PROCESO MINERO CERREJÓN
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EL CERREJON
PROCESO MINERO
AGOSTO 2003
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TABLA DE CONTENIDO Pág.
1
SISTEMA DE EXPLOTACIÓN....................................................................................................................1 1.1
ACTIVIDADES DE LA OPERACIÓN MINERA.................................. MINERA................................................ ............................ ............................ ............................ ....................... ......... 3
1.1.1 1.1.2 1.1.3 1.1.4 1.1.5
Desmonte y descapote ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ........ 3 Remoción y Restauración de Suelo................... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... . 3 Remoción de material estéril estéril ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ........ 5 Extracción de carbón .................. ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... . 5 Control Control de Polvo ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................ .. 6 1.2 EQUIPOS EMPLEADOS EN LA EXTRACCIÓN DE CARBÓN ........................... ......................................... ............................ ............................ ............................ ....................... ......... 7 1.3 PROCESO DE PERFORACIÓN Y VOLADURA BAJO MANTO ........................... ......................................... ............................ ............................ ............................ ..................... ....... 8 1.3.1 Utilización y Manejo de Explosivos ................................................................................................................. 8 1.3.2 Diseño de Perforación y Voladura................ Voladura..... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ............. .......... ... 10 1.3.3 Controles al impacto ambiental de las voladuras ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ...... 12 1.3.4 Otros controles de calidad ............................................................................................................................. 12 1.4 INSTALACIONES Y ADECUACIONES ........................... ......................................... ........................... ........................... ............................ ............................ ............................ .......................... ............ 13 1.4.1 Suministro de combustibles, lubricantes y refrigerantes................................................................................ 13 1.4.2 Línea de Listos............. ........... ..................... .......... ........... ..................... .......... ........... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... .... 15 1.4.3 Subestaciones y Líneas Eléctricas.................................................................................................................. 16 1.4.4 Fuentes de Suministro, Tratamiento y Distribución de Agua Potable. .......................................................... 16 1.4.5 Sistemas Sistemas de Comunicació Comunicación n ........................... ......................................... ............................ ............................ ............................ ............................ ............................ ............................ .............. 17 1.4.6 Lagunas de Retención............... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... ............. .......... ... 19 1.4.7 Embalses para Almacenamiento de Agua .................... .......... ..................... ........... ........... ..................... .......... ........... ..................... .......... ........... .................. .......... ........ 19 1.4.8 Redes de tubería y Torres de llenado .................... .......... ..................... ........... ........... ..................... .......... ........... ..................... .......... ........... ..................... .......... ........... .... 20 1.5 OTRAS INSTALACIONES Y SERVICIOS DE APOYO ............................ ......................................... ........................... ............................ ............................ ............................ ................... ..... 22
2
BENEFICIO Y TRANSPORTE..................................................................................................................23 2.1 2.2 2.3 2.4
TRITURACIÓN Y ALMACENAMIENTO DE CARBÓN EN LA MINA ............................ .......................................... ............................ ............................ ....................... ......... 23 PLANTA DE LAVADO ........................... ......................................... ............................ ............................ ........................... ........................... ............................ ............................ ............................ ................... ..... 25 TRANSPORTE DE CARBÓN POR TREN............................ .......................................... ............................ ............................ ............................ ............................ ............................ ..................... ....... 27 EL CARBÓN EN EL PUERTO ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ ..................... ....... 28
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PROCESO DE MINERIA A CIELO ABIERTO EN EL CERREJON 1
SISTEMA DE EXPLOTACIÓN
Los tajos son desarrollados de manera continua y secuencial, como una operación estándar de palas y camiones, en todos los tajos de El Cerrejón. (Ver Figura 1). En los reemplazos futuros de equipos, se adquirirá la mejor tecnología disponible para este tipo de operaciones. El sistema de producción (Ver Figura 2) y manejo del carbón, localizado en La Mina y El Puerto, comprende instalaciones con capacidad para explotar, triturar, almacenar y embarcar más de 22 millones de toneladas de carbón por año. La relación de descapote total es variable y superior al promedio de los tajos durante los primeros años cuando gran parte el material meteorizado, es removido y se adelantan actividades de desarrollo. En los años siguientes la relación de descapote se normaliza alrededor de 6.8 metros cúbicos de roca por tonelada de carbón producida. La minería se inicia con el desmonte y la disposición de la cobertura vegetal. Todo el suelo recuperable en las áreas de tajo y botadero es cargado utilizando traíllas o camiones y cargadores y dispuesto en pilas cuyas dimensiones y localización cumplen con los estándares de Ingeniería Ambiental de CERREJON. Siempre que sea posible el suelo removido es llevado a áreas de restauración para su disposición final. El suelo apilado será remanejado en el futuro para labores de restauración.
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Figura 2. Sistema (Pala - Camión) empleado en la operación minera en el Cerrejón. El estéril es fragmentado y en su mayoría, cargado por palas eléctricas con la ayuda de palas hidráulicas y cargadores frontales. Para la apertura de bancos y la excavación de cuñas en la pared alta se utilizan palas hidráulicas retroexcavadoras. Los camiones utilizados son de 240 Ton. aunque algunas unidades de 170 Ton. son utilizadas para actividades como remoción/remanejo de suelo y acarreo de triturado. En el futuro es posible que el tamaño de los camiones de estéril se incremente siguiendo las tendencias de la industria. La minería y acarreo del carbón se hace limpiando y empujando el carbón con tractores de oruga. El cargue de carbón se hace en su mayoría por cargadores frontales sobre camiones carboneros del tipo 170 T, con capacidad de 148 toneladas. Una pequeña fracción del carbón es cargada por palas eléctricas, mientras que las palas hidráulicas retroexcavadoras minan y cargan el carbón de las cuñas en la pared alta. Los camiones carboneros salen del tajo por rampas en la pared alta y se dirigen a la vía de acarreo de carbón
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permiten llegar a los niveles requeridos de botado. Todas las rampas para acarreo de estéril y carbón se construyen con pendientes del 8%.
1.1
ACTIVIDADES DE LA OPERACIÓN MINERA
La operación del Cerrejón es típicamente de palas y camiones. En los reemplazos futuros de equipos, se procurará adquirir la mejor tecnología disponible. La mayoría del estéril es cargado por palas eléctricas e hidráulicas frontales en condiciones normales de operación. Las palas hidráulicas retroexcavadoras son utilizadas principalmente en la excavación de cuñas y apertura de niveles. El carbón es cargado en su mayoría por cargadores frontales, con volúmenes menores cargados por los demás equipos, según lo requieran las condiciones de los frentes.
1.1.1
Desmonte y descapote
Las actividades de desmonte y descapote son realizadas, además de las áreas de tajo y botadero, en todos los sitios en donde se proyectan nuevas obras tales como: vías de acarreo, instalaciones móviles o permanentes, diques y canales, lagunas de sedimentación y almacenamiento, etc. El proceso de desmonte se inicia en cada área con el retiro de la vegetación existente, removiendo los árboles y arbustos junto con las raíces de la vegetación leñosa, la cual será derribada y amontonada con bulldozer. Se aprovecha el mayor volumen maderable posible en labores tales como cercado de áreas y producción de estacas para topografía; topografía; el material restante se pica y se dispone en las pilas de suelo y en botaderos de estéril. Posterior al desmonte se realiza la remoción de la capa orgánica de suelo, cuyas áreas, espesores y volúmenes a remover serán determinados por Ingeniería Ambiental de CERREJON, de acuerdo al tipo y cantidad de suelo. El almacenamiento se hace en pilas, en los lugares previamente determinados para tal fin, aisladas de las demás actividades de la mina, y preservadas con el establecimiento y mantenimiento de cobertura de especies herbáceas. El suelo almacenado se reutiliza posteriormente en los procesos de rehabilitación de tierras aplicándolo en capas de 30 cm de espesor, tanto en las zonas de botadero de superficie como en zonas de retrollenado.
1.1.2
Remoción y Restauración de Suelo
El suelo recuperado se coloca en bancos de almacenamiento ubicados entre el botadero de superficie y la cresta del tajo, para su posterior utilización en las labores de rehabilitación de las áreas intervenidas en el botadero de superficie. Las áreas intervenidas por el Dique de protección y las operaciones mineras (retrollenado), serán utilizadas como botaderos (Retrollenado y de Superficie) Superficie) para los futuros tajos. En la Figura 3, se muestra el avance del proceso de rehabilitación del botadero de superficie. En el primer banco, se observa la configuración final del botadero, el segundo banco, muestra el estado del botadero después de suavizar la pendiente del talud 3:1, el tercer banco muestra el talud después de la colocación del suelo y el último banco, muestra el talud una vez se ha introducido pasto. La Figura 4, muestra el estado final del talud rehabilitado.
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Banco 4 Banco 3
Banco 2
Banco 1
Figura 3. Proceso de Rehabilitación de botaderos. botad eros.
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1.1.3
Remoción de material estéril
Para extraer el carbón las capas de roca que cubren los mantos, son removidas en bancos de 10 metros de altura. La minería en el Cerrejón es una operación de remoción de estéril ya que por cada tonelada de carbón 3 producida, es necesario remover aproximadamente 6.5 m -banco de roca estéril. Esta operación unitaria constituye el mayor componente del costo total de operación. El material estéril extraído es depositado en botaderos de superficie o en áreas de retrollenado de tajos. Una capa de material aluvial y roca meteorizada de hasta 18 m de espesor se encuentra cubriendo todas las áreas de minería. Se trata de una capa de material blando, fácilmente saturable y con poca capacidad portante cuando está húmeda. Este material es cargado en forma normal con palas eléctricas e hidráulicas hi dráulicas y puesto que no se encuentran mantos de carbón, el empuje con tractores se mantiene al mínimo. Solo se utilizan voladuras donde la dureza del material lo requiere. En condiciones difíciles de piso (épocas de lluvias) se utilizan palas hidráulicas más livianas y versátiles. Cuando se encuentran acumulaciones de material aluvial con cantos rodados de buen tamaño, el material material es excavado en forma selectiva y acumulado en pilas de almacenamiento que sirven de alimentación a las dos plantas trituradoras existentes. En las plantas de agregados se producen triturados de 2”, ¾” y finos (desechos), los cuales se consumen en las operaciones mineras y el ferrocarril. Parte del material aluvial es utilizado directamente como material de sub-base para la construcción de vías. Una vez removida removida la capa de aluvial y meteorizado se inicia la profundización del tajo y debido al buzamiento de los mantos y al esquema de avance de la mina, esta operación comienza con la excavación de cuñas en la pared alta con retroexcavadoras hidráulicas. Solamente cuando el espacio entre la pared alta y el primer manto de carbón es mayor de 30 m, la apertura de bancos se hace con palas eléctricas. Después de la extracción del primer manto de carbón, se ejecuta la operación normal de cargue con palas eléctricas e hidráulicas frontales. A medida que la excavación de un banco progresa se presentan diferentes condiciones de cargue. La cuña inferior que queda después de la extracción de un manto causa causa deterioro de la productividad de los equipos de cargue por disminución de la altura de banco y fragmentación más pobre de la roca. La altura de banco se incrementa gradualmente hasta llegar a una situación de frente completo ("full face") de 10 m de altura y en estas condiciones la productividad de los equipos de cargue es óptima. Cuando el manto siguiente es alcanzado, el avance libre de la pala es interrumpido y esta operación se vuelve enteramente dependiente del empuje de la cuña superior con tractor de orugas (D11/D10). Al completarse el empuje de la cuña superior el techo del manto es expuesto quedando listo para la operación de limpieza y extracción del carbón.
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almacenamiento temporal. Cuando el área de operación no es suficiente para la operación de cargadores frontales (p. ej. en cuñas en la pared alta), las palas hidráulicas y/o eléctricas cargan el carbón. (Ver Figura 5). Cuando el buzamiento de los mantos de carbón es demasiado alto para la operación de los tractores de oruga, se utiliza una combinación de palas hidráulicas y tractores de oruga empujando en el sentido del rumbo. Si el espesor del manto es demasiado delgado para permitir la operación de tractores, solamente se utilizan las palas hidráulicas retroexcavadoras, de largo alcance.
Minerí a de estéril Perforación Overburden
Tractor
Pala Eléctrica Pala Hidráulica
Minerí a de Carbón Tractor
Cargador
Camiones Carboneros
Camiones estéril
Estéril a botaderos
Pilas de carbón e interfase 45
4 4 41
51
Al Sistema de Manejo de carbón
Planta de lavado
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Para un riego eficaz en las vías de acarreo, rampas, corredores y botaderos, se debe regar en forma intermitente, 20/20, veinte metros mojados y veinte metros secos. Si la vía no esta totalmente seca regar manualmente 20/40, veinte metros mojados por cuarenta metros secos, especialmente en las rampas, ya que debido a la pendiente de la vía, se humedece más la parte inferior de las mismas.
Figura 6. Control de Polvo en vías de acarreo.
1.2
EQUIPOS EMPLEADOS EN LA EXTRACCIÓN DE CARBÓN
La operación minera de El Cerrejón, está diseñada para alcanzar niveles de producción de 25 Millones de 3 toneladas por año en el 2004 y para ello se deben remover anualmente del orden de 163 millones de m banco de roca. Una operación de esta magnitud implica grandes inversiones de capital en equipos e instalaciones. Cerrejón cuenta con las flotas de equipos mineros requeridos para la operación. Igualmente
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Tabla 1. Actividades De Minería - Equipos Utilizados ESTIMATIVO DE UNIDADES REQUERIDAS PARA UN TAJO PARTICULAR ACTIVIDAD
EQUIPO
CAPACIDAD
TOTAL CERREJON (ACTUAL)
1.3
27 M 3 18 M 3 17 M 3 17 M3
MINERIA CARGUE MINERIA CARGUE MINERIA CARGUE MINERIA CARGUE
PALAS ELECTRICAS PALAS HIDR. FRONTALES PALAS HIDR. RETRO CARGADORES CARGADORE S FRONTALES
12 8 5 9
MINERIA PERFORACION ACARREO ESTERIL ACARREO ESTERIL ACARREO CARBON
TALADROS HIDRAULICOS CAMIONES DE ESTERIL CAMIONES DE ESTERIL CAMIONES CARBONEROS CARBONEROS
MINERIA SOPORTE
TRACTORES ORUGA CAT D11
14
MINERIA SOPORTE
TRACT. ORUGA CAT D9/D10
38
MINERIA SOPORTE MINERIA SOPORTE REMOCION SUELO CONTROL DE POLVO
TRACTORES DE LLANTAS MOTONIVELADORAS MOTONIVELADOR AS TRAILLAS TANQUEROS
21 25 4 17
13 240 TON 170 TON 148 TON
35 TON. 18000 GAL.
97 50 31
PROCESO DE PERFORACIÓN Y VOLADURA BAJO MANTO
Todo el material estéril excavado en el Cerrejon, es volado utilizando explosivos a base de Nitrato de Amonio. A partir de 1989, se implementó en El Cerrejón el sistema de Voladura Bajo Manto, el cual busca fragmentar el
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especialmente construido, con bermas de cerramiento de más de cinco metros de altura. Los demás materiales explosivos como detonadores de fondo, retardadores y cordón de disparo (Nonel) son transportados separadamente y almacenados en depósitos cubiertos especialmente construidos (polvorines). El explosivo a granel, utilizado en la mina, es una emulsión a base de Nitrato de Amonio, A.C.P.M. y aditivos especiales que estabilizan la mezcla. La emulsión se prepara en una planta con capacidad para producir toda la emulsión requerida en la operación. La emulsión preparada es transferida a un silo donde se cargan los camiones cisterna que la transportan hasta los sitios de cargue de voladura. Estos camiones están dotados de dispositivos especiales que permiten cargar los barrenos con la cantidad exacta de emulsión requerida en cada uno. Vale la pena anotar que la emulsión así preparada es inerte y solo puede ser iniciada con explosivos especiales de alto poder (boosters o detonadores de fondo) los cuales son colocados en el barreno al momento del cargue. Todas las operaciones de preparación de emulsión, manejo y transporte de explosivos y cargue de áreas a volar son manejadas con extremas medidas de seguridad y por personal altamente entrenado. El acceso a la planta de emulsión y a las áreas de cargue es restringido. Las áreas de perforación y voladura son acordonadas y señalizadas y solo se permite el acceso a personal autorizado. Las voladuras se ejecutan durante el descanso de medio medio día (12:45 p.m.) cuando la mayoría mayoría del equipo rodante se encuentra encuentra en las líneas de listos. Todas las áreas afectadas por una voladura son evacuadas y acordonadas al momento del disparo. Las voladuras se ejecutan de manera controlada, con retardos para reducir la vibración y evitar la proyección de rocas. (Ver Figura 7). 7).
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1.3.2
Diseño de Perforación y Voladura
Las experiencias obtenidas en los procesos de Perforación y Voladura Bajo Manto, en los tajos que están actualmente en operación, han permitido logros importantes en los l os mencionados procesos. La voladura se hace con la técnica de voladura bajo manto, utilizando patrones de perforación (distancia entre 7/8 pozos) que dependen del diámetro del pozo y del tipo de roca. El diámetro de barreno a utilizar es de 9" y 9 " (228.6 mm y 250.8 mm) con espaciamiento de 6.5 m x 7.5 m ó 6.8 m x 7.8 m y 14 m de profundidad promedio. Cuando en una voladura no existen mantos de carbón, se utilizará voladura normal con cargue continuo. (Ver Figura 8).
4.5 Mts 6.5 Mts 10 Mts
12 Mts
Figura 8. Diseño de voladura bajo manto.
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Figura 9. Sistema GPS portátil.
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1.3.3
Controles al impacto ambiental de las voladuras
Para el control de vibraciones, se lleva a cabo un monitoreo en la totalidad de las voladuras ubicadas en sectores que puedan afectar a comunidades vecinas, que incluye seguimiento a las condiciones ambientales, ubicación de las voladuras y direccionamiento de la secuencia de amarre y control de la cantidad de explosivo por retardo. Desde Enero de 1999, se establecieron una serie de controles para medir vibraciones originadas por las voladuras los cuales continúan aplicándose en las operaciones de perforación y voladura en los tajos activos. Entre los más importantes a saber son: •
Un programa de monitoreo de vibración y onda aérea dentro de la propiedad con instrumentos especializados. Para el monitoreo de vibración del terreno y estallido del aire se esta analizando con el equipo Blast Mate Series III (Figura 11), por medio del cual se determina si los niveles de vibración y onda aérea cumplen con las normas vigentes.
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Figura 12. Equipo de medición de Velocidad de Detonación. 1.4
INSTALACIONES Y ADECUACIONES ADECUACIONES
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Figura 13. Esquema típico de una Isla móvil de Combustible.
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1.4.2
Línea de Listos
Las instalaciones de la Línea de Listos incluyen área de parqueo, comedor/sala de reuniones, oficina para supervisores, tanques de agua potable, baños con pozo séptico, microondas para calentar comida, iluminación y aislamiento perimetral con berma. (Ver Figura 15).
1 Comedor/sala de reuniones
Tanques de agua potable
2 Oficina supervisores
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1.4.3
Subestaciones y Líneas Eléctricas
En el proceso de operación minera a cielo abierto se utilizan palas eléctricas que requieren suministro de energía a 7200 voltios; para abastecerlas es necesaria la instalación y el montaje de líneas eléctricas de alta tensión (69 Kv), sub-estaciones móviles que reducen el voltaje a 7.2 Kv (Ver Figura 16) y líneas de distribución de 7.2 Kv. El consumo promedio de energía eléctrica en la operación minera (excluyendo instalaciones y plantas) es de 4.8 Millones de KWh/mes.
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tratamiento de cuatro etapas: ablandamiento, floculación, filtración y desinfección. La planta está dotada de un sistema de producción de hipoclorito de sodio para la desinfección. Los efluentes de la planta de tratamiento de agua se descargan a la Laguna de Retención Este. El agua tratada es distribuida por una red de tuberías a las instalaciones permanentes que están cerca de ella y a aquellas áreas donde los consumos lo justifiquen. Para áreas apartadas y de bajo consumo se ha implementado un sistema de camiones cisterna y tanques elevados de almacenamiento que permite atender todas las necesidades de la operación. Así las líneas de parqueo, islas móviles de combustible, oficinas de campo y demás instalaciones no conectadas a la red de suministro de agua potable, son atendidas por camiones cisterna en frecuencias que varían según el consumo.
1.4.5
Sistemas de Comunicación
Los sistemas de comunicación utilizados actualmente incluyen: A. CTD ( Computarized Computarized Truck Dispatching System) con con GPS. B. Radio de comunicaciones de
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B. Radio de Comunicaciones de voz La señal es generada por un radio de comunicaciones desde cualquier punto de la mina (Cada equipo pesado y liviano tiene radio de comunicaciones y toda persona que se encuentre en la mina debe tener un radio portátil). C. Sistema Aquila DMS & GPS Emplea GPS de alta precisión y monitores en la cabina. Cada monitor muestra los patrones patrones de perforación, usando coordenadas predefinidas para los pozos de voladura. Con esta información el operador ubica las coordenadas del punto a perforar, obteniéndose resultados de alta precisión. (Figura 18).
Información de
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(((
Estación remota. Oficinas en campo ))) con conexión a red para computadores y servicio telefónico
Puente
Vehículo liviano de supervisión. Trabaja
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1.5
OTRAS INSTALACIONES Y SERVICIOS DE APOYO
En la operación se cuenta actualmente con Centros de Atención de Emergencias (CAE), (Ver Figura 23), los cuales ofrecen asistencia médica de primeros auxilios y combate de incendios en sus áreas de influencia. Prestan servicio las 24 horas y están equipados con ambulancia, camión de bomberos, sala de primeros auxilios y oficina.
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