7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

DOI: 10.7251/BMC170702215H

PROPOSALS FOR THE COMPLETE MINING OUT OF ASAREL

DEPOSIT

Stoyan HRISTOV1
1
Bulgaria, sofia0571@abv.bg

ABSTRACT

The author discusses some considerations for applying a combined system of mining of deep-seated
deposits in Bulgaria. The aim is to mine more reserves from these deposits. Special attention is paid to
the limited time for research and design of the combined mining method and the transition from
opencast to underground mining of the copper ore.
The peculiarities of the combined system of mining are discussed. There is a special focus on ensuring
the stability of the rock mass during the driving and supporting of the mining workings.
Potential schemes for combined mining of Asarel mine are presented.
Some recommendations for the significance of the transition from opencast to underground way of
mining of deep-seated deposits are given.

1. INTRODUCTION

The practice for designing and mining out of deep deposits of mineral resources (Elatsite,
Asarel, Kremikovtsi, Medet, etc.) shows that there is a need for periodical reconstruction. It is
especially necessary in case of extending their boundaries, proving of new reserves and
transition to new system of mining. For example, the transition to combined mining (opencast
and underground) in Asarel mine will be made after the costs for the stripping operations
become greater than the costs for underground mining, i.e.:

So  Sм , (1)

where So – costs for opencast mining of 1 t of ore, in BGN;

SM – costs for underground mining of 1 t of ore, in BGN.

The reconstruction is characterized by high material and labour costs and a lot of time for
preparation. The world experience shows that they can be significantly decreased if the
reconstruction is planned in advance, during the construction and extraction of the pits.
In such cases, it is desirable not to allow the remaining of ore deposits under the bottom of the
opencast pit as in Medet and Kremikovtsi.

215
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

In the near future such reconstruction will also take place at Asarel mine which is
characterized by relatively low quality indicators and complex mining and geological
conditions which determine the high operating costs of the enterprise.

2. STATE OF THE MINING WORKS AT ASAREL MINE

At present (end of 2016) approximately 300 mln. t. copper and pyrite ore has been mined
from Asarel mine.
The design project (2016) foresees about 242 mln. t. ore still to be mined out till level 465
(Fig. 1).

Figure 1. Transverse profile of Asarel deposit“

From a mining and technical point of view it is possible in the future to develop the mine with
three new working horizons (till level 400) and thus to mine out more ore in an opencast way
(Fig. 1).
The results from the preliminary geological prospecting show that there are about 230 mln.t.
of ore till level 300. This ore should be extracted in the most effective way as it is necessary
for Asarel Medet JSC and the country.
This can be done by gradual introduction of a combined mining system and extraction of the
remaining part of the reserves from the deposits, i.e. to make a transition from opencast to
underground way of mining.
There are three ways for extraction of the reserves through a combined way of mining of a
given deposit: 1) the upper part of the deposit is extracted in an opencast way and the lower
part – in an underground way (e.g. the pits Elatsite, Asarel, Kremikovtsi, Medet); 2) initially,

216
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

the reserves of the lower part are mined out in an underground way and afterwards, in an
opencast way (e.g. the mines Hristo Botev, Bobov dol); 3) the deposit is mined out
simultaneously in an opencast and underground way. This technology can be applied in the
transition period in the development of Asarel mine (2027-2040). However, the transition to
such system requires serious preparation – additional prospecting, development of different
variants, working design and its confirmation, training of specialists for underground work,
review of the legislative regulations, etc. Therefore, the time should be sufficient (8-10 years)
in order for the company to prepare for these types of work.

3. CHARACTERISTICS OF THE COMBINED MINING

a) Use of two different technologies – opencast and underground mining in one and the same
deposit;
b) Extraction of much more reserves from the deposit;
c) Better drainage of the underground waters, improving the conditions for mining,
decreasing the costs for dewatering and ventilation of the mine;
d) Reducing the volume of overburden and the transportation costs for the mined mass;
e) Part of the overburden or tailings from the processing factory can be used for backfilling
the empty spaces in the underground part of the mine.

During the design and construction stage of the combined system of mining some other
difficult tasks should also be considered:
 Defining the parametres of the pillar between the bottom of the opencast mine and the
underground pressurised water logged horizon;
 Calculation and protection of the thickness of the ore pillars between the benches of
the opencast mine and the underground mining workings;
 Calculating the parametres of the vertical and inclined shafts and their retaining
pillars;
 Protection of the common opencast and underground technological space and their
mutual influence;
 Selection of the most suitable (skip, conveyor, etc.) transport, the place for the
crushing and sieving facility (CSF), shafts, galleries, the type of the machines and
equipment, etc.;
 Ensuring the stability of the mining workings, especially in the period 2027-2040;
 Reclamation of the damaged areas by the mining works.
It is necessary to ensure sufficient time for preparation as there are many tasks which should
be implemented in the transition period.

217
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

4. STAGES IN THE DEVELOPMENT OF ASAREL MINE

а) Stage from 2022 to 2027

During this stage the rubber conveyor belt CFT-3 (Cyclic Flow Technology) is eliminated in
Asarel mine. The ore and overburden are transported only with auto transport to the crushing
site of the processing factory and the north waste dump, respectively. Thus, the transportation
distances are increased almost twice (from 2.79 km to 4.25 km), the number of the dump
trucks is increased with 3 more trucks to 7; respectively, the number of drivers increases 3 to
4 times, i.e. the price of 1t mined ore is increased. At the same time, the equipment for CFT-3
remains idle at the repair site while there is a possibility to place it at a new site in the mine.
From the analysis which was made, CFT-3 can be built at a new place and to form CFT-4.
Our opinion is that the most appropriate place is the north-east part of the mine (Fig.2). In
fact, it can be situated from level 735 in the middle of the mine to level 905 – close to the
lump crusher. It is built with slope of 15-16° and length of 600 m. In order to move it,
appropriate trenches, roads, CSF and other necessary measures should be implemented. The
new CFT-4 should be placed taking into consideration the place of CSF555.

b) Stage from 2027 to 2040.

One of the most important periods is the gradual stopping of the mining operations in Asarel
mine. In fact, this is the transition stage for the preparation of the combined way of mining
(from opencast to underground mining).
The current design of the mine [4] till 2027 foresees the extraction of more reserves from the
western section of the deposit. Thus, a working site is formed at level 555 (Fig.3). An inclined
or vertical shaft for the underground operations is constructed from it.

Figure 2. State of the mining and transportation operations by 2022

218
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

At the same time, the future CSF555 is constructed. During this stage the driving of the
necessary underground workings and equipment is implemented – loading and unloading
sites, galleries, etc. (Fig.3 and Fig. 4). The ventilation shaft is also constructed. The most
appropriate place is the east board of the mine since it guarantees better stability of the
facility. The transportation of the mining mass from the underground faces to CSF555 is
carried out with the help of skip or conveyor transport. The crushed ore is transported from
CSF555 by auto transport to the lump crusher in the Processing factory and the overburden is
transported to CFT-2 where it is crushed to 300mm and transported with conveyors to the
west waste dump (Fig.4). All calculations for the driving of the mining workings and
equipment are made on the basis of the mine productivity and the selection of the stope
machines and equipment. After the construction of all these facilities (till the end of 2040) the
mining of the ore under the bottom level 465 of the central body of the deposit can begin, i.e.
to start the underground mining in Asarel mine.
Of course, many other options for extraction of all reserves from Asarel deposit are possible,
this is a subject for long research, design and construction..

c) Stage after 2040.

Asarel deposit is mined out in underground way.

Figure 3. Variant for combined mining of Asarel mine

219
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

Figure 4. Technological and transportation scheme of Asarel mine after 2027

5. STABILITY OF THE MINING WORKINGS DURING THE UNDERGROUND

MINING OF THE DEPOSIT

One of the most difficult and responsible tasks during the combined mining of Asarel deposit
is ensuring the slope’s stability of the opencast mine and the stability of the underground
mining operations. This task is quite important, complex and insufficiently studied.
It is known that the decreasing of the board’s angles leads to increasing the overburden
coefficient, worsening of the technical and economic indicators of the enterprise and early
transition to underground mining. On the other hand, the increase of the boards’ angles leads
to landslides and negative consequences during the underground operations. The retaining
rock pillars should be strengthened and built in order to protect the underground workings
from destruction. The situation is especially serious in the sections where there are waters,
faults, fractures and other disturbances. As a result of them, potential surfaces of sliding Li
occur. The resistance forces of the rock Ni and more specifically, its cohesion Ci, decrease in
these zones.
With the simultaneous development of the mining operations in the two parts of the ore field
(opencast and underground) there are instances when the constructive elements of the
opencast mine can be placed upon the underground mining workings and thus we can have a
combined way of mining. Open and underground limited spaces are formed where the
physical, mechanical and strained stress condition of the rock significantly influence the
further development of the mining operations. This is especially the case when the slope’s

220
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

stability in the opencast pit is disturbed as a result of the undermining by the underground
mining operations. Thus, the area of the surface of sliding Li and the rock cohesion Ci, which
so far has sustained its stable condition, are reduced. For example, the driving of gallery Bi in
proximity to the potential surface of sliding L1 reduces the coefficient of reserve of stability 
 1 (Fig.3).
n
 Pi cos itgi  Ci

 Ni  1
i
(2)
 Ti n
 Pi sin i
1
where i, Ci  the angle of internal friction and cohesion of rocks, angles and N/m2;
L = li  the length of the surface of sliding, m;
Ni – restraining forces, KN/m;
Ti – sliding forces, KN/m.
The increasing of the lost restraining forces of the slope T3   Ti   Ni can be achieved
by flexible mining, strengthening with pillars, anchor bolts, retaining walls, etc.
According to the scheme for the distribution of the strengthening measures they can be
situated parallel, vertically, horizontally, inclined under a certain angle of the slope, mixed,
etc. This distribution depends most on the mining and geological conditions of the deposit and
the means at our disposition [1].
The above-mentioned shows that the volume, assessment and maintenance of the stability of
mining workings when developing deep deposits is a difficult, responsible and expensive task.

6. CONCLUSION

The implementation of combined mining of Asarel deposit requires:

1) A lot of time for preparation for the transition from opencast to underground mining of
copper ore;
a. Moving the CFT-3 to a new place;
b. Setting up of new CSF 555;
c. Driving of shafts and workings;
d. Training of specialists;
e. New working designs, etc.
2) Widening of the theoretical and practical research and elaboration of new normative
regulations and instructions for safe work;
3) The full extraction of the reserves within the boundaries of the Asarel ore field cannot
be implemented without the use of combined mining;
4) The combined way of mining has its future and development for the conditions in our
deposits Elatsite, Medet, Kremikovtsi, etc.

221
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

REFERENCES

[1] Hristov S.G. Management of the slope’s stability of an opencast mine when applying combined way of
mining. VII International Conference in Geomechanics, 27 th June – 1st July 2016, Varna.
[2] Hristov S.G. Technological and geomechanical problems in the design and operation of opencast pits and
quarries. S., 2013.
[3] Hristov S.G. Textbook on stability and dewatering of slopes in opencast pits and quarries. S., 1999.
[4] Updated overall working design for mining of Asarel deposit and Asarel deposit – section West. Minproekt
JSC, S., 2016.

222