The K2-LV Experiment: Mining the Future

Project Report

Engineering Design 100: Section 004

Team: K2-LV

Submitted to: Wallace Catanach

Date: April 30, 2017

Logan Bayer: lmb6082@psu.edu Keith Griffith: kkg5246@psu.edu

Jiajie Chen: vincentcjj2g@gmail.com

Kainian Chen: kkc5296@psu.edu

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Index Title Page

Executive Summary ………………………………………………………………… 4

Introduction …………………………………………………………………………. 5

Patent Research

Underground Mine Ventilation System…………………………………………. 6

Underground Mine Surveillance System ……………………………………….. 6

Vehicle for Underground Mine Shafts ………………………………………….. 6

Block Caving Mining Method ……………………………………………………… 7

Customer Requirements …………………………………………………………….. 7

Global Marketplace …………………………………………………………………. 8

Concept Generation

Super Elevator …………………………………………………………………... 9

Funnel Elevator …………………………………………………………………. 10

Track and Elevator System …………………………………………………….... 10

Conveyor Belt System …………………………………………………………... 10

Guys with Shovels ………………………………………………………………. 10

Concept Selection …………………………………………………………………… 11

Embodiment of Design ……………………………………………………………… 12

Final Design Description ……………………………………………………………. 16

Geothermal Energy ………………………………………………………………….. 17

After the Mining …………………………………………………………………….. 19

Conclusions ………………………………………………………………………...... 19

References …………………………………………………………………………… 20

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Executive Summary Team K2-LV was one of the many teams designated to develop a new method of extraction for

rare earth elements in the Pocono Mountains. Client General Electric specifically cited block-

caving as the primary method of removal. Block caving requires a weak host rock as the entire

premise of this method relies on the rock fracturing in certain areas. The host rock in the Pocono

Mountains consists of fine to medium grained sandstone, siltstone and conglomerate rock. This

means that the rock is relatively stable and is able to self-support roughly 90% of the mine; this

requires support systems for the remaining 10% of the mine. Although the primary investment

for this method of mining is very high, the payoff in the end is worth it. K2-LV’s goal was to

design and prototype an innovative take on block caving that would solve 8 main problems,

including: airborne contamination, environmental management, stewardship of the ore,

occupational health and workplace safety, operating costs and productivity, local community

engagement, waste management and disposal, and mine closure and rehabilitation.

Before detailing a design for GE’s rare earth element mine, some preliminary research had to

take place. Through GE’s given parameters a few things were clarified. To begin with the mine

has already been setup as a block cave operation with a ramp from the surface to the production

level intended for primary transportation of ore. The ramp is 15.3 km long at a constant 20%

grade. In addition, the ore maintains a uniform concentration throughout. This leads to each

extracted ton being worth approximately $10,000. Each of the 100 draw points throughout the

mine provides a continuous flow of ore as well. This simplified scenario allows the design team

to construct a proper cost model for the mine. The mined ore only travels 300 meters on average

from draw point to haul zone locations. Taking of all the background clarifications and customer

needs into account, K2-LV began brainstorming. These brainstorming sessions led to the

development of a fully automated mine.

There were a number of problems encountered throughout the design process. Initially, worker

safety was a major issue. The best solution we found to this problem was to entirely remove

them from the equation. By automating the whole process we were able to complete the project

without compromising safety. Another major issue we found was a way to supply power to our

mine. The ability for our mine to run all day would allow for max profit in the long run. Since

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geothermal energy is a renewable energy source that is able to create energy at a fairly constant

rate, this was chosen as a power source. Finally, we needed to find a way to access the

automated equipment for repairs. There are multiple ways that this can be done. Robotic

vehicles would be able to do this after development, however, ventilation and access shafts were

put in place. This would allow for miners to access the conveyor belts for repair. The final

prototype and design is scheduled to be delivered to client GE on April 26, 2017.

Introduction

In the Pocono Mountains (pictured) in Northwestern Pennsylvania, the company General

Electric has the foundation laid to set

up a mine. The mission is to extract

many Rare Earth Elements (REE)

from the site. These elements include

Neodymium (Nd), Europium (Eu),

Terbium (Tb), Dysprosium (Dy), and

Yttrium (Y).

Without having a plan in place

to harvest these resources, and not having an idea for a mine design, GE called on K2-LV for the

solution. The team had just completed Wally’s Catanach’s Zero Energy Home needs. K2-LV

had many problems to overcome, and they were all very important aspects to cover.

These problems all spout from the depth. At around 3,000 meters below surface level,

the first problem we encounter is a higher everything. Higher temperatures, higher humidity,

higher natural gas emissions: all problems for human beings. They can’t even flee into the safety

of their diesel vehicles, as the depths cause challenges operating these vehicles as well. Team

K2-LV was ready to take on all of these challenges.

Patent Research

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Underground Mine Ventilation System

US 20120309283 A1

This patent is for a simple underground mine ventilation system,

as suggested above. This patent calls for fans by non-pressurized

ventilation shafts, and it calls for a natural free-flow of air.

Underground mine surveillance system

US 3949353 A

This patent, as suggested by the title above, it is for a

surveillance system. Instead of using video cameras or recording

devices, it rather monitors energy usage. Seismic energy is

processed and classified into meaningful data, and can monitor work and productivity.

Vehicle for underground mine shafts

US 5909780 A

This patent is for a mine shaft vehicle that can transport human bodies into mine shafts. This

vehicle has many safety features similar to regular cars, such as emergency brakes, and a door

security monitor that only allows it to work if the door is shut and the circuit is complete.

Block Caving Mining Method

The method that General Electric wants used is called the block caving mining method. It can be

a very intricate process, but it can be simplified into 5 simple steps.

1) An extraction layer is dug below the rock that is to be

fragmented. (Right)

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2) Using explosives, charges are set off at draw points. Through this

explosion and natural rock decay, fragments break off. (Right)

3) The fragments are collected via special underground mining

trucks. These trucks are called LHDs (Load-Haul-Dump), and

require human drivers to operate them. (Right)

4) The LHDs carry the collected fragments through the

series of tunnels to the crusher. (Left)

5) The crushed fragments are taken to the surface via

conveyor belt. (Right)

Customer requirements

Customer statements Needs statements

We want to reduce the cost. The mining system will use an Automated

System to reduce the labor costs and to

transport waste material at a low cost.

Dangerous gas, humidity and high

temperature in the mine can cause serious

accidents.

A cooling system will be used while mining to

ensure the dangerous gas does not react and to

reduce the temperature. A ventilation system

will reduce the amount of dangerous gas in

the mining area and decrease the amount of

total heat affecting the equipment.

Hazardous environment will be an issue for

our workers.

As long as we use automated system, we will

not require workers work in those conditions.

Our mine should be environmentally friendly. Tailings will be recycled in order to maintain

the overall flora and fauna of the area.

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Our main customer, GE, is mine owner who owns land that contains Rare Earth Element (REE)

ore in the Pocono Mountains. GE listed the following requirements: environmental

consciousness, as both long term and short term hazardous environment effects should be

minimized, safety and health of our workers, all while reducing costs. It is necessary to keep the

cost low in order to receive the maximum amount of profit.

Global Marketplace

Mines have been an important part of US

and World history. The Rare Earth Elements we

are seeking have many uses. The graph

demonstrates some of the uses, and the

breakdowns of them.

Uses that are personal to the everyday

man, and more commonly known include

computer memories, DVDs, rechargeable

batteries, fluorescent lights, and much more.

The demand has gone up a lot over the past

several decades.

China by far has the largest market for these, followed by the US, and then many other

nations. A few examples of block caving mining can be seen throughout the world. To begin

with, Northparkes (Australia) began using block caving mining in 1996. The mining base is 600

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meters under the ground. The main extraction materials are gold and copper. In addition, Auto

Load-haul dumpers (LHD) give 20% more output than the manual LHD. It has reduced the

working times for all workers. Workers no longer need to work 12 hours in order to produce the

same amount of product.

The Henderson molybdenum mine, a mine located in Clear Creek County, Colorado, is North

America’s largest producer of molybdenum. The Henderson mine was the successor to the Urad

mine and was discovered in 1964. Climax Molybdenum Co. was the company associated with

the discovery of the deep orebody. Production began in 1976 and still continues today. Roughly

500 million pounds are estimated to be left. With roughly 40 million pounds of production each

year, the mine brings in roughly $1.1 billion yearly. Soon after production began, the mine

broke through to the surface. This mine utilizes a 15 mile long conveyor belt that travels below

the mine. Prior to the use of a conveyor system, a train was used to transport the mineral.

However, this was only possible when the ore was above the track.

Concept Generation

The brainstorming phase of the process led us to a handful of ideas. K2-LV had to

narrow down the ideas to be scored and then selected. Before we get to the scoring and

selection, here are the ideas we put up against

each other.

The Super Elevator

This idea consisted of collecting the rock

fragments by a series of underground trucks, and

then being transported to a massive elevator.

This “super elevator” would carry the fragments to the surface where it would be unloaded. The

elevator shaft takes up a lot of square footage, and makes any plan for afterwards very difficult

and problematic to implement.

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The Funnel Elevator

The idea of the funnel elevator is one that is very similar to the super

elevator above. The main adjustment here is that when the fragments are

placed on the elevator and taken to the surface, they pass through a funnel at

the top of the elevator shaft. This funnel focuses the fragments into one point

and allows for easier collection. Like the elevator above, due to its massive size, any plan for

use of the site afterwards would be very difficult.

The Track and Elevator System

The idea of a track and elevator system was by far the most

complicated idea thought up. This system was a series of conveyor

belts and elevators that carry the fragments to the surface, after being

collected by underground mining trucks. A downside of this concept

is the lack of a plan for afterwards.

The Conveyor Belt System

This idea uses nothing but conveyor belts to

transport the resources to the surface. After

going through a funnel and then a grinder, a

horizontal conveyor belt carries the grinded up

fragments to another diagonal conveyor belt,

which takes it to the surface. The plan for afterwards is to turn the mine into a ski resort.

Guys with Shovels

This idea was never meant to be

taken seriously, nor did it have a chance to be

selected. Purely for comedy, this idea of

getting thousands of men with shovels to go

down into the mine and take out the resources. It may have been via buckets, or they all may

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have made a chain to transport it out. It wasn’t thought the whole way through. No real plan for

the use of the mine after its time has run out.

Concept Selection

When it came time to select one of our ideas to further develop, we used a simple

plus/minus scoring system using the customer needs we derived from earlier.

The idea of guys with shovels came in last, as to be expected. Slightly above that idea

was the track and elevator system. This concept failed due to the fact that it was too complex

and had unnecessary components. Tied for second were the super elevator and funnel elevator

system. Both provided safety, lacked a plan for post-mine use, and were very similar in the end.

The concept that took the cake was the automated conveyor belt system. It was a positive

on all of the customer requirements, putting it far above the rest. It’s automated system took

workers out of the equation, making it the safest environment possible for them. Not to mention

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the planned ski resort afterward, a great use of any waste and a way to get the local people of the

Poconos involved.

In addition to the selection of our concept versus other concepts, an AHP chart was

created. This chart shows the importance of significant factors in comparison to others.

A few concepts were highly rated including the cooling system, automated system, worker safety

and use for waste. Ventilation system, however, was the least important metric showcased in this

diagram.

Embodiment of Design

The above image showcases the complete underground system of the mine. Further details will

be explained in the following images.

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The image here shows the conveyor belt required to lift material out of the mine. The ore is

transferred onto the lift by another conveyor belt. The ore is then carried directly upwards

towards the processing plant. The plant is located directly over the exit area of the mine. This

ensures efficiency for processing.

The above image showcases the grinders that are located directly below the orebody. The

grinders ensure that the ore is of manageable size for the conveyor belts.

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The above image shows the exit of the material from the mine.

This image is of the transfer conveyor belt. This is located directly below the orebody, funnel,

and grinder. This conveyor belt transfers the material from the grinder to the exit conveyor.

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This is representative of the orebody.

This solidworks model shows an example of an auger/grinder that is able to crush the material to

a manageable size as was represented in the above images.

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This is the conveyor belt that would transport the material to the surface. The horizontal belt

above the surface provide convenience for fixing trucks.

This conveyor is present directly below the orebody and is responsible for moving the material

from grinder to the upward conveyor.

Final Design Description

The final design is rather simple. Unlike the traditional block caving mining method,

The grinder is placed directly below the draw point. This removes the need for trucks and for

people in those trucks. The fragments are funneled into the grinder, where they grinded

fragments fall onto a horizontal conveyor belt. This belt runs to a diagonal belt that carries the

resources out to the surface, where it can be hauled away and used in production.

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Geothermal Energy

Geothermal energy, as was previously listed, was chosen as the primary energy producer for this

mine. Geothermal energy works by using steam to turn a turbine. This turbine then generates

electricity. As hot water is drawn up through the earth, flash steam is created. The hot water that

is not turned into steam then runs through a vaporizer, allowing for double draw from the power

source. The steam and excess water are then passed through a condenser and pumped into the

ground. As long as the amount of water being drawn is less than or equal to the rate it is being

pumped back in, the geothermal power plant will continue to run. Our model showcased a

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simplified version of a geothermal power plant.

The image in this case utilizes different colored balloons and straws to represent different parts

of a geothermal unit. The red balloons represent the hot water areas. The red straws are

indicative of steam pipes. The green straws represent the cooler, but still hot water. The green

balloon is a vaporizer, allowing for another draw of energy. The yellow straw is a condenser that

wraps around the blue, cooled steam straws. The cooled water is then pumped back into the

ground, showed by the smaller blue balloon. The green bottle represents the generator that

would then power the mine.

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After the Mining

Ski facility can be built up on the giant pit after the mining. It will not only increase the

economic effect in the mining areas but also protect the environment.

Conclusions

In conclusion, K2-LV was effectively able to design and prototype a mine system that fulfills all

of the needs of GE project. This was also completed on a strict deadline with a plethora of

customer needs. The project could be considered by many a success, despite temporary

ineffectiveness within the team. The difficulties were solved and the project came together to

produce a quality product. For many, these difficulties would have caused a shutdown, but for

K2-LV nothing is impossible.

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Links

https://www.google.com/patents/US20120309283

https://www.google.com/patents/US3949353

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

GE Mining Presentation

http://www.heavyequipment.com/heavy-equipment/earthmoving-mining

Bing Images (Through PowerPoint)

http://www.greenegroup.co.za/foundations-for-surface-mine-ventilation-fans/

http://www.concordpianoservice.com/what-exactly-is-humidity/

http://www.rnaautomation.com/products/automation-solutions/

http://followgreenliving.com/geothermal-energy/

http://www.trendhunter.com/trends/mitsubishi-electric-elevators

http://digitalmarketingphilippines.com/lead-generation-funnel-what-is-it-and-how-does-it-work/

https://www.amazon.com/Accessory-Elevator-Attachments-Playsets-Flipo/dp/B01LQT3WR6

http://www.mafdel-belts.com/product/positive-drive-conveyor-belt/positivebelt-conveyor-belt/

http://www.outsidethebeltway.com/otb-caption-contest-125/

http://www.open.edu/openlearn/science-maths-technology/science/environmental-

science/energy-resources-geothermal-energy/content-section-8

https://www.youtube.com/watch?v=gI6BhEy7yXo

http://geo-energy.org/Basics.aspx

http://english.visitkorea.or.kr/enu/ATR/SI_EN_3_6.jsp?cid=1976359

http://geology.com/articles/rare-earth-elements/