOO ~
X
I METRIC TONS PER DAY
,.Ot2(X),·'61
2 ..... '(JC)··ss.
z
10,'"
1,000
1.219(X)0.7IO
~
100,ODO
I
~
x .!. ItO,OOD
II
I I
. .I
I . ., ' "
I,'" METRIC TONS PER DAY
11,0"
1",1"
~LOAT!D
~LOATED
5.1.3.1.2. TWO-PRODUCT FLOTATION
5.1.3.1.3. THREE-PRODUCT FLOTATION
5.1.3.1.3. THREE-PRODUCT FLOTATION
5.1.3.2. CONCENTRATE THICKENING This operation covers only the partial deWatering of the pulp following concentration and before the pulp moves on to the filters. Very little labor is required durinq this point of the conc~ntratinq process. The concentratp. pulp is considered to contain t2S7. water.
This curve covers the operation of ~ills producing thre~ separate and distinct concentrates.
The averaQ~ lahor cost is $7.68 per worker-hour with operators at $8.34 and laborers at ~6.91. Supplies consist of electric power 33~
reagents
F.quipmpnt operation consists of parts R9% and lubrication 11%.
67% and
The labor cost is based on the use of utilityman at $7.95 per worker-hour.
a
repair T~e
supply curve consists of electric only. If flocculants and/or reaqents are required for concentrate thickeninq, they do not constitute a siQnificant cost in the overall operation. If the user wishes to include a cost for these additives, other sourcp. data should be consulted. pow~r
Fquipffient operation consists of parts 83' and lubrication 17~.
72
repair
10 ••• 1
1....
~,
,,'"
..
11.
..;:,'''~r ~i'n
, ....
......
...
10
...:
..
b...
...
v"
§
I~O!
~'\\Ot-
.:
§
,,0:
~ f--
10
..
1-"
!I;\'
.
~\o~
10-'"
... ......
.10
TL •
,,0:
1.227(lIC)D. ''''
1't: • • • nocx)'·
,
~
11
lOO
l,Oto
I
.1 LI
10,000
100.000
Ye
= o.anoo G. lt51
J.113(X)·,"9
1,000
I II
I
I
10,000
I I
10',0"
FILTR~TION
5.1.3.4. LEACHIIG 5.1.3.q.1. CTAIIDE VAT LEACH
During the filtration process the water in the concentrate pulp is reduced from 125~ to 11~. Unless drying is required, this is the last step in producing a concentrate ore product.
These curves cover the cyanide leaching of gold and silver ores from the point where the fine-ground ore enters the first thickener, successive agitators and thickeners, and finally through the filter presses. This process does not cover any reduction of the gold-silver product. The curves are inclusive of the counterrurrent decantation method.
The
labor cost is based on the use of a filter/dryer operator at $1.68 per worker-hour.
Fquipment operation consists of parts 61~ and lubrication 39~.
100
5.1.3.3. CONCENTRATE
5.1.3.3. COICE.TRATE FILTRATION
consists of
= .... s.. CX)O.t19
:II
METRIC TONS PER DAY FI LTERED CONCENTRATE
5.1.3.2. CONCENTRATE THICKENING
curve
YL
Vs
I
10
.'
... ... --'
S,!X.!)O,ooo
.10
Ml!TRIC TONS PU DAY THICKENED CONCENTRATE
The supply pOWE'r only.
o,,""'r--
... .......
nl
x .!. ,o,000
I III
t.~'\
!I;\''''
'S ••• OU(K)··""
.11
-
__ i-'
"
~.. " ~~~~....'" ... ~... -I':'to'l
.~
~"
,,'.."
1....
->~. ~
i f
1.-,'
~
~lectric
The average labor cost is $7.16 per Yorkpr-hour with operators at $8.34 and laborers at $6.91.
repair
Supplies consist of zinr dust S6~, other reagents 27~. and electric power 11~. Equipment operation consists of parts 92% a~d lubrication 8%.
repair
Factor: For carbonaceous ores, incr~ase the cost of supplies by 8.57. due to the addition of chlorine for oxidation of the carbon.
73
10,'"
If the Ll1 (Liquid Ion Exchange) method is to be used for metal extraction from the preonant solution, where 1ump leaching is practiced. reduce the laLor cost by 15~, reduce supplies by 60~, and increase equipment operation by 45~. Electrowinning is not includ~d in this process •
",'"
1-'" '"
",,,,,,,,,, 'I.~"'"
....11'"!~(
1,0'0
~.
J.aG"
'" '" --~
.--.; ~
-- ----
In LIX extraction. if the ore is finely ground and leach~d in pachuca or othpr agitator tanks. reduce labor 20~. supplies 607.. and increase p.quipment operation 45~. The cost of hauling to tan's is covered under Section 3.1.1.3. (Exc8vatior. load and Haul - Overburden and Waste), crushing under Section 5.1.1. (Crushing). grindinQ under ~ection 5.1.2. (~rindinq), anj hauling to disposal site by truck under Section 5.1.6.6. (T,onq Distance Tra nsportation) •
",'
1/'"
,: on
o
u
IDa
~~aI.:~'r
~;
.....
/
':;"~:-'
./'
~
..
YL • 7a., U(X)·, Ult
V
Ys
:II
2.J27CX)··919
Y E
:II
O.IU(X)O.627
100 :! X ~ \,000
The averaq€ labor cost is ~7.59 per workpr-hour with operators at $8.34 and laborers at $6.91.
10
tot
1,000
10,000
METRl C TONS PER DAY
5.1.3.4.1. CYANIDF VAT LEACH
S~pplies
31~,
consist of acid
61r., and electric power
scrap iron
8~.
5.1.3.4.2. DU"P. HEAP OR VAT LEACH These curve~ cover dump or heap leaching of pit or·minp. run ore and subseQuent precipitation of the metals in the preQnant solution by passage over scrap ferrous metals.
Equipment operation consists of repair parts 73%. fuel and lube 1~~. and tirps 9%. 100,000
--f-
Initial or~ dumps and subsequent layers of raw ore placement are not included here but are in the mining and hauling sections. Costs included in these curves include scarification of dump surfaces with tractor and long ripper tooth, removal and reinstallation of polyethylene distribution piping. charging scrap metal into precipitation cells. and removal and loading out precipi ta t€: •
10,000
".;;''!)?
~
.
.,at
V
/
.... i!l u
For vat leaching. use a factor of 2.5 times the labor and equipment curves shown. This increase in cost covers the removal of leached ore from the vats. Costs of placing ore in vats or on heaps. unle~s placed there by the mining operation, or removing heaps must be added and is covered under Section 3.1.1.3. (Excavation. Load and Haul OVerburden and Waste). Cost of crushing, if required. must be added and is covered under Section 5.1.1. (Crushing).
/'
--100 1
./
!--
-
..-
~~ ...'
o~
/
5.1.3.4.2.
--- r-· .-. ----- 1 - - --- r-
--
,/
O~
Y'
$62
-
..
/'
~~
~~~... ,:;'~ l '
'K.
--
·1-
1,000
74
V
,to" ./
-
f-----
-- - -
-.---
YL
=
= 12.1t9(X)O.735
YE
=
24,18(X)O.198
O.OB7(x)O.95 0
x .!.
20~OOO
100 .. 00
LITERS PER MINUTE
DV~P.
--
Ys
1 .. 000 .!.
10,000
.- -
HEAP OM VAT LEACH
~a9netic
5.1.3.4.3. URAIIU" ACID LEACH
separators is required, the curve should he entered as many times as required using, in each case, the reduced tonnage input to the separators.
These curv~s are a composite of the current solvent extraction and ion exchanqe processes. The curves follow the ore after fin~-Qrindin9, through the leachinq, extraction, countercurrent decantation, precipitation, and yellow cake filter presses.
For operation of either induced magnetic or high tension separators, increase equipment operation value 'O~ and supplies 770. Since the input material must be dried before passing through either of these process separators, the user must include the cost of drying from Section 5.1.3.8. (Drying Concentrate).
The average labor cost is $7.54 per worker-hour with a foreman at $8.68 and laborers at 56.91. supply curve con~ists of reagents and electric power 33%.
The 67~
F.quipment operation consists of parts 921. and lubrication 87..
repair
10, ...
""
,,""
~."."
NOTE: High tension or induced magnetic separation is generally confined to input tonnaoes under 10,000 tid.
"
11,100
./ ./
1-"
~y
"',, l..7 §/ ""
//
1,000
l4"
1,,00'
"
/' t.
~
Oft
8
V·
./ 1 DO
r(
0
'L
II
1t,.S1(x,O.519_
Ys
=
J,I6J
'E
iii:
l.S2lCX)D.682
..0:
'100 ~ x.! 6,000
1,000
$9 1
UR~NIUM
'
10
10,00
METRIC TONS PER DAY
5.1.3.4.3.
-'
101
,\,0+
..
101
" "" ,,' " " ,," " " ,,' " ,,' ..' "" ..V ,,' """ ,l1"'~" 7§,....,~~" "" " ':i " bo!' •r " ,. "" ~~/If~ " ,: . "" " " "'~'/ 8 . ,," ,,",,' ,,' , " " ." o. n.ex)'·'·· ,,' 'e: ••. n1(x,··n. ""
" ~ V'
i r•
"
ACID LEACH
TL •
TS ••.• "(,,,0.177
5.1.3.5. "AGNETIC SEPARATIOI
101
1
The curves cover only the operation of and slurry the magnetic separators pumps.
1. .
I,'D'
~
X .!. 100,000
10, ...
101,"0
METR I C TONS PER DAY
5.1.3.5. MAGNETIC SEPARATION The average labor cost is 57.45 per worker-hour with operators at $8.34, laborers $6.19, and utilitymen $7.95. The supply power only.
curve
a
multiple
These curves cover the cost of separating ore minerals andlor waste material after the crushing process. The costs follow through the thickener circuit where the desired ore material passes on to a concentrator and the remaining m~dia returns to the circuit or on to another process. Equipment
consists of electric
Equipment operation consists of parts 88% and lubrication 12%. If
5.1.3.6. HEAVY "EDIA SEPARAfIOR
repair
pass of the ore through
75
operation includes pumps, screens, heavy media cones, conveyors and thickeners. Fach pass through the circuit is a separate operation and should he so costed. Th~ user must determine the amount of feed material for each pass through the circuit.
laborers $6.91. The supply curve power only.
consists
of
electric
Equipment operation 1s composed of parts 90~ and lubrication 10~.
The average labor cost is $7.82 per worker-hour with operators at $8.34 and laborers at $6.91.
If spiral classifiers are substituted for jigs, the supply curve should be decreased 3370 and equipment operation decreased 35".
Supplies consist of the heavy media (ferrosilicon or magnetite) 84~ and electric power 16~.
Jf tables ~re used for separation, the supply curve should be decreased 30" and equipment operation decreased 25~.
Equipment operation consists of repair parts 87~ and lubrication 13~.
1,'"
1O,DOO
/'
:/ /'
#./
/'
1,000
"t."/
:tP'
,? ~
100
V
/
uo
-
./
V
.... ~
.::
~/
y /"
V
~t.~
V
I 'L '5
= =
10
n.21(X,O.3l2 O.6ID(X)a.u\
ItOO
L
L
V
/
L
l
~ ......~"o~ 0' \,.,.~:;;...-
~
/
V
./
YL·7.71SCX>D"t,O
Vs.
0.J670)0.731
-
YE • O.29ItCX)O.UI
lOa.! x ! ".000 ~
1,000
~
L 10,00
"ETR! C TONS PER DAY
$&.09
i x i 10.000
, ,000
V
'k:
I
'! = O. U2(X)D.110
/'
,,~,
..~'I.
~o~o/
10 100
V
"...-
I-
~I.~
/
V
/'
V
~ 10,000
5.1.3.7. GRAVITY SEPARATION
METRIC TONS PER DAY
5.1.3.8. DRYIRG CORCENTRATE
5.1.3.f. HEAVY MEDIA SEPARATION
Drying operations generally use natural gas when and if available; otherwise, fuel oil is used. Products covered are magnetite, barite, potash, molybdenum, and others.
5.1.3.7. GRAYITY SEPARATION Thesp curv~s cover the processing of barite and narnet by the use of jigs, conveyors, pumps and screens. Water usage for this operation has been assumed at 7.6 m3 (2,000 gallons) per t of feed material. Alluvial tin, free 901d, and platinum are also commonly processed usinq this method. Dredge processing of free gold and platinum is covered in ~E'ction 3.1.2.3. (Dredqino). The averaqe workf>r-hour
These curves are based on using rotary kiln dryers equipped with dust collectors. The average labor cost is $7.56 per worker-hour with operators at S8.34 and laborers at S6.91.
labor cost is $7.68 per with operators at $8.34 and
~upplies consist of natural Q8S 82% and electric power 18~. If fuel oil is used
76
instead of natural Qas, increase portion of the curve by 18%.
that
v
Equipment operation consists of repair parts 95~ and lubrication 5~. 10.008
10.000
.."
to"
V
./
~,,\~
..;:,f
,,-
/"
// 1.000 ...t;
"'''
./'/ 'or,,'
'"/~~" ..)'/ LL'"
10'
'"
i
.
,iI:
/'
r
l/~
,:
§
?
,,
1,000
..
~'
r
I...."
,
,,"'
'"
..,.,
/'
V
./
Vl°1I.
.,::;--- ;;;0-
"" ~
.;-
L.----:~\oy
o,t;
~
,,\'?'
t,(t
lOO
~
o~;"
""
/"'"
"'~",'" 0.';" ,,~
YL" 57.IO(X)0.31]
Ys" 7.JUOOO. BS v • • 1.213eX)0.90]
I'
100 .!
....'
100
'L • ,.ISt(X),·5Itl
VI • 1.'UCX)··sn
1
I'
6~OOO
100
1.'00
:!.
_
5.1.3.9. LIMESTONE CLINKER
II,,'"
I .....
10.000
1,000 METRIC TONS PER DAY
YS • ,.2760)" U,
s .! x I
x .!
10
"'' '
.
--
5.1.4. WASTE ARD TAILIRGS DISPOSAL
lO .....
METRIC TONS PER DAY CONCENTRATe INPUT
5.1.4.1. TAILINGS DEWATERING 5.1.3.8. DRYING CONCENTRATE These curv~s cover the cost of pumping waste pulp materials from the mill to the dewaterinQ thickeners.
5.1.3.9. LIRESTOIE eLIRIEB These curves cover only the actual passage of ground limestone through the kiln and include the operation of the kiln and the blower cooling of the clinker.
The average labor cost is S7.43 per worker-hour with either a laborer at $6.91 or a utilityman at $1.95 assigned to this operation. Often, however, there are no workers assigned full time to the operation.
The average labor cost is $1.15 per worker-hour with operators at $8.36 and laborers at $6.91.
The supply curve consists of electric power 901. and miscellaneous items, includinq some flocculent, 10%.
Supplies consist of natural gas 85% and electric pover 151.. If fuel oil is used instead of natural Qas, increase that portion of the curve by 18%. Equipment operation consists of parts 91% and lubrication 9%.
Equipment operation consists of parts 91% and lubriCation 9~.
repair
repair
If cyclones are used for tails dewaterinQ. the supply cost should be increased 51"!. and equipment operation reduced 60%.
77
1, ...
L" .... 1.-'
F,guipment
~'
....; v'
. . v ..",,,,, ~
..." .... '" "....... ",'" '" } '" '" V.... "' .. ~~~"';"'" o<)~~~
10
.;'
"'~
~
",'
~,'~" ....
'"
'"
2".
83~,
operation
consists of repair 15~
fuel and lube
and
tires
For each 100 m incr~ment of pumpinQ distance greater or lesser than the 1 km ~ase, add or subtract 6.5~ from supply curve.
YL ••• .,U(X).· 565 'S • O,lOJeX'·· 797 VI!
'"
I
1
X
--,--r-
.i lDO,OOO
I
10,000
1,000
---
'G,aa u
O.lOJCX)··601
11.
lOt i
~
110
parts
and
If the tails flow by gravity to a ponding area, subtract 90~ of power portion of supply curve and reduce equipment o~eration by 90r..
'"
",'
",'"
o,t.'!' . ;,
~
~~
~,
........
'"
'"
'"
Ui~'"
.:
.. I.-'
"...
.'"
....
i r• 8
~
....
1. .
and lumber, pipe supplies, miscellaneous items 25X.
I I I 100, '00
METRIC TONS PER OAY WASTE MATERIAL
5.1.4.1.
T~ILINGS
DEWATERING
i-':
1,000
~
V
5.1.4.2. TRANSPORT AND PLACE TAILINGS These curve5 cover the cost of transportino the partially dewatered tailings to a tailinqs pond. The tailings darn is raised hy the constant addition of new material. The curves are based on the following data: Percent solids in slurry = 46~ Specific gravity of slurry = 1.226 Total head 15 m Pump efficiency = 80~ Pump operation time : 80% Pumping distance 1 km
=
~
".
"to
100
V
~~
k?'
Vi.-'
/
/
, ~"&' " ......~ ",,0'" V ,/ vV"" ~? / ~t.... / !} /' ./
V
V'
./
~~
o~
..8
.:
<.
,:;"'~
10
./
"""/
~
./
V
=
Usinq the above data, the user can factor the costs obtained from the supply and equipment operation curves to any set of conditions as follows:
./
V
YL:I: 1.21t9(X)O.SU
Ys :. O.092()C)O.828
V I
100
Ye 100
1,000
=
O.DItHlC)o.n'!
.! x .!.
10,000
lOO~OOO
100,000
HETRI C TONS PER DAY TAl LI NGS PROCESSED
Factor
=
(Sa/S)(Ha/H)(E/Ea)(Ta/T)
5.1.4.2. TBANSPORT AND PLACE TAILINGS
Where: S = Specific Qravity of slurry H =- Hearl, total E = Pump efficiency T Pump operatinq time a Subscrirt denoting actual c:ondi tit ion~.
= =
The averag~ lahor co~t is $7.88 per worker-hour with a foreman at $8.68 and laborers at $6.91. ~uppli~s
ccnsist
of electric power 7Sr.
5.1.4.3. RITER RECLAftATION These curve~ COVer the cost of returning water from the tailings ponds to the mill. In many cases lime and flocculent must ~~ adde~ to settle out the colloidal particles. The curves are based on the followinq dat~: Specific Qravity of fluid Total head = 15 m rump efficiency = BO~
78
= 1.02
=
5.1.6. GENERAL OPERATIONS
Pump operating time 80~ Pumping distance = 1 km
5.1.6.1. GENERAL ITEKS COKKUNICATIONS, SAIITATIOI, HODSEIEEPI.G, FIRE PROTECTION AND ELECTRICAL
Using the above data~ the user can factor the costs obtained from the supply and equipment operation curves to any set of conditions using the equation ~iven on page 229.
These curves cover the cost of general yard vork~ carpentry repair, janitorial services, plumbing, road grading, ditch cleaning, general mechanical repairs, handling incoming supplies and
~he averaQ~ labor cost per worker-hour 1s S6.91 for a laborer.
materials,
Supplies are composed of electric power for the pumps 57%, lime and flocculent 33~, and miscellaneous items 107. r.quipment operation consists of parts 90r. and lubrication 10~.
electrical
maintenance
and
repair, and general housekeeping.
The averaoe labor cost is $7.63 per worker-hour with general laborers at $6.91. The size of the workforce will vary from a small crew of one or two persons working a fractional day to possibly 3 shifts of 50 to 60 persons per day.
repair
For each 100 m increment of pumping distance greater or lesser than the 1 km base, add or subtract 6.5~ from supply curve.
Miscellaneous SO.Oll/t.
1,000
supplies
are
priced
at
./
V
Equipment operation is composed of repair parts 53~, fvel and lube 30~ and tires 17~.
V l/
1/11
100
/
./
10,010
V
..
."'..
V l/
~
I--
b! ~~ ,,'-
~~
10
.o'
. / 't-'"
'"u0
"
a~
V V V~V
~'t-
"
g;,~"./
1,000
",0:.
v/ V
,£;..
/
j; .... /
V/"V/ 0.10
Ys
:=
3.02X1O- 3 (X)O.971
YE
=
1.18XlO- 3 (X)O.930
100 H]/DAY
10
..5 X ..5 32S~OOD Hl/OAY
100
~,
..'
1,.00
L' ~ ... I.-
~'
V
1~~~
~~"'"
;
8
...
~
a~~" ~"; L'
;'
. . .... ,
.:
5.1.4.3. WATER RECLAMATION
L
....
~
.,.......~",.~;~
.. I.-'
100
CUBIC METERS RECLAIMED WATER PER DAY X 10 3
5.1.5.
..
YL := 1.81X1O- 3 (X)O.951
~
$0.09 0.10
.. . .... , . . ,'....
10"
V "~?' V
.
1,.'
~1/
;' ~,,~
~'
~
RESTORATION DURING PRODUCTION
10
~ ~
Permits are generally required prior to disturbinQ the Qround surface, and topsoil must he removed and stockpiled for reuse. The areas surrounding benefjciation area (plant) must be planted. It is estimated that restoration would cost about $5.000 per surface hectare.
"
'L·l.711(X)··7D' T• • • • "OCX)l ••
' • • o.,OS(X)··72.
11. 1 1
x1
•
100
l"aOG
10 .. 000
Ml!TRI C TONS PER DAY MILL FEED
5.1.6.1. GENERAL ITEMS
79
1.... 00.
I
I "',000
5.1.6.2. CO"PBESSED AIR PLANT The use of compressed air is generally very low in most beneficiatin~ plants. If it is reQuired, the compressor has no operator assigned to it and therefore only repair labor is chargeable to the operation. Low pressure air is often used in flctation and high pressure air is used for controls and oeneral use.
For beneficiation of ores where a flotation process is not involved the user must estimate the water requirements for the system being used, then apply the ccst per m3 cost given above. 101,'"
1/
1I,0tt
The labor curve is based on a cost of $7.Q5 per worker-hour. The
supply pow£>r only.
curve
mechanic
consists of electric
1/
1#100
i
Equipment oreration consists of repair parts 71% and luhrication 29% and takes into account intermittent compressor usage for this type of an installation.
..•...
.:
,.,'~
~
100
8
l,.I
V
11
100
V
~
.-
.,.' , _ ~ .,..,. ~ .. I" .;,-
tl't
-
0t..".--
E lI\f'!";-
10
--
~-
-- .,.'"--
I-
... 1-'" .,.
~.,.
.,.--;'
...
EIl"1\~- J.-
io'"
--
.,. .... 1.-
,,1I01l
IS "'/DAY ! lit.! .,0#100 "'/DAY
I
10
-
1 •• 00
11,1"
5.1.6.3. WATER SUPPLY
100,'"
I .... , ...
SYSTr.~
5.1.6.4. DRAINAGE AND DISPOSAL SISTE"
\~':,.
These curvps cover the cost of general drainage control around the beneficiation area, and are composite averages for this item which includes culverts. ditches. drains, and sumps.
~"
YL
= o... ,a.(X)··'17
The
labor curve is baspd on the cost of laborers at $6.91 per worker-hour.
Ys • O.O'7CX)O.615
'!
Ii
1.n\(x)O.216
100 .!
0.11 100
100
CUBIC METERS PER DAY, MAKEUP WATER
.,1-~"
1.. ..
'I • e.ltlcx)1.1
/'
1,.1"
.
lL
1,000
x .!
lOO,ODD
10,000
Supplies consist of materials.
100,000
100%
miscellaneous
HETRlC TONS PER DAY MILL FEED
Equipment cperation consists of repair parts 53%, fuel and lube 30r. and tires
5.1.6.2. COMPRESSED AlB PLANT
17'; •
5.1.6.3. VATER SUPPLY SIST!" NOTE: The wat~r supply system cost curve is based on supplying a certain quantity of makeup wat~r to the plant. The total II'ill W8.ter requirement is based on supplying 2.5 to 4.5 m3 of water per t of material floated. Makeup water is estimated a~ 10~ to 40~ of the total water requirement with reclaimed water supplyinq the remainder. The cost of makeup wat~r has been priced at $0.10 per m3 and is the sole component of this curve.
The equipment operation and supplies curves are Identical and the user should apply the full value obtained to each of these items.
80
·1•I" /
1.M'
workforce of 1,800 persons is equivalent to S8.50 per person per day. If the calp 1s to be operated on a seasonal basis dUe to inclement weather, increase the cost 25 ~.
/
~
v.;'~
11..'.1-"" u.
L
V
i ...E
/
~
,),~
V
/
~V
~y ~ ~.,~ V'
:> ~ / V"
V
I
/
V
II.....
/
/
/
v'
/
/
10 •••• ~'
V
//
V
~.1.6.4.
/
V
/
-
'L • 0.1,,(:0 1 ••
's • 'olnex)l.' 100 .! X .! UO,IOI
I I ... '
II ....
III!TRIC TONS PElt DAY HI LL
I
I
I
I ....
~EED
/
I ••••
-
'I ••• IU(X,I.0
L
. V 10.
/
'5 •
/
Assume a beneficiation operation requires an average daily workforce of 100 persons. Enter the curve wit.h 100 persons and determine a daily cost of $1,168. If 60~ of the workforce require room and board and 40~ require only room (i.e. units have kitchens), then: Cost per day $841
= 1,168(.3)+(.7)(.6») =
n. JOCX)"
I"
10.! X.! 1.... 0 "
••• 5(X)1.·
1 .... .!
I I I
10.
10
5.1.6.5. CARP OPERATION
This is a daily operating cost and is in addition to townsite capital cost, Section 6.1.7. Of the daily cost obtained frem the curve, 30~ is for housing and 70% for food aDd lIIess facilities. The following example serves to illustrate the Use of this curve.
CN'P OPERATION DAIU COlT
/
DRAINAGE AND DISPOSAL SYSTEM
Where conditions such as a remote location or seasonal operation require that camp housing (i.e. room and board) be made available to mill workers, the daily cost obtained from the curVe should be used. The user must determine the averagE daily workforce using the camp in the overall operation under consideration.
/
x .! .,000
I
1,000
I
I 1•• 00 ••
TOTAL DAJ LY MANPOWER
5.1.6.5. CAMP OPERATION
5.1.6.6. LONG DISTANCE TRANSPORTATION 5.1.6.6.1. RAIL TRANSPORTATION The following table gives th~ cost in tit-kill to ship materials by rail in various sections of the Unite~ States based on a 100 km haul and Denver rates in July 1975. To adjust this cost for any haul length, multiply by the factor obtained frem the following equation:
Example: To estimate the cost per t-km for moving 100 t of iron concentrate 200 km through the Official area: Denver rate = 1.374 Areft factor 2.3 Distance factor = 0.78 (from equation) Therefore: Rate 1.374x2.3xO.78 2.465 tit-kill Total Cost = 2.465x100x200/100 = $493
=
=
~ote that from an economic sta~dpoint the lower limit is $150 per day (for 10 persons) and the limit above a daily
81
=
_Factor Mate,l .. to be .hlpped
Denver Rete
Mtn-Plic. Foetor
Wee"'" Factor
S._.....
1.4 1.1
1.3
1.374 2.143 2.441
1.0 1.0 1.0 1.0
u.
Mlner.'or.Iron concentratl fluxing IIm••tone Send or ,,'Ivel
Factor
.8
-.
1.1
1.1
1.5
.1
1.1 .7
2.3 1.3 1.1
Industriel ••nd end
2.172
grlvel Ceramic or clay
3.021 1.112 2.164
Phosphate rock
Rock aah
1.0 1.0 1.0 1.0
1.2
.1
1.1
1.2
NA
NA
.9
.4
.8 1.0 1.6
..
Class 10
F
=
16.08(X)-O.710
Factor
.1
..
NA
-Factor
1.2 1.8
.B .B
To adjust values for competitive haul areas us~ It factor of 0.68; to adjust for nonmountainous areas use a factor of 0.95; and, to adjust for loads of 23 t or more use a factor of 0.95. Example:
·U•• Mlnera. Or. "te and factor. for commodltlea not shown.
For a Class 50 haul of 200 ~m in a competitive area with a load of 25 t: Factor = 15.P9(200)-o.?O? 0.375 Rate 11.61xO.68xO.95x.375 = 4.21 t/t-km. Total Cost = 4.27x25x200/100 = $214
The folfowlng map Indicate, the d."gnated factor .,...
=
=
5.1.6.6.3. VATER TRANSPORTATION Barge shipment is significantly affected by the follcwing variables: Access to a commercial waterway at both shipping and receiving points, duration of shipping season, adequacy of dockage and faci.lities for transfer of cargo, and tonnage to be moved by waterway. The data and classifications used for rail transportation are based on U. S. DepartMent of Transportation, Federal Railroad Administration, ·Carload Waybill Statistics, Territorial Distribution, Traffic and Revenue by Comlllodity Classes."
The major cost variables are: Amount of cargo to be moved (size of tow), covered or open hatches, special or standard holds, and the possibility of barge carrying cargo on back haul inst~8d of making return trip in ballast.
5.1.6.6.2. TRUCK TRAISPORTATIOI The following oives the rates per t-km for contract truck transportation in mountainous areas. Three classes have been designated to cover the value of various materials to be shipped: Class 35 elass 50 Class 70
less than SO.SS/kg from SO.aa/kg to S2.20/kg qreater than S2.20/kg
Th~ noncompetitive 50 kill haul based on Denver in July 1975 are:
rates
Class 35 Class 50 Class 70
14.76 tIt-kill 17 .61 tlt-km 20.84 tIt-kill
"'distances 0 adjust
these rates for other haul where X distance in It.• :
Class 35
F = 14.41(X)-O.68Z
Class 50
F
=
=
Typical rate is $0.006/t-km and if cargo is available for return trip reduce cost by 40~. 5.1.6.6.4. PIPELINE TRANSPORTATION Pipeline costs are appreciably affected by vertical alignment (i.e. number of lifts or pumping stations required and tyPe of material). Typical rates for well lubricated nonviscous materials are: Few lifts - SO.004/t-km Several - SO.008/t-km
5.2. BEIEFICIATIOJ - ADftIRISTRATIYE COSTS 5.2.1. GENERAL EXPENSE 5.2.1.1. ADBIRISTBATIYE SALARIES AID
VlGES
15.89(X)-O.70.,
The
general
expense
curve
for
beneficiation administrative salaries and wages is intended to c~ver the supervision and various other administrative functions required for mills of varyin0 sizes. The number of administrative (salaried) employees varies from 3 to 4 persons workin~ a sin9le shift in the smaller mills to as many as 100 or more in the larger mills. The breakdown of personnel into various classifications together wi th the average percentage of cost attributable to each is as follows: Classification
11,0"
V' /'
31
~o,
..,..~ ~o,
1,000
o,t'
9
;7 ...... V /'
5 8S
no
/
/
~o,/
",0,
VV 10
V
The above monthly salaries do not include an allowance for burden. If these personnel are covered hy the sallie fringe benefits as the mill workers add 357. to the Administrative Salaries and Wages curve. However, if they are not cov~red, add only 2~~.
V 1 100
.,.....,o~
V
V
~..t-
o~
"'~~ ...
~Q..:;;r
.~ ~
......~
~>
"':"--
5.2.1.1. Yl
;<
5.2.1.2. Ys
= O.069(X'O .... ,
l.Jll(x,O.751
5.2.1.3. y~ :c 0.056(X,O.6" 100! X! 100,000
1,100
10,000
METRIC TONS PER DAY
5.2.1. GENERAL EXPENSE
5.2.1.2. ADRINISTBATIYE PURCHASES The curve for administrative purchases covers office, engineering, safety and first aid supplies, and expenses such as telephone, telegraph and postage, travel and entertainment, miscellaneous fees, dues and donations and professional and computer services when applicable. Also included are small tool and supply allowances assumed at 37. of the direct mill labor. to to
83
./
~'Y
L
./
I;
....t-"'~
....
.,........
V
~.:l~~
.,?;..;~"o,z
V
..::
NOTE:
40%
/
0,.
$2,200 1,500 1,500 2,000 1,600 1,500
60~
/
o,"~
6
The curve is apportioned administrative purchases and small tools and supplies.
/
,$,'
e
Selected median monthly salaries are follows:
V
.t-"
8 23 19
Clerical Engineering Assaying & retallurqical Purchasing f, Warehousing Safety & First ~id Security
Superintendent General Maintenance Foreman Electrical Foreman Plant Engineer Safety Director Purchasing Agent
This curve includp.s administrative equipment operation expense for vehicles such as s~dans, pickups and fl~tbed trucks. The curve components are: tires 2%, parts 40%, fuel end lube 37~, and repair labor 21~ assumin? the equipment is used ~01. of its available time.
Percent
~upervision
~ill
5.2.1.3. ADRIIISTRATIYE EQUIP"EIT OPERATION
101,'"
84
6. BEJEFICIATIOB CAPITAL COST ESTIRATIOB
Regrinding: F O.003357(I)(X)0.702(A-B) Where: r = Factor I Work Index (see table in Section 5.1.1.) X = Feed size to grinding, cm P Product size from grinding, mesh H Product size from regrinding, mesh
=
Throu9hout ~ection 6. the user should note, specifically, the number of shifts per day upon which the capital costs are based. Then, for the numb@r of shift~ per day desired, multiply the daily tonnaoe by the ratio of the base number of shifts divided by the shifts desired. Unless otherwise noted, cost is based on a three-shift operation.
=
=
=
= (,,)0.699
A
6.1. BEIEFICIATIOB - CAPITAL COSTS 6.1.1. CRUSHING
Note: ~e~h
Crushing capital cost is for the acquisition and installation of ~quipment to crush mine run are to fine or~. Crushers, conveyors, screens and feeders are the major equipment items. The cost is distributed to purc~ased equipment 62~, construction labor 21~ and construction materials 17~. The curve cost is b~sed on a three-shift operation and on the reduction of a medium ore (Work Index·: 12.0) from mine run size to 0.95 cm (3/8"). The following factor should be applied foro other combinations of hardness and lor product size: F
= 0.0799(P)-0.s30(I)
cm
=
is USA-AST" standard screen size 2.354(rnesh)-J·090
Work indexes used for this curve are based on the assumption that 80~ of the product will pass a certain size. If the user's requirements arp such that some other percentage passin? a product size is desired, it will be necessary to obtain or estimate a grain siz~ distribution curve. For example, if it is desired to grind to 6070 passing a 60 mesh screen. th~ sieve analysis might show that 80~ will pass a 40 mesh .screen. Then 40 mesh would be the product siz~ to be used in the preceding factor equations. 100,000
"'here: F Factor r = Product Size in centimeters I = Work Index. (see table in Section 5.1.1.)
=
,/
6.1.2. GBIHDIRG
.'
",- " ,
10,000
.::: ..
Grinding capital cost is for the acqUisition and installation of equipment to fine grind are to size for beneficiation. Ball mills, rod mills, classifiers and cyclones are the major equi~ment items. The cost is distributed to purchased equipment 661., construction labor 20~ and construction materials 14%. The curve cost is based on a three-shift operation and on the reduction of a medium are (Work Index = 12.0) from 0.95 cm (3/8") to 100 mesh. By applying the propet factor, below, this curve can also be used to determine regrind cost. The following factor should be arplied for other combinations of hardness andlor material feed size and/or product size:
~'
~+",,,
/"
" "" -'
" '+)~,~" "'~1
~.~~~ "
'"
(;
~.
""
~;,.v
1,000
~
"-,
l/
~
COST
f/ ,/;.
COST
,," 101 100
1,,000
10 1 000
6.1.1. CRUSHING 6.1.2. GRINDING
=
85
= ~58J(X)0. 7~9
100 ~1
METRIC TONS PER DAY THROUGHPUT
GrindinQ: F O.003357(I)(X)0.702(P)0.699
= 9272(X)0.6}2
iRlNOING
x
~ 1~0,000 lOO,OOO
6.1.3. COMCEI!RA!IIG
10 ••••
6.1.3.1. FLOfA!ION II
Flotation is divided into elements for one-, two-, and three-product processes. The cost curve covers acquisition and installation of slurry pumps, piping, float cells, and aqitators or conditioning tanks.
/ V~
The cost is distributed to purchased equipment 62r., construction labor 26% and construction materials 12~ and is based on a three-shift operation. For the flotation processes described below, the tonnages given refer to the daily mill feed into the first flotation process.
/
//
.
.: §
/
=
t/rl of material floated
For
. two-product (copper-molybdenum) the curve range is from 10,000 to 100,000 tId floated and should be multiplied by 1.934.
V
/ fLOTATION .AS!. CURVE SEE: TEXT fOR AP'PLICATIOH COST. U,'ltl(X)··JU liD! X ~ toO, DOD ,ACTOR '"01 SIH5LE, TWO, OR THRI!I!~PRODUCT fLOTATlOH
111
ltO
1,010
10.000
100.110
METRIC TONS PeR DAY FLOATED
6.1.3.1. FLOTATION
1.616(X}-0.040
Where:
X
. .V
.::
For two-product flotation (other than copper-molybdenum) the curve range is from 100 to 40,000 tId floated and should be multiplied by the following factor:
=
V
/
1."0
The curve is for a single-product flotation process and is valirl from 100 to 40,000 tid of material floated.
Factor
V
6.1.3.2. COMCEITRATE THICKENING This cost covers acquisition and installation of thickeninQ equipment only. The curve is based on the tId output of thickened concentrate.
flot~tion
For three-product flotation the curve range is from 100 to 40,000 tId floated multiplied by the and should be following factor: Factor
= 1.961(X)-0.056
The cost is distributed to purchased equipment 6R~, construction labor 17~, and construction materials 151. and is based on a three-shift operation. The capital cost curve is based on a settling area of 1.1 m~/t (11 square feetlUS ton). Typical settling areas for various mineral concentrates are as follows:
Where:
X
= t/rl
of material floated Mineral Concentrate
Settling Area !!I 2 /t
~l~aline leached uranium Copper concentrate (average) Molybdenum concentrate Cobalt-nickel sulfides Lead and silver concentrates Tin concentrate Gold tellurides
Zinc concentrate Acid leached uranium Molytdenum sulfides Copper tailings
86
0.40 to
1.30
1.00
Nickel sulfide concentrate 2.50 to
4.00
5.00 to 12.50
Uranium precipitate
40.00 to 60.00
Manoanese sulfide
The cost is distributed to purchased equipment 66~, construction labor 21%, a nOd construction 18aterials 13~ and is based on 11 three-shift operation.
0.08
0.02 to
Iron concentrate
concentrate.
11."1
To adjust the capital cost for settling areas differing from the base value of 1.1 mZ/t, multiply the curve cost by on~ of the following factors: For settlino 1112/t. Factor
areas
greater
than
l/
1.0
)/ '"
1.'00
= 0.923(X)O.775
For settlinQ areas less than 1.0 m2 /t.
V
...
= .
....
1.1
~/ /
§
Where: X = Settling area in m2/t
v
V
III
/ /
10, •••
,
V
COST
5 .!
II
1.11'
'"
.;
V
/v 10
10.000
101.000
~ILTERED
teaching is divided into elements for cyanide vat leach. dump/heap/vat leach and uranium acid leach. Costs are for acquisition and installation of leach circuit ° equipment. Major items of ~quipment are pumps. thickeners. agitators. filters and front-end loaders.
V
v
1....
6.1.3.'. LEACHIRG
./
..
UI
6.1.3.3. CONCENTRATF. FILTRATION
V
[/V'
.::
10
METRIC TONS PER DAY
V 100
1
= U.I72(X)Oo550 x .! 30,000
V
6.1.3.4.1. CIA.IDE 'AT LEACH COST • ItU2(X)O. Ult
s .! x .! 1
I
1
10
lOa
1.000
The cost covers acquisition and installation of thickeners. vats. agitators. Rnd all pumps through the filter presses. The cost is distributed to purchased equipment 62~. construction labor 26%. and construction materials 12r, and 1s based on three shifts per day.
]0,000
I II
I
1O.OOD
I
I
100.000
METRIC TONS PER OAY THICKENED CONCENTRATE
6.1.3.2. CONCENTRATF THICKENING 6.1.3.3. CORCERTRATE FILTBATIOR This cost covers acquisition and installation of concentrate filtration equipment only. The curve is pased on the output (tId) of filtered
87
10,000
10,000
1,000
r
V
'"o
/ v v
~
,/
./
1,000
V
,/
/'
V
./ ~
V
V
><
><
... o'"
u
COST 100
100
100
= "S,]27(X)O ... !1t
.s
X
COST
! ",000
1,000
100 1,000
10,000
METRIC TONS PER DAY
.! X .! 20,000
18,000
lOO,OOO
LITERS CYCLED PER HI NUTE
6.1.3.4.2. DUMP, HEAP OR VAT
6.1.3.4.1. CYANIDF VAT LEACH
6.1.3.4.2. DU"P, HEAP OR VAT LEACH
LE~CH
6.1.3.4.3. URAIIU" ACID LEACH
~he cost covers acquisition and installation of dump dozer, pu~pinq systems, front-end loaders, precipitaticn vats and precipitation equipment. The cost is distributed to purchased equipment 94~. construction labor 6~. and construction materials
The cost covers acqUisition and installation of thickeners. agitators, vats, pumps and filter presses. The cost is distributed to purchased equipment 65~, construction labor 24~, and construction materials 11~ and 1s based on thr~e shifts per day.
1 Or. •.
In order to arrive at a capital cost for placinq or removing ore from heaps or vats. the user must add the applicable costs covered under Section 4.2.5. (Mine :quipment Capital Cost. Surface rcinin7). If crushing is required. the cnpital cost of crushing equipment must te added. Refer to Section 6.1.1. (Crushing). The costs are hased on thr~e shift~ per day.
1l,716CX)·,sn
I:
1,000
.
10,000
,/ /~
// // 1,000
If leaching vats are rpquired, the cost will be an additional $22.50 per t capacity. distributed 44Y. to construction labor and 56~ to construction materials. Heap leaching pad cost is an additional $5.60 per t of ore. distributed 28~ to construction labor and 72% to construction materials.
.,-/ /
..
//
. ==
//
V
0-
S
// COST
The user must determine the num~er and capacity of vats or pads, bearing in mind that while some are in use. others will be out of service for cleaninq or loading and unloading of materials.
100 laD
=
~~S.'(X)1.0
'too:! x .! I
6,000
I
1,1" METRIC TONS PER DAY
6.1.3.4.3. URANIUM ACID LEACH
88
I 11,101
each circuit rather combinpd ca~acity.
6.1.3.5. ""RETIC SEPARATION The costs are for acquisition and installation of the maQnetic circuit equipment. ~ajor items of equipment are maqnetic separaters, screens and pumps. The cost is distributed to purchased ~quipment 62~, construction labor 261., and construction materials 1270 and is based on three shifts per day.
than
/
/' ",-'
-'
",'"
~/
"
" -'
v/
..
S COST
II, ...
~O\~
./
..::
/'
-'
$2°'7 /
'"
,,'",-'
1,000
NOTE: High tension or induced magnetic to separation is generally confined input tonnaQes under 10,000 tid.
I,'"
the
10,000
If hiQh tension or induced maQnetic separation circuits are to be added, increase th€ curve cost by 83~.
.. v
using
lOO lOO
/
= 2763(X)0.758 x
~ IO'rOO
1,000
I 10,000
HETR!C TONS PER DAY
6.1.3.6. HEAVY MEDIA SEPARATION
V
6.1.3.7. GRAVITY SEPARATION
./ ./
Gravity separation costs are for the acquisition and installation of equipment for the gravity separation process. Major items of equipment are jigs, screens, conveyors and pumps.
V
"
.. §
/
I ..
./
1/
/
The cost is distributed to purchased equipment 62~, construction labor 26:T" 12% and is and constructi~n materials ~ased on one shift per day.
./
COST
100
II lot
l r 'OO
:I:
~
12,..CX)O •• ltl
x .!
If separation is to be made with Humphrey Spirals, multiply the cost curve value by 2.AO. The resultinq cost would then be 1istributed to purchased equipment 65%, construction labor 24~, and construction materials 1'~.
100,000
lG,IOO
lot,OOO
METR I C TONS PER DAY
6.1.3.5. MAGNETIC SEPARATION
6.1.3.6. HEAVY REDIA SEPARATION If separation is to be made with tables, multiply the cost curve value by 5.00. The resulting cost would then be distributed to purchased equipment 65~, construction labor 241, and construction J!Iaterials 11%.
media separation costs ar~ for the acquisition and installation of the heavy media circuit equipment. Major items of equipment are heavy media cones, screens, conveyors, pumps, thickeners and magnetic separaters. The cost is distributed to purchased equipment 6470, construction labor 23r., and construction materials 13~ and is based on three shifts per day. ~eavy
The user must determine the number of Circuits to he use~ and the capacity of
89
$1,0",50'
1,000
10,'01
",'"
",'"
1;"
",'" ",'"
,,/
~'"
'"
",/ 1,000
",'" ",'"
./
",'"
100
/'
>C
V '"o
....
. . '"
'
.,
>C
.
..
..... ~.
..
101
~
u
COST
=
203leX)0. 755
100 $. X $. _,0 00
1
ID 100
1
1,000
I 10,000 COST = 33,~39(X)O.339
METRIC TONS PER DAY
S'sX.5.JO,OOO
l'
6.1.3.7. GRAVITY SEPARATION
I
100
1,000
10,000
10.# . . .
METRIC TONS PER DAY - DRYER FEED
6.1.3.8. DRYING COICENTRATE 6.1.3.8. DRYING CONCENTRATE Prying cost~ are for the acquisition· and installation of equipm~nt for this
portion
of
the
6.1.3.9. LIftESTONE CLINKER
beneficiation process.
items of equipment are kilns and convpyors. The cost is distributed to purchased pquipment 66~, construction l~bor 23~, and construction materials 11% and is hased on thr@e shifts per nay. ~ajor
Limestone clinker costs are for the acquisition and installation of the clinker equipment. ~ajor items of equipment are kilns, fans and conveyors. The cost is distributed to purchased ~quipment 68~, construction la~or 23'", and construction materials 9~ and is base~ on thrpe shifts per day.
90
•,
steel pipe) 28~. and installation labor 16~ and is based on three shifts per
10,0"
y 1,'"
V
/
V
day.
/v
1',0"
:"..... //
/'
/
// 1,000
~r.
...,..y ~ ~....
,/
.
. /
.:
iPr. ... ......
8
,.:
8
110 COST' 23, BOOeX)o. 630 100
100
.!
",/
X .! 6,000
d7
....~"
./ \ ... :!.;. ';:,
I
,-\~.....
'"
/
V'17
"c.t-
~o ,,-
0";';;-
.:~"
TAl LiNerS DEVAUItNC
'55.,eX)'··'·
COST. taO .$. x.i 100,000
V~v
10,1"
1,000
100
V'
TRANSPORT AND PLACE TA-ILlteS
METRIC TONS PER DAY
COST z 25S0(X)O ... I.
6.1.3.9. 6.1.'.
LI~ESTONE
100
CLINKER
It 110
VASTE AID TAILIMGS DISPOSAL
6.1.4.1.
6.1.4.3.
F
VATER BECLAftATION
= L/1
Where: Factor = Len'lth in km
F L
=
The cost is distributed to purchased equipment 17~, materials (including steel pipe) 55~, and installation lator 28r. and is based on three shifts per day.
= L/1
Where: F = Factor L Len'lth in 1I.m
=
56~,
100,000
The cost curve shown is for the acquisition and installation of the equipment and materials required to return decanted tailing pond water to the mill. "'he two major items included in the curve are pumps and steel pipe. The pipe has been sized so that the total head loss for any quantity is 15 m. The pipeline length has been taken as 1 km. For other lengths, use the fo1low1no factor:
TRIRSPORT AND PLACE T1ILIIGS
is
100,000
6.1.4.2. TRANSPORT AND PLACF. TAILINGS
The cost curve shown is for the acquisition and installation of the equipment and materials required to transport tailings in a slurry to a tailinQs disposal pond. ~ajor items included in the curve are pumps, cyclones, and steel pipe. The pipe has been sized so that the total head loss for any quantity is 15 m. The pipeline lenQth has teen taken as 1 km. For oth~r lengths, use the following factor:
The cost equipment
x~
6.1.4.1. TAILINGS DEWATERING
TAILINGS DEWATERING
o
6.1.4.2.
~
10,000
METRIC TONS PER DAY FEED
The cost curve shown is for the acquisition and installation of equipment required for dewaterinQ the tailings. Major items of equipment are thickeners and pumps. The cosb is distributed to purchased equipment 68~. construction labor 19%, and construction materials 13~ and is based on three shifts per day.
F
1,000
NOTE: For the tYPE of installation 1escribed above, the minimum cost can be expected to remain constant in the range below
distribut",(i to purchased (including materials
91
2,000 m3 /d.
If a subcontractor is used, multiply labor by 1.50, supplies by 1.20, and equipment expense by 1.20 to compensate
1,000
for subcontractor's markup. 1,000
./
1/
V 100
/
,/
./
j...-
>C
.. 10
I
/
100
=
392.9(X)O.SI9
2,000 .! X
!J.10
COST
0.10
10
... :
1/
1,008
100
CUBIC METERS PER DAY X 10 3
~ 8
6.1.4.3. WATER RECLAMATION
6.1.4.4. EARTHFILL DIKES AND
V
L
! 325,000
= 20,300
!"OR X .! 2,000
.j..
V
/
i-COST
/
I
I
lL
V
S~ALL
COST
:=
2Z.9J2(X)O.UQ
5,000 .! )( !:. 5;)0,000
DA~S
10 10
Dikes and/cr small dams use1 to contain wast£' and. tailings disposal va ry with th@ terrain ann materials to be used ann must meet the regulations for small dam construction. No allowance has been mad0 for transporting or purchase of 5uita~le fill material. If these costs are uot a part of other mining and/or millinry operations, then ~he user must determine either the cost of fill material or may use $0.20 per m3 of emtankment. Transportation cost may be calculated using Section 3.1.4.5. (Lonq Distance Transportation).
100
1,0 00
CUBIC METERS OF EMBANKMENT X 10'
6.1.4.4. EAFTHFItl DIKES AND SMALL OAMS
6.1.5. SITE PREPARATION 6.1.5.1. CLEARING The curve for clearing is based on estimated ccsts for medium light growth on terrain with a side slope of 207. to 507. Estimate one tree, 0.33 m in diameter, ~er 40 m2. The clearing rate for the ar~a encompassing the heneficiating plant and support facilities is based on the equatio~:
Cost is nistributed 58% construction labor. 2% construction materials (fill material net includ~d), 15% tires and 25~ fuel and lUbe.
Y
=
0.153(X)O.678
~here:
Where
it
is necessary to purchase ~quirmpnt Dr have a su~ccntractor perform the work, multiply the equipment operation value by the following applicable factor in or~er to ohtain the total valu~ of equipment expensp for ownership aliO operation:
Shifts p",r Day Factor
1
2.05
7 1 • 79
Y X
= ClearinQ Rate (ha/d) = Total Clearing Area (ha)
The above equation is valid between the X limits of 1 to 500 ha. Abovp 500 ha the costs are expf>cten to remain constant.• For light clearing consistinq mainly of brush and sm,-,_ tre'i"s the costs should be reducert 75~ from thoGe shown for
3
1.70
92
medium clearing. For heavy clearinQ the cost should be increased 75~ over those shown for medium cle~ring.
For terrain on level to
20~
10,000
side slopes,
costs should be reduced by 20~ from those shown. For terrain over 50~ UP to 100% side slope, costs should be increased 20~. On rocky slopes and slopes over 100% the costs should be increased 2 to 3 times.
--
. ! .... .: .8 u
average labor cost for a composite clearing cre~ is $7.30 per worker-hour with laborers at $6.91.
- --
l-- ~--
EQUIPMENT OPERATION
-
100
---
LA80R
..._- --- --- --- --- - -
! L
The
---
1,000
--- --- - -
--- --- - - ---
SUPPLIES
Supply costs are 651 fuel oil for burning and 35~ for tools, cable, chokers, etc.
YL
Fquipment operating costs are 7570 for dozers and 25~ for trucks, pickups and saws.
II
=
1 .i 10
REPAIR P~RTS
Crawler Dozers Other Equipment
FUEL 3 or.
33~
63"
1
1.75
2 1.56
I
100
I I 1,000
TIRES
6.1.6. UTILITIES AND FACILITIES 6.1.6.1. VATER SUPPLY SISTE"
/.fro
Where it is necessary to purchase equipment or have a subcontract~r perform the work, multiply the equipment operation value by the following applic~ble factor in order to obtain the total value of equipment expense for ownership and operation: Shift s per Day Factor
10
500
6.1.5.1.CLEARING
(; I.USE
707-
1
x .!.
HECTARES
EQUIPMENT OFF.RATING C05T DI5TRIBUTION DESCRIPTION
1129(X)-0.107
Ys • 101.6CX)-0.031 YE = US.3(X)-0,0~9
The cost shown is for the acquisition and installation of equipment for supply and storage of both fresh water and mill water. ~ajor items of equipment are pumps, piping and water tanks. The cost is distrihuted to purchased equipment 70,", construction labor 17"" and construction materials 137. and is based on a three-shift mill operation.
3
1.50
If a subccntractor is used, multiply labor by 1.50, supplies by 1.20 and equipment expense by 1.20 to compensate for subcontractor's markup.
93
I', •••
I .....
V I, ...
/
'"
..
/"
==
1/
i,.-'
V-
1,'"
.
V
V
... ==
Vi.' /'
./
,'-
1.1 V
1-'
I ••
10'
--'
V
...
V
--'
V
V
i."
./
V
V
~
V" I.
COST • SIS. teX)O. 7_2
V
I ..
"I 1,'"
COST. 5SU(X)' ., ...
l-
100 .!
.! X .! 110,110
11,001
I I
"• 1
1•• ,'"
Ml!TItIC TONS I'I!It DAY MILL ,UD .
1 00' M~TRIC
r-
100,000
I
lO 000
I lOO,.O.
TONS peR DAY
6.1.6.2. ELECTRICAL
6.1.6.1. WATER SUPPLY SYSTE"
x .!
SYSTE~
6.1.6.3. "ILL BUILDINGS
6.1.6.2. ELECTRICAL SISTER
The cost shown is for the mill building or huildings, erected on cleared land.
The cost shown is for the acquisition and installation of the main substation, yard distribution. lighting. and com .. unications for the mlil. ~ajor items of equipment include transformers. switchgear, power lines. and telephone syst~.. Telephone service is based on a complete telephone system with installation by an outside agency. The cost is distributed to purchased and installed equipment 71~, construction labor 20'", and construction Materials 9~ and is based on a three-shift _ill operation.
This cost curve is based on a one-product mill and includes foundation and floor excavation, concrete floors and footings, prefabricated and erected steel buildinqs, subfloor electrical and mechanical work, interior lighting, floor gratinqs and supports, insulation ftnd concr~te block control and instrument room. Normal mill repair shop equipment and overhead cranes are included. The cost is distributed to purchased ment 55"., building and eguipconstruction labor 28%, and construction materials 17~ and is based on '8 three-shift mill operation. "actors: For a two-product mill floatinq from 100 to 40,000 tId. the base curve should be increased 297.. For a copper-molybdenum (two-product) mill floatinQ from 10,000 to 100,000 tId. the base curve should be increased 35". For a three-product mill floating from 100 to 40,000 tId, the base curve should be increased 357..
94
If fine ore bins are to be included the added cost maJ be calculated as follows: ~dded
Cost
sa.e facilities the user must determine, usinQ a knowledge of the require.ents, what can be jointly used and how .uch, if anJ, increase to the cost aust be .8de for jOint U88ge. The cost 1s based on a three-shift .i11 operation.
= 218.67(X)o.?ge
Where:
X = "ill reed in tId
The following distribution oives the percentaoe allocation of total costs 8pplicabl~ to the offices and laboratory facilities:
To insulate fine ore bins add $2 per tId of .111 feed. Cost The mill buildinos are based on weather requirements for the Denver area and the cost may be reduced 5~ for more aoderate areas or increased 5~ for aore severe areas.
Cost Co.ponents ~uildings
and Fixtures Erection t Installation Excavation and Concrete Equipment
iI." ./
V V
.....
I
•
... :: •
~
..
.,:
/
I
.. V
7~
1~~
3~
15~ 13~
3~ 8~
,,10-'
/
V
./
"
100'
./
/
... V
L
V
~ ....
,/
V
.
37J
/
!/ V
Lab 's
./
,I
1...
•
V
Offices
'"::
t_
...•
MILL 'UII.OIMS US. III TIlT I'0Il APl'LlCATIOII
COlT • 7UseX)··11I 1.. SXS1......
I II
I
1..
I
.......
_ , • ".tUCK'"
I
...
11
6.1.6.3. "ILL BUILDIMGS
I....
us
..I.! . ! '",''' 1 I I I I 11 .... ......a
IlETalt TOIlS PO DAY MILL rllD
6.1.6.4. OrFICES AND LABORATORIES
6.1.6.'. OFFICES AID LA808AtOlIES
6.1.6.5. VEHICLES
The cost shovn for offices and laboratori@s includes construction of oeneral offices, enoineerino and safety offices, and laboratories, includlno furnishinos as veIl as all necessary assay and metalluroical equip.ent. The cost is based on steel huildino construction. The buildlnqs are based on veather require~ents for the Denver 8.rea and the cost lIay be reduced 5l for more 1I0derate areaS or increased 5~ for more severe areas. If the mlne and henetic~ation plant are to share the
The costs shown are for the service vehicles assiqned exclusively to the mill. "ajor items of equipMent include pickup and flatbed trucks, hydraulic cranes, front-end loaders, fork lifts and SMall dump trucks. The costs are h8se~ on a three-sbift mill operation.
96
1,00
°
10,00
°
I-'
/'
,/
V V ./
IDa
I--' i'
V/
1,000
./
'"o
V
l---'
v'"
...' o ~
u
7
~.'"
100
/
lo"
..,..;
10
.....
=
~OO ~ 10 100
1,000
XI
'"
","
COST = 973.8(X)0.5S710
~
X
~
10,000
10,000
100,000
METRIC TONS PER DAY MILL FEED
11,39I(X)0.35~
~ looioo~ ~
10,000
1,..'"
,.",'"
100 COST
l...
",'"
6.1.6.6. MISCELLANEOUS
100,000
METRIC TONS PER DAY MILL FEED
Streets (5.5 - 7.3 m wide 5 cm asphalt or 7.5 cm gravel, limited curbing)
6.1.6.5. VFHICLES
$270.00
6.1.6.6. "ISCELLAJEOUS EQUIPftEJT
Patios and walks $250.00
The
costs shown are for nondefined equipm@nt that may be included in some operations anrl exclud~d in others. Items in this category would be instrumentation, communjcations, emerQency li9htinq, standby 9€nerators and special purpose equipment. This curve was established as 5~ of the cost of utilities ani facilities excluding the mill huildinqs item.
Sewers - connected to trailer $210.00 Water - connpcted to trailer $240.00 Electrical - yard liqhting and 80 amp service connection to trailer $460.00 Laundry and recreation building $770.00
6.1.7. TOWIfSITE
Total Typical Si te Cost
S2,P.OO.00
The followinq housing costs are hased on using trail~rs in a fairly level and accessible site containing between 75 and 125 units. (For 40 to 60 units, increase ccsts by 10~: for 150 to 250 units d@creas€ costs by 10~). These costs are quoted per individual trailer nnd may bp factored by the BLS Industrial ~aterials Cost Index.
In addition, the following accessories may also be required: Skirting at base of trailer S200.00 ~andings
$150.00 Canopies OVEr landings $150.00
Site costs for family or bachelor unit: Site preparation (typical area 250 m2
and steps
Air conditicning - using existing heater $600.00
)
$600.00
96
The total design, engineering and construction management f~e curve is based on a sinQle firm performing both tasks. The other- two curves are based on different firms performing each task.
Housinq trnits FaMily units with living, dining. kitchen, bath and sleeping facilities for 2 adults and 2 to 4 children: $17,000.00
10, ...
Type A bach€lor units with living, dining, kitchen. bath and sleeping facilities for 2 persons: $7,000.00
/ ,/
~"
~~ "" ~ ~~
Type B bachelor units with bath and sleeplnQ facilities for 6 persons: $14,000.00
(>'
~"I
.......:."" +(> t
.,o;':fj,.f
For type B bachelor units, add for each 1 to 6 units, $50,000.00 for camp livin9, dining and kitchen facilities. For each additional type R bachelor unit add $3,500 to the $50,000 amount.
i'
~,
,,"
~~'
..::
6.1.8. RESTORATIOI DUBIIG CORSTBOCTION
...,~(> 'l;9~" ,+.,.,; ,
101
.",.,L.
~ "/
>C
...,,;
Permits are generally required prior to disturbing the ground surface, and topsoil must be removed and stock- piled for reuse. The ~rea around heneficiation plant ~ust be planted. It is estimated that restoration would cost about S5,000 per surface hectare.
6.1.9. ENGINEERING AND "ANAGEflENT FEES
t~~'
~,.
_" ,,' ,,"
j'
...~~~ L'
"
V V." "
/
10
r:/,,' "
...,os
P~ ..~ Cl
,.
,/
~/ ,," i'
. CONSTRUCTION
CONSTRUCTlON MAHAGEtoENT FEE
DESIGN AND ENGINEERING P'EE •
= O.090(X)o.glt. = •• "7(0)··196
TOTAL DESIGN, EN'INEERI~ AND .: O• .\15(X)O,911t CONSTRUCTION MANAGEtENT FEE
100,000 ~
x~
100.000,000
1 100
The curves arA based on percentage of net constructed cdst anrt the complexity of the project. Over the years, ~ngineerinq experience has establishe1 some approximate correlations between engineering and construction costs and these correlations have resulted in the curves presented herein. ~he curves for design and engineering services fees are based on ASCE - Manuals and Reports ~n FnQineering Practice No. 45. Construction management fees are not as well establishpd, but have been based on the practices of several firms engaged in this type of construction management.
1,000
10,000
100,000
NET CONSTRUCTION COST X 103
6.1.9. ENGINEERING AND CONSTRUCTION lHNAGFMENT FEES
6.1.10. WORKING CAPITAL Working capital needed for a millinq operation is a variable factor that cannot be tied to mill production and cost curves only. Basically, it is the capital required to meet payrolls, pay bills for material inventory, product inventory, and to carry accounts receivable until ore sales produce revenue to r~y for these items.
The net construction cost is the sum of the group cost for Sections 6.1.1. through 6.1.8.
Working capital is estimated as 60 days of operatinQ and administrative costs. For beneficiation, the working capital needs are ~reater on maintenance and parts labor and on utility costs, while repair parts and operating labor are relatively lower. Support materials such as reagents, thickeners and various additives are factors affectinq this itp.m.
Factors for escalation, location, etc., should not be app~ied to thA design and engineering fee and only a factor for remote and/or inclement locations should be applied to the construction manaQement fee.
97
88
7.
SAMPLE PROBLEMS 7.1. GENERAL The sample problems shown in this section are intended as a guide to the user of the handbook and are n2~ intended to represent any existing or proposed mine or beneficiation plant. These exaaples also are n21 intended to indicate good aininq or beneficiation methods, but rather to show how soae of the handbook curves, factors and the user's judgement may be used in arriving at cost. All units of input used are in the metric system, except for manufacturers' sizes, which are given in the United States system. Input costs are in July 1975 dollars. All output costs, unless otherwise noted, are based on escalation to average 1976 using the following factors. (See Section 2.8., ·Cost Indexes" for July 1975 basic indexes.) All costs are rounded to the nearest dollar. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Item
Escalation
Kine & Plant Labor 1.090 Construction Labor 1.068 E~uipment & Repair Parti 1.074 Bits & Related Steel 1.094 Timber & Lumber 1.184 Fuel 1.068 Powder & Blasting Agents 1.056 Tires 1.088 Construction Materi~ls 1.111 Industrial Materials* 1.065 Transportation 1.065 * Use for items not otherwise covered.
Where NL", "Sh and "E" are used in calculation sheets the} indicate Labor; Supplies, Materials, Luap Sua Entries, Installation, Erection or Other CostS) and EQuipaent Operation or Purchase. Three sample problems, a surface mine, a beneficiation plant and an underground mine are illustrated. The surface aine uses multiple labor cost and escalation factors, the beneficiation plant uses a sinole average labor cost and multiple escalation factors and the underground mine uses average labor cost and shifts from the handbook (i.e. mine is located in Denver cost area) and multiple escalation factors. An example of crushing multiple feed quantities and product sizes has been included. A similar approach may also be used for grinding multiple feed quantities, feed and product sizes.
7.2. SUBFACE KINE - OPERATING COST - BASIC DATA Pover: SO.0294/kW-h average for 1976 Clearing: 0.2 hald, light, < 20~ side slope $10.73/hour average labor cost Overburden and Waste: 38,000 tId at 46 m depth 550 • at 8% and 2380 II level haul tabor Costs: $10.25/hour average- Drill & Blast $10.79/hour average - Excavation, Load Equipment: 9 cy Shovel 85 ton Trucks Rotary Drilling Core Drilling: 4.6 ~/d at S62/m + 1.5 assays per day at SS each $293/d
& Haul
=
tlining of Ore: 20,500 tId at 46 II depth 550 )I at 8% and 370 1!1 level haul tabor Costs: $10.25/hour average - Drill & Blast $10.79/hour average - Excavation. toad & Baul
Restoration: 0.1 hald at SS,OOO/ha General Labor Cost: S10~11/hour average Drainage and Disposal: 250 eu mId at 48 ~ head Camp Operation: 150 persons~ 60r. requiring rooa and board and rooll only Ad~inistrative
Burden:
2Sr.
Administrative Equipment Usage: BOr.
100
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106
7.3. SURFACE KIKE - CAPITAL COST - BASIC DATA All work schedule.
is
subcontracted where applicable on a 5 day, 1 shift
Exploration: Color Aerial Photograph - 40 Sq km Airborne Magnetic Survey - 500 line ta Airborne Radioactive Survey - 500 line ka Airborne Electromagnetic Survey - 500 line km Access Roads: 10 II vide, 8 km lono Standard clearing. 25" side slope 50:C in si to r·ock S11.50/hour average lobar rate Clearing:
250 ha, light, < 20X side slope $10.73/hour averaoe labor cost
Overburden and Waste: 81,600 tId, 29,000,000 t waste 550 II at 8~ and 2380 II level haul, pit 46 II deep Labor Cost: $10.25/hour average - Drill t Blast $10.79/hour average - Excavation, Load & Haul Equipment: 9 cy Shovel 85 ton Trucks Rotary Drilling Mine Plant and Buildings: 58.500 tId ore and vasto Railroad Construction: 9.65 ~m spur line Drainage System: 250 cu mId at 48
II
head
Townsite: 50 Type A Bachelor Units 25 Type B Bachelor Units 50 Family Units Restoration: 10 ha at S5.000/ha Enoineerino
Fe~
only
106
7.3.1. SUMMARY OF ITER COSTS
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7.3.2. CALCULATIOM SHEETS
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112
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t
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= (.5~+.OcP+.ll+.0;)(I.I\\)+(.lb+.OZ)(r.068) +(.18 ~.olHl.014):: 1.090
t
4.2.2..7. Office~ LQbo~to,.ies Esco.lo. 1:.;0 n F.,..,c'lc.r'::. (. S1 + .01 +. I!::>+. 0 3)(1.1 \ \) t (.I4.+. 3){ I· ObS) + (,1 ~+.08)(1.014) ~ l.o9h Area. Fo.c.tor = O. '75
°
4.2,2,8. Sl",.t'ace BI.,:lclihSs
.
'Esc.c" ...~:on ra.ctor" := .2.3(1,0(,,8) -i- (.,)1 -\-.20)(1.111) ': 1.\01 Areo.i='o.c.t.ot"':::' 0.95
(SOA" Z5e. '70 Fo.rr'I;'Y . . 1f.5{2800) : I Z. 'j (200 -+ 150 +\&0 tG..OQ) ;:r :: eo (1000) ~ :. 25(14,000) '::
4,2.0. \ownsite
Site cost I:xcra. E) A's e's Fo.m~ly
Adde. ~',:>
• (, iOt
=
'=>0(11,000)
85 0 ,00 0 3~o)ooo
550,000
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SUJFM,J; "Ill AlII) mro:l~IATlOII PI.MT TOtS • "llIED PEa DAY • 2Q:lQg TOIlS ORE PROC£SSED PEl DAY •
._ .... I.
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IlEIt COSTS·
1953-03
IIT' ....' I ...
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TOTAL 'UIrACI "IMI ."11. AND ADMIN. COl"
11"'"01"" . . . . . ACCesS lOADS COST ,.1
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7.4. BENEFICIATION PLANT - OPE.ATtIG COST - BASIC DATA Plant is shifts ..
operated
on
a 3 shift basis, elcept crushinv is on 2
"ill reed I 20,500 tid
General Labor Rate: S8.80/hour a.erage Electrical Pover Costl SO.0294/kW-h Crushing: 1.27 ca, Vork Index. 15 Grindin9: 1.27 c. feed, 200 "esh output, Vork Index. 15 Regrindings 200 "esh feed, 325 "esh output, 2,000 tid Flotation: 408 tid output, 2 products (Cu-Bo) Copper Heap Leaching: 20,000 t for p~s It,OOO Llain Hauling cost included with ain1nv operat1on. Dryingl 10 tid
011 fired
Vaste & Tailinvs Disposal: 20,000 tid
Cyclone dewatering, 1/2 crew on1, 1.6 ka transport and place b, vra.ity Vater Bec1a.ationl 6,800 cu ./d Vater Supply: 66,000 cu aid .ake up Restoration During Production: 0.05 hald at S5,000/ha Caap Operation: 100 persons, 40X requir1nv rooa and board and room only Transportation: Rail - Mountain-Pacific area 113 tid Copper - 595 ka 23 tid "oly - 1lt5 ka Truck - Class 35 272 tid - 113 km Competitive, dewaterinv < 23 t per truck Administrative Burden: 25"
Administrative Equip.ent Usagel 60" 116
60X
reQu1ring
7.4.1. SURRAII OF ITER COSTS
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7.5. BEIEFICIAtION PLAIT - CAPItAL COST - BASIC DATI For data not shown, see Section 7.4., -Beneficiation Plant Operatinv Cost - Basic Data-. All work 1s subcontracted wbere applieable on a 5 day, 1 shift sehedule. Dike E.bank.entl 18.700 eubic .eters Site .aterials u.ed for fill ClearinV: 11 ha. light. < 201 side .lope Townsite, 16 raally Units a Type A Bachelor Units 1a TIPe B Bachelor Units Re.torationa 10 ha at $5,OOO/ba EnGin.erinv and Constraction Ranave•• nt Fee.
7.5.1. SURRAHY OF ITER COSTS _AIf IfF IIt.'I
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7.5.2. CALCULATION SHEETS 1~5~-o~
I'IIOJICT NO
_HUT
SUBJEcT·-!:B!..Se~....~t!.L.f!!iiic:.!!ij),,:::.!t:.!.!::C7::.!.!')~_ _ _ _ _ _ _ _ _ --=C~D-~~'!..Jt~~:.!..\..JC-.l.O,"~ut..?.'!I_ _ _ _ _ _ _ _ _
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Go.• \,~,
2. C.OV'lc:e"'~"c:t~e Th,c\:.c.I'\\V\~ FAC.+O~ ~ s, ... nCIoOl:.e)+,\S(\i\l\) II 0.:3&\-8 co:: .c"s (,.07'+')· 0.130 .. .
'= ~ c:.A' ~+, 0"
128
~.081
".CUICT NO .HUT
SUBJECT
512""c:tic ;o.tior\
G"
,...::c.::.:Q.:::.l'fF-,:....:\-~p..;::,.\.:....;:C::.::O::;.:~~-\-....~'-________
A'r"e t>-
'1
F'~d"or ~
r= .O)'Z~ ( "~)".115
=
(',113.~. CO"'c.eW\~""f'~~ E.~e.o.\o..\.\O'"
I,I~'
F,\tt-o..t,o"'l
F~c.\-or~·. S :' .21(Lot.B)+ .\'~<",l\'):: O.~(., E ': '.~C.(I.OVt) " O. 'o~
,. t. 3" 'to I?. H eo..r ,Let).Gh;",~
E,=,c~\c:...ho,,", fo.G+or~: S = .O~CI.O~8) l' .10(1.1.11)= 0.1'5 E:: .81t( \. 01't) :: o. ~QZ. Pc:a.d Cost -=. 5.t..O(2..0,)OOO)~ 1\21(103
Po-d
E~c.edO\.+,o"",:
S ... Z,e,( ,.()c..e) T, 1Z( \1\\\) \ \,O~~,
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G,.I. ? 8
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6."
= 0.1'09
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eSc.~\"" ~\ 0,,", ro.c.to\'"'S " , '5= ~I'?> (\,o~e) + Il"~ (l,,") '~ O,,~a+'T E-=: .(,8 (\,'01,+) ,0,'00'
=
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r+a.. . e\
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f>\ Q.ce
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127
i ~ iii 0-
03
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P.O•• C~ NO
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8Y
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fe· ,
5~_-I
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I.IM _ _ _-I
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O\\4.e.
Eor.eoJCI.\-; 0", F"o.c.+or = •se(l.OloS)t .o2{i.\\\} + .\'!,(I.0ee,) ~h~
1". Z~( 1,0("8) ::' t.o~ 2-
+t
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a
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t\-e,"""'''''j ~)\~C
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:. O. 3'2.~
128
:.
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190 0'" 0 '>
4 OI'---'~'--_ _ I Dy~QMIAAMDATlII/2 '/71
.HUT
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SUBJEc:T_....
_ .....C..AOA!.fI':..J..:ilO.lg=..iI~C""'ou:isu..L.o:LS_ _ _ _ _ _ _ _ G"OU~
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E.lec.tricClI Sy.st.em ~~c..tOf"'.s ~
E8C6ttli.i Dn
So: .eo('.oG.8)·"O~('''II\ ~c ~, I (l.o14)
Ir
0.314-
:: 0.1G:.a
,. 1.'.3. t-'\ \t \ P.:> Lli Ie:! i n:J oS 2.-Product Cc..I-Mo Fa.ctor = \.55
Weather- F~c.:~or O. 9~ Fir'\e Ore &:-06: ef8.CDl (20/~00)'7ge &
t: 6CCl'~iio t\ F~d:.o r ~: s= ,f6(I.OG.8)4-.'1(1.11I)
-=
5CD8 X 101
~ 0.488
E.. ,'5S (I .0"'4) :: 0.591 (t>, '.~,4.
Offlcefl (. LQ.bo"'c::lt.or~e~
WQ~the('
Fo.c..i:.o,-" 0.90 E'Oc.o.\o.tioo fo.c.tor-s:
S~ (,·t4-+,O~){I.O~~)-+ (,I~t,O~)(/.'II) .. O,~S2 1::,- (·~7+.o1)(I.lll)+(.I~+.OB)(t,074)::; 0,'14-
'.1, b.",
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F.!:Ic.o.la.tion
(0,"
b,(", l'1i~ce\\o neou~
ii ~CQ.IQt; 0 ~.
~o.d.or:. I.O<'~
1'\ F~c. t.o ('
1:: 9 ,,; pme ni:
= I. D G, J!)
"1, Tovvo ~ite Sile Cos\. = 4~(2dOD) E.,c.lrt!'6:' 42.laoc+ISo+ 150+,"00)
A'a
8(1000) ... \8(,4DOO) ' '" ( Ii 0106) L
8'$ F'oMi \"
A~d6
=
.,
~
( IB-~)(650o)
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= '-::,
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To'lD.1
.
:.
\, 11
~OD
4', e..oo !>~) 000
2.52.1 000 2. 72 1 000 00,000
42.,0l>o
635)0 0 0
::.
"o~':>
129
,._-----------------------------, _,~~~~ P"OJECT NO
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SHUT
P.>eY"o e-tie i a. tio",
SUBJECT
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GROUP
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OF
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om ~m_
R::., e1S. tb.8. '
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0.115 5. \ 2. ';ft/t.
(3.\t5~.j-t)(ZOJ500t.)(~Oc:\~~~) :
130
TABlUTlOII OF ITEII COSTS SURFACE "IIIE A,1D Bt'IEFICIATlOII P!A'IT To:tS ORE "1:0 PER DAY' TOIlS ORE PROCESSED PER DAY • 2Q:igg n ....
.-,
MO.
------
",C."'IOIII
$MIlT NO.
£;1V1RD:I£JITAl ""ACT STATOCIT
"'A
I.
.......'r SHleT
1.1.
I • II
1.1.
I . I
.,.
,.
I.
IIPLOI""'. AND ACCiSS IOAOI COST ~. ,". CU.TA&. COSf
I ' ..
.,
1.1.
I
r.
foTAL SUI'ACt ...... OPII. MIO ADM'". COl'
.
..
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1.1.
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I • I
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.UATINI COlT IJII tON
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,
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1·11
I
Cf"UArtNG
I ••
I
ADMINUTa"" VI COST I'll T.
i
rOl.L leNf"CIA'ION a-tl. AND ....... COS"
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i
I
I I
r.
t ..!
i
rOM
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TOTAL IINfPICIA?lOfiI:C.-UAl. COt' (i.I.)
i
!
I
!
I I
I I
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I
r.~'
i I - Ite
r·
I
0.15e ;
r
°
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... n::~7
'T:--A.A-~
DA'r:..!UsoLrr
caOW' TOTAL
'",I"'IN1' OI"rIAl'ION/PUACttASI
" ! 'II!!
I
.,. '!"9" f
-,I
I I
I
. ;
r· .
.... 'o!
r .'
'U !!R
I
I I
I. lUll 0016
r •
1.097
pc, rON
I~ i
r°
--W.&l,"'~
I
Ir •
r
o
___
~!
II!I
M
o
._~!ro
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Ult
I I I S,lIIfI
r ° 9·5"7'
.,. "9'
t-i l"J tIC
&1:10 0'1"'5
1 J
r
°
~IZlS
: ° ..J.2»,4-~" ·r. , .... , r.
2.111.1/00
n rn t-i rn o
pC'T"
i
I
. • o
M
i
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I
I.
t-i
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I
t
I
.
II
.
;
TO!
I
•UI •\.II •
~
I
i
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TOTAL COST •
"I!! 'It!
!
I.
&
I2c".~. fl·1t:
T- 1
T
THI
~.
.-n.'ALI. SU,."""ES L'" 1\,111 tNTa'f'
i
faTAL • .,.PACI .... c»1Ta.,. eM'
con
CH
....
I
SURFACE ftl;U:tG
1IO.~~oS
-:arPAlrD • .,:
-
I
NO~
en
po
7.6. URDERGROUHD RINE - OPERATING COST - BASIC DITA !ine i. located in the Denver cost area. factor. 1.0. A ca.p 1s not required. Horizontal Cut and Fill ftinino ftethod AbrasiTe, touoh rock Production I
600 tId ore, 145 tId waste
Electrical Power Cost: $0.0294/kW-h
Escalation factor
= 0.029410.025
•
1.176
Production Development per Year: 144,000 tly ore Develop.ent Drifts: Battery Loco.otiTes 1,300 m, 7.5 sq a area Reoular pattern rock boltino Sinkino Shaft: 60 aIr, 10 sq m area, timbered DriTino Raises: 5 raises at 60 m each, 3 .q a .re. Timbered, si.ple chute. Preparino Stopes: 3 m aTeraoe width Slusher aethod Tiabered sets Core Dril1ino: 650 m, AX size IUnino of Ore: Cut and Fill Stopes: 12 t/manshift, 24 tId 3 • averaoe width Slusher method
132
Use labor location
7.6.1. SURRAH! OF ITER COSTS
_,
IaIIS 111£
~11EIi
111'.*'1 ... J 953-0, ........ I - ,_
PO IMY. -..;; ............ ...;;:" ....... , ..,
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600
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OF 1.1tJI COSTS
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_ . P, IlUI\GRD!J!I! ","I. ftMTlIIIi COSTS «00'.) .... : TOIlS !ME "IIIED PU DAY • • PQ TON$ pCB ~~ _____________-"--'4"''!!''-'Tg!:!.~ PIIII p ....... -_STE
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133
~Ull'lARY
••ov.: 3.4. wo .. :
U~;)(P.G~u;m ~I:IWG Ail"I~'STRATlvr CO~T~
ryF 1m:
CIl!'T~
fS.' ....'E .....
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TO~IS CPE ~I':ED FER DAY· .:IoQ PorI'! p~~O~ _ _--'-_ _ _ _ _ _14:1:1_ "T'Q!:'.1LP_~R.j) ... y- WASTe
".r."....!D
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- 100
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~
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TOTAL AOIiIINz,nArrVI!
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7.7. UNDERGROUND KINE - CAPITAL COS! - BASIC DA!A For data not shown, see Section 7.6., ·Underground KineOperatin9 Cost - Basic Data-. Construction and installation i. to be performed br Ovner's personnel on a 5 dar, 1 shift schedule. Construction equipment is to be purchased. Exploration: Core Drilling, 14,000 • at $401. Access Roads: 9 a vide, 7.5 k. long Heavy clearing, 35% side slope 95" hard rock Gravel surfaced Sinkin9 Shaft: 1,220 m Stope Preparation: 12,000 t
20 days production
Drifts: 1,300
1\
Rises:
5 at 60
II
Core Drilling: 650 a, AX size Clearino: 25 ha, lIedium, 20-50" side slope Compressed Air Facilities. 200 cu a/min installed No Townsite Restoration During Construction: 23 ha at S5,000/ha Engineering Fee: 10" using Owner's staff
139
7.7.1. SU!!ARI OF ITE! COSTS
JfO, __.lJtQ9-'_ _ , '_ __ NO._I_'_<_,_______ .___ ·.I!Ii'",.U ":Jct~_ _ _ our:.!.I/2Sb1 UTI .... "
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_.: TO.'I$ I!f!E 1"8 PER DAY. 699 7PN:a PC! 0 ...... - ORE, _ _ _ _ _ _ _ _ _ _ _.L.:'4~7__!..!T~~ ..I='_C-f-P""V - """SoT!!
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7.8. CRUSHING MuLTIPLE FEED QUANTITIES AND PRODUCT SIZES Section 5,1.1. "Crushing" used for example. Basic Data: Crushing 10,000 tId to 2.540 cm Crushing 2,000 tId from 2.540 cm Work Index 12
=
to
0.635 cm
Determine cost/d from curves for 10,000 tId: Il - $895/d
Is Ie
= $550/d = $7971d
Determine cos tId from curves for 2,000 tId:
Il Is Ie
= $372/d
= "S1121d = $174/d
Determine size factor for 2.54 em: F
= 0.0799(2.54)-o.830(1a) = 0.442
Determine size factor for 0.635 cm: F
= 0.0799(0.635)-0.830(12) = 1.398
Therefore the total costs are: Il
Is Ie
= 895{.442) = 797(.442)
= 550(.442)
+ 372(1.398-.442} + 112(1.398-.442)
+ 174(1.398-.442)
149
= $751/d = S519/d
= S350/d
