FUTURE OF CASCADE MINING METHOD IN JUNGLE LODE

OF KATHPAL CHROMITE MINE, FACOR

Snehal Purohit, General Manager, Facor

Santosh Kumar, AMM, Boula Chromite mines, Facor

ABSTRACT
This paper deals with sublevel open stope with cascade method in moderate/flatter dip
ore body. It includes recovery of left over muck above sill pillar/crown pillar. Techniques
provide for stability of hangwall and crown pillar.
Key point: sublevel stoping, cascade mining, Up-retreat mining, cable bolt, buttress
pillar and slot formation.

INTRODUCTION
Ferro Alloys Corporation Ltd was floated in 1955 by the House of Saraf and Mors and
was become the first major producer of ferro-alloy in the country. FACOR become the
largest manufacturer of ferro alloys, producer of quality steel, Charge Chrome and
Chrome Ore. FACOR is actively operating two underground mines of Chrome ore in
Boula, (Keonjhar dist) and Kathpal (Dhenkanal dist), one opencast mine in Ostapal
(Jajpur dist). One opencast chromite mines in Bhimtangar (Jajpur dist) will be
commenced shortly. All the mines are located in Orissa state.
PRESENT STATUS
The Kathpal Chromite Mine is situated in the south western part of Sukinda valley,
Dhenkanal District, Orissa, India. The lease hold area is 113.312 hectares is entirely
within Birasal reserve forest of Kamakhyanagar East range. It has two lode- Jungle lode
and Maheswar lode. The ore body is a predominantly stratiform deposit. The ore
segments have been severely intercepted by basic dykes and granophyres. The
chromite is associated with serpentinite (altered dunite). Strike length in Jungle lode is
40m to 70m, dipping is 35 to 550 NE, width is varying from 3m to 8m in different ore
segment and its reserve depth is upto -210 mRL. Finite element mesh showing stopes
and open pit in Jungle Lode, Kathpal Chromite mines as shown in figure1 (U.K. Singh
2011).
The mining operation commenced in the year 1973 by opencast mining and the
underground operation commenced during the year 1983.

Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 1
PRESENT MINING ACTIVITIES

Development
Access to ore body is made by vertical shafts, which are deepened further as the ore
body extends to further depth. Sub-levels are driven 15 m apart and main levels are
driven 30 m apart all in the ore body. Foot wall/haulage drives are made on the main
level to connect with ore drives by transverse cross cuts to withdraw the ore from the
stope void through EIMCO Rocker Shovel. Sub-levels are connected through Raises
and Winzes for ventilation access and for providing a free face after widening
Raise/Winze known as slot against long hole blasting while commencing stoping.
Development drives are supported with grouted rock bolts 1.0 m apart. Level
development is done with Jack Hammer and Eimco Loader. Muck is loaded in mine
cars, which are trammed manually up to shaft bottom for hoisting. Winzes are sunk by
conventional method with sinking bucket while raises are driven by drop raise method
and occasionally by manual method for short distance. All horizontal drives are made
about 2.8 m x 2.8 m and raise/winze drives are being made 2 m x 2 m.
Method of extraction (stoping)
The method of stoping is sub-level open stope with ring hole drilling of 57 mm dia.
Stoping is carried out by blasting vertical slices into an expansion slot. Ore withdrawal
is done by Track-mounted Pneumatic Loaders EIMCO 21B. Ore is transported by mine
cars manually. Adequate barren pillars due to dykes/faults/injections or ore pillars which
are vertically left unexcavated in the stopes act as abutment/rib pillars, horizontal pillars
are left at about 30 m act as crown/sill pillars as shown in figure 2, 3 & 4. These pillars
protect the Hangwall and level above. The strata monitoring of void areas are done by
sensitive instruments is a regular feature. Adequate capacity of Winding Engine, Direct
Haulages are used to hoist the mineral from the underground.
Stope Drilling
Initially ore geometry is decided of the levels of the stope for drilling designing. Slot
raise is formed in Hangwall or Footwall side at the end of stope along the dip of the ore
body for creating a free face for blasting, after that it has enlarged up to planned stope
width by vertical/Inclined drilling. Slot raise act as ventilation raise for that stope. Ring
pattern have toe spacing about 1.8m and ring to ring burden 1.5 m and drilled from
Footwall ore drive by BBC 120 simba drill in upward direction as shown in figure 5.
Blasting
Stoping typically commences by blasting the faces in longitudinal direction from stope
end and then moves progressively to other end. For blasting of 57 mm dia holes, bundle
of 2 to 3 cartridge of 20 mm slurry explosive (powergel) is used. Explosive are
detonated with proper sequence of short delay period electric detonators under the
guidance of assistant manager. The stope blasting is done at the end of shift after
ensuring that all the men are out from underground. Powder factor is about 4-5
tonnes/kg of explosive.

Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 2
 Transportation
The blasted ore mucking is done from the Footwall/Hangwall ore drive at 15 m sub-level
and at main level about 30 m apart vertically. Mucking is done from H/w, F/w and
footwall x-cut by deploying EMICO loader 21B into tubs. The loaded tub is transported
manually upto shaft bottom and there from hoisted to pit top at the surface.
Ventilation
The stopes are ventilated by accessional ventilation. The air enters from haulage drive,
transverse cross cut and service raises and travels upwards to the stope, ventilating all
the levels and sublevels. Some development drive faces are ventilated by auxiliary
ventilation fan. The stoping sequence is from top to downward so that there will not be
any working in the upper levels and in the return airway. After completion of extraction
in any level the entry in the same level is blocked by brick walls.
Support
In development drives/cross-cut, 1.5 m length and 20 mm dia meter rock bolts are
grouted into the roof, at right angle to the joint planes at 1 m apart keeping the rock
bolts within 1.5 m distance from the face. Stopes are being monitored with following
instruments:
1. Tape Extensometer
2. Bore Hole Extensometer
3. Load cell

FUTURE SCOPE

Introduction
Jungle main ore body in upper level is steeply inclined about 650 with strong hangwall
and footwall (RMR about 65) whereas in lower level (below -77 mRL) , inclination of
main ore body has been encountered to 350-400 with good H/w and F/w rock (RMR
about 60 as per CSIR norm) and fair ore body (RMR about 50 as per CSIR norm) due
to complex fault and shear zone intrusion. Due to flatter dip of ore body, stope drilling is
preferred from F/w ore drive so that drilling length will be minimum as comparison to
H/w drilling drive as shown in figure 5 and 6. But figure 5 also indicates that more holes
touch to H/w side when drilling is preferred from F/w ore drive as comparison to H/w ore
drive as shown in figure 6. Due to this reason after blasting, H/w is more exposed than
plan and it may be also the reason of dilution. So we should prefer to have H/w ore
drive for drilling purpose.
Here we are introducing other mining technique in sublevel stoping. Its name is
Cascade Sublevel mining method. In this method, level will be divided in 2-3 sublevel of
small vertical height about 10 m. Buttress inclined pillar will be left in place of crown
pillar. Its inclination will be about 900 from footwall to hangwall (Normal to the dip ore
body) as shown in figure 7. Sublevel will be blasted from lower level to upper level (up-
retreat i.e. overhand). Up-retreat method is best suitable for shallow/flatter dip due to
huge free face available in lower level for ore flow-ability

Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 3
 (Ernesto Villaescusa 2003). In this method H/w may be supported by cable bolt from
H/w ore drive and Buttress pillar may be supported by cable bolt from F/w drilling drive
in lower level, so that buttress pillar may act as artificial pillar and its size can also be
reduced in comparison to pillar without cable bolt as shown in figure 7
A more detailed description of this method is given in the following paragraph.
A. MINING ABOVE -92 mRL

Mining method
sublevel cascade open stope method is best suitable for flat dip ore body in Jungle lode.
In this method inclined crown pillar (buttress pillar) will be left which will act normal to
F/w and H/w. This will be providing best flow-ability for H/w side muck. Muck slide
tendency will be towards footwall side Waste drive. Less tensile stresses will be
developed on pillar due to change in orientation.
Development
Sublevel will be opened at -86 mRL for drilling drive in waste (size about 2.8 ×2.8 m) at
footwall side through raise as shown in figure 10. Drilling drive size should be optimum
so that after stoping left out muck will be minimum. At the end of block, slot raises will
be formed by any one from 3 methods as shown in figure 8 & 9.
1. Footwall waste slot raise (figure 8)
2. Shrinkage slot raise parallel to buttress pillar (figure 9)
3. Combination of above two.
Footwall haulage drive (2.2×2.2 m) will be driven parallel to Footwall drilling drive at
distance of 5 m. Both drives will connect to transverse cross cut of size 2.2×2.2 m. End
of T- cross cut size will be 2.8×2.8 m, so that loader can operate easily for stope
mucking. End of haulage drive will be connected to -77 mRL through Raise for proper
ventilation and man access. Transverse cross cut will be driven at about 7 m interval
from centre to centre. This development muck will be loaded by loader and transported
manually upto dump raise (timber or steel chute can be formed). Raise to shaft bottom,
muck will be transported manually again.
Drive support
For drive development following point should be considered.
1 Arc shape drive should be preferred, so that minimum stress will be developed
on drive wall.
2 Keep development dimensions as small as possible so that waste and stress
generation will be minimum.
3 After blasting screw props are erected temporarily before emplacement of rock
bolts in to the roof.
4 Rock-bolt drilling and grouting should be taken on priority with advance.
5 When weak zone intersect in development face then W strap support or any
other best support should be preferred.
6 Transverse x-cut brow area should be supported by extra precaution.
Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 4
 7 Cable bolt support may be required in buttress pillar as shown in figure 7.
8 Cable bolt support system pattern is 2.0×2.0 m in burden and toe spacing. So
that pillar will be more stable.
Stoping

Drilling and blasting

Slot formation:- Slot raises will be formed at the end of each stope by any one method
from 3 methods as shown in figures 8 & 9 whichever is more practicable.
1. Footwall waste slot raise.
2. Shrinkage slot raise from footwall to hangwall, parallel to buttress pillar.
3. Combination of above two.
Raising slot will be widened from F/w to H/w or vice versa as shown in figure 8 & 9. In footwall
side, waste will be also blasted as per convenient up to 45 to 550 from horizontal so that muck
can flow easily.
The blast holes will be drilled with BBC 120F longhole drilling machine, pattern of holes will be
ring hole pattern to blast vertical slice of ore between F/w (550 from Hz) to H/w (above buttress
pillar) as shown in figure 10.
Transportation of ore
After blasting, ore will slide in F/w drilling drive due to inclination about 55 0 in both sides.
Mucking will be done by loader from F/w drilling drive and Transverse x-cut. Stope muck will
be also trammed manually same as drive muck.
B. MINING BELOW -92 mRL
Development: Following development is required for mining below -92 mRL:-
1. -92 to -125 mRL staple pit (raise or winze)
2. -92 to -132 mRL shaft sinking
3. -105 to -125 mRL ore pass & manway
4. -92 mRL Hangwall ore drive
5. -105 mRL Hangwall ore drive
6. -115 mRL Hangwall ore drive
7. -125 mRL Footwall drive in waste
8. -125 mRL Footwall haulage drive in waste
9. -125 mRL Transverse X-cut
10. Or 1 extra sublevel at -105 mRL
11. Slot raise (any one)
a) Footwall slot raise (-125 mRL to -92 mRL)
b) Footwall slot raise (-125 mRL to -92 mRL) with Shrinkage slot raise as shown
in figure 12. Or
c) Footwall slot raise (-125 mRL to -92 mRL) with hangwall slot raise (above -92
mRL).
Drive support:- Discussed in previous page.

Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 5
Hangwall portion will be supported by cable bolt from Hangwall drive with advance of
development before stope drilling, so that dilution will be controlled with major safety.
Cable bolt of 10-12 m have to be installed in a pattern of 2.0×2.0 m (burden and toe
spacing ) as shown in figure 11.
Stope drilling and blasting
From -125 mRL to -115 mRL slot raise will be driven at 45-550 inclination from
horizontal with footwall contact. -115 mRL to -92 mRL footwall slot raise will be driven
about 400 as shown in figure 12. Above -92 mRL slot raise can be formed in Shrinkage
slot parallel to buttress pillar or Hangwall slot and widening can be started from -105
mRL with combination of -92 mRL. Below-105 mRL portion will be widened from -115
mRL as shown in figure 12.
About 840 m development will be required for mining below -92 mRL as comparison to
925 m development when sublevel -105 m will be connected with shaft. In present
mining method development will be required about 850 m for main ore body (excluded -
92 mRL development).
For best fragmentation of ore, stoping should be done from lower level (-125 mRL) to
upper level (-92 mRL) [overhand stoping] as shown in figure 13 & 14.
Transportation
Transportation will be done from -125 mRL as same process as discussed above.
Advantage of cascade mining method
1 Crown pillar stability is quite high
Reason
a) Stress will be reduced due to establishment of crown pillar parallel to principal major
stresses or normal to dip ore body as shown in figure 15 & 16 (U.K. Singh 2011*).
b) Hangwall will be supported by cable bolt easily from hangwall drive (below -92
mRL).
c) Buttress pillar will be supported by cable bolt from footwall drilling drive.
2 Whole Muck will slide in footwall side drive so ROM recovery will be increased in thick
ore body (> 4m).
3 Left over ore, above -77 mRL will be extracted easily.
4 Less Crown pillar thickness will be required thus recovery will be increased.
5 Extraction of rib pillar and crown pillar will be easy in future in comparison to present
sublevel stoping.
6 Sorting recovery will be increased (below-92 mRL).
7 Safety will be increased due to very less brow area required in F/w side (since mucking
will be done from F/w drilling drive and Transverse X-cut).
8 This is best applicable for flat ore body (< 400). This is also applicable for steep dip.
Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 6
Disadvantage of cascade mining method
1 In India, it is not well familiar. Thus adoption by technical persons will take time.
2 Near to buttress pillar, drilling should be done with high accuracy. i.e. ring pattern
should be perfect.
3 Accurate gradient line of level, exact dip angle & ore body width etc will be required.
Otherwise adverse effect may be observed.
4 Competent skill person will be required for designing & drilling.
5 Close supervision and careful planning of sequence of development and stoping are
necessary.

SCOPE FOR FURTHER STUDIES

 Details numerical stress analysis is required for determination for accurate pillar
size requirement for stability in open stopes up-to bottom level mining.

ACKNOWLEDGEMENT
Thanks are due to the management of The Ferro alloys Corporation ltd for permitting to
publish this document.
REFERENCES
1. U.K. Singh, Unpublished paper 2011 “ 3D Numerical modeling Analysis for
subsidence to assess long term damage on surface vegetation due to
underground mining at Kathpal Chromite mines, Facor, Bhadarkh, Orissa.
2. Mabson, L.R., and Russell, F.M., 1981, “Applications of Sublevel Open Stoping
on the RCM Limited Mines of the Zambian Copperbelt,” Design and Operation of
Caving and Sublevel Stoping Mines, Chap. 43, D. Stewart, ed., SME-AIME, New
York, pp. 585–607.
3. Ernesto Villaescusa, MPES 2003, Conference Kalgoorlie April 2003, “Global
extraction sequence in sublevel stoping”
4. U.K. Singh, Unpublished paper 2011*.

Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 7
Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 8
Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 9
Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 10
Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 11
Future of cascade mining method in Jungle lode of Kathpal Chromite mine, Facor Page 12