CAPITAL AND OPERATING COST ESTIMATING SYSTEM
May 9, 2017 | Author: Russell Hartill | Category: N/A
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CAPITAL AND OPERATING COST ESTIMATING SYSTEM A MANUAL FOR MINING AND BENEFICIATION OF METALLIC AND NONMETALLIC MINERALS...
Description
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-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' ~~ .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
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.
~. ~
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. 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~" ,+.,.,; ,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:/,,' "
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P~ ..~ Cl
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. 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
40~
requiring
7.2.1. SUMMARY OF ITE" SlWARY OF 'TD1
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104
1
= 1.01,
SUBJECT
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3. \.1\- •. '-\.• C"'_? E~c._\G..""O"
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I
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COu 1"'.(:"" c e ""'V"'" , Ad y,,\ . . . ,~+ to ·hye
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3.~. \. \. kdM'\-.' ~ ~ rc:..~ \V~ ~~\Q,," ,e.~ ~ WOo')e'!> E~eo..\o..ho"" F6.c:..~or -= ,.OOJO f.,,,, ... cl e", fo.c.J Dr = \. 2. ~ ~, 2.. I. ~. c ~ e co... \
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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
••_. '.1.
[1P1.~'.\Il11l ~'C
I.cass ~D~
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E: .%.3(1.089)'" .'tI(I.ol'fo) t.3G.U.obe) = 1.015 5h\~+ FAc+or = 2.05 .-3ubco ... t~j).c.","o,~~ Fc:a.e~ors La \. r:, 5: f:. J..Abo ... loc:~t,QI'\ fo..e~ot"~:: 11,50/ e,C?>~ : \. ~85
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