Grasberg Block Cave Haulage

Project: Design & Construction

Update
May 2016
 Contents

• Describe Designs and Schedule, Construction Status and

Operational plans for the Grasberg Block Cave Mine (GBC)
Haulage Project

• Overview of Grasberg Mining District

• Grasberg Rail Haulage System Overview
• Rail Design and Specifications
• Schedule
• Construction
• Operations
• Conclusions/Questions

2
Grasberg (Ertsberg) District Location

3
 District Orebody & Access Overview

N Grasberg
open pit
Grasberg
Grasberg

Kucing Liar

DMLZ
DMLZ
DOZ
DOZ

Grasberg GBC
GBCTerminal:
Rail Terminal:
Big Gossan
Block Cave 2560m
Kucing
Mill Liar
N Amole
Portals
2,900 m elev DOZ
Plan View
Big
Kucing Liar Spur
Gossan
Grasberg
MLA
BC Spur DMLZ

Big Gossan Spur DMLZ Spur

AB Portals
Portals Common Infrastructure
(at Ridge Camp) Common Infrastructure System:
2,500 m elev

2,500m elevation 4
5
GBC Rail Haulage Overview

6
 GBC Mine General Layout

GRS Final Pit

3000 Amole Adits

GBC Hoistroom
Service Interlevel Ramp
2850 Undercut Level Shaft
Batch
2830 Extraction Level Plant
2810 Vent/Service Level
2760 Haulage Level
Crushers
2710 Drainage Level Pumps
Interlevel Ramp
2535 GBC Terminal AB Adit
7
 GBC Haulage Project

 Why a Rail Haulage system?

 Overview
- 160,000tonne/day operation
- 120 ore chutes (peak of around 70 open concurrently)
- 23km of track
- 11-12 Production Locomotives
- 3 unloading stations
- 1 Rail Construction permit

8
Rail Haulage Layout

9
Rail Haulage & Extraction Overlay

10
GBC Rail Design and Specifications

11
Rolling Stock

12
 Rail Haulage Workshop

 Maintenance?

13
Loading Chutes

14
 Rail Haulage: Ore Delivery

 Automated Rail System

- 1435 mm (standard) gauge
- Overhead Catenary System on main lines
- 40t Schalke electric locomotives (11-12 trains plus one spare)
- 20 x 20m3 NMT bottom-dump cars
- 120 loading chutes in full layout
- NMT Unloading Station x 3 delivers ore to 1400-tonne bins / crusher
- Communication-Based Train Controls System: Midroc / Bombardier

15
 Track Profiles - Origional

Embedded track Ballasted Track 16

 Track Profiles - Updated

 Chosen for geotechnical

reasons
 In practice has been easier
to install ground support
 Challenging to take
turnouts, but has good
results
 Mainly used for ballasted
track in the production
areas

17
GBC Rail Construction Schedule

18
 Schedule Overview

 Development schedule feeds into Rail construction schedule

 Key dates:
- Undercutting Jan 2018
- CG45: Commissioning March 2017
- CG44: Commissioning August 2017 *
- CG43: Commissioning May 2018
- CG33: Commissioning November 2017 *
- CG32: Commissioning March 2018
- 601 Unloading Station: Commissioning July 2017
- Peak production 2024
- Production completed 2039
19
 Schedule Challenges

 Challenges
- Long single access drives with large intersections
- Ground support
- Complexity due to access restrictions
- Drainage
- Rail construction permit – change to installation strategy

20
Construction

21
 Underground Rail Construction - Training

Bending Machine Ballast Turnout

Power Pack Rail Drill Rail Saw Turnout

22
CG45 – Chute and MCC

23
 Loading Chute Construction

Loading Chutes – Chute Gallery 45

Unloading Station

Loading Chutes – Chute Gallery 45

DCS Midroc – Train Controls
24
Operation

25
 Simulations

 Arena simulations with various scenarios, particularly rail loop

development and construction restrictions

26
Thank You

27