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Henderson DUSEL Conceptual Design

Mark Kuchta Mining Engineering Department

Colorado School of Mines

Lee Petersen, CNA Consulting EngineersGreg Hulne, Miller Dunwiddie Architects

Dale Holland, Dunham AssociatesJohn Jenkins, ILF

Craig Covil, ARUP

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Engineering Design Team

Colorado School of Mines: Mark Kuchta, Scott Kieffer, (Mining Engineering, Geotechnical Engineering)

Henderson Mine: Chip deWolfe, +

Staff (Mining Engineering, Safety)

CNA Consulting Engineers: Lee Petersen(Engineering Team Leader, Civil Engineering)

Dunham Associates: Dale Holland(Mechanical/Electrical Engineering)

Miller Dunwiddie Architecture: Greg Hulne(Architect)

ILF Consultants: John Jenkins(Internal Shaft Design)

ARUP:(Cost review, construction management plan)

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Conceptual Design Overview

•Shared Mine Infrastructure

•Mine Services Summary

•Rock Conditions

•DUSEL Access Ramps

•Campus Layouts (Upper, Central, Lower,

Outposts)

•Development Sequence

•System Design

•Fire and Life Safety Concepts and Code

Review

•Surface Facilities

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Shared Mine Infrastructure

Overriding design criteria

•Safety

•Share infrastructure that is of benefit to share

•Keep the DUSEL and mine operations as separate as possible

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Site Overview

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Shared Mine Infrastructure

Ventilation

•150,000 cfm available for DUSEL

Electricity

•14 MW with 14MW backup available for DUSEL.

Mine Dewatering

•About 3000 gpm pumping capacity available for DUSEL

•DUSEL estimated need 500 gpm

URAD Water Treatment

•About 2000 gpm in excess capacity available for DUSEL

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Shaft Schedule: Man Cage

Double Deck Man Cage

•Capacity 100 people•Overall availability about 93.5%•Normally available 24/7

Service Cage•Capacity 100 People•30 Ton capacity•Sling 50 tons with crosshead•Cage – 23 ft. long X 8.5 ft Wide X 13 ft high

•Can move DUSEL supplies at 1140 tons/week to 7500 tons/week depending on shift schedule used.

(SNOLab: 336 tons/week)

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Rock Handling System

80 ton trucks dump rock at crusher.

Gyratory crusher reduces to –4 in.

1 mile PC1 and 10.5 mile long PC2 underground conveyors.

4 mile long PC3 surface conveyor to mill site.

•40,000 tons per day capacity

•Mine currently producing about 30,000 tons per day

•Maximum planned DUSEL production 3,000 tons per day

•DUSEL rock will be dumped at the crusher on the 7065 level,

•A fee ($/ton) will be charged for rock removal

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Henderson DUSEL Layout

Central Campus Elev. 6800 ft, (4300 mwe)

Midway CampusElev. 5850 ft, (5100 mwe)

Lower CampusElev. 4900 ft. (5800 mwe)

Internal Shaft

Access Ramps

EarthLab/GeoscienceArea

Silver PlumeGranite

Silver PlumeGranite

Urad Porphyry

7065 Level

7500 Level

Shaft

Red Mountain Porphyry

Henderson Granite

Primos

Porphyry

Henderson Orebody

Harrison MountainElev. 12,300 ft

Red MountainElev. 12,300 ft

1st Drill Hole

2nd Drill Hole

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RQD DUSEL Exploration Hole 001

Section

Plan

RQD90-10075-9050-7525-50< 25

Average RQD = 92 (Very Good)Three < 10 ft fracture zones

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LA Ramp

Primary Access Ramp

Central CampusElev. 6,800 ft(4300 mwe)

Secondary Access Ramp

PC2 Conveyor to Mill Site

7065 LevelCrusher

7500 shaft station

DC1 Ramp

7625 shaft station

PC1 Conveyor

Dedicated Exhaust Drift

Exhaust air

Fresh air

Henderson DUSEL Central Campus Access

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Access Ramps

Central Campus Elev. 6800 ft

Midway Campus Elev. 5850 ft

Lower Campus Elev. 4900 ft

EarthLab/GeoscienceArea

7500 Level

7065 Level

Internal Shaft 2nd Drill Hole

1st Drill Hole

Secondary Access Ramp

Primary Access Ramp

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Ramps

Central Campus Elev. 6800 ft

Primary Access Ramp(to main shaft)

Ramp to Midway Campus

Secondary Access Ramp(to crusher)

Internal Shaft

Exhaust Drift

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Internal Shaft (winze) – Top at Central Campus

•20 ft diameter

•Concrete lined

•Capacity 5 ton

•Capacity 20 people

•Sink top down

•Keep sinking bucket for hoisting Lower Campus excavation rock

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Shaft Cross Section

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Access Ramp Cross Sections

Muck Haulage Shipping Container

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Upper Campus Layout

8100 Shop(2500 mwe)

7500 Level(3300 mwe)

#2 Shaft

Ventilation Shaft

Mining Area

PC2 Conveyor to Mill Site

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Upper Campus Layout

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Central & Lower Campus Isometric

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Central & Lower Campus Building Blocks

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Central Campus Layout

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Central Campus Layout w/ Large Multi-Purpose Detector

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Lower Campus

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shopInfrastructure Design Life Criteria

• Suggested initial design life (capacity only)• Lab life—50? years

• Drift cross section—sized for full expansion

• Duct size—20 years

• Power conductors—20 years

• Power transformers—10 years

• Chiller piping—20 years

• Chiller plant—10 years

• Communications—10 years

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Lab vs. Infrastructure Development Plan

Lab Infrastructure

Day 1

Year 5

Year 10

Year 20

Year 300

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4

6

8

10

12

0 5 10 15 20 25 30 35

Year

La

b &

In

fra

str

uc

ture

Siz

e

Lab Infrastructure

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Development Sequence

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Fire & Life Safety Concept

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shopLower Campus FLS Provisions

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shopLower Campus FLS Provisions

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Fire & Life Safety Next Steps

• Meeting with MSHA and OSHA Regional offices on March 30, 2006

• Meeting with Clear Creek County building code officials on March 31, 2006

• Objective—MOU defining jurisdictions, codes, etc.

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Henderson DUSEL System Design

• Ventilation System

• Electrical System

• Incl. redundant, backup and emergency systems

• Fire and Life Safety

• Compartmentalization

• Monitoring & alarm

• Fire suppression

• Fire separations

• Egress routes & exit indicators

• Security stations

• Refuge Chambers

• Evacuation Routes

• Water & Wastewater Systems

• Data Systems

• Personnel control

• Control room w/ CCTV

• Cameras

• Personnel monitors

• Paging system

• Emergency & rescue systems

• Ambulance & fire truck

• Emergency cabinets

• Blast doors

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shopSystem Conceptual Design

• Basic services:• Provided to occupied Upper, Central and Lower campus

areas

• Power, air, potable water, fiber communications, lighting, emergency safety systems and selected drainage

• Ventilation systems:• Provided to Upper, Central & Lower Campuses

• Basic normal and emergency ventilation

• Distribution systems

• Central services:• Terminate at the experiment caverns for tenant connections

• Fresh air, chilled water, power, process piping, communications, and safety systems

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Ventilation & Cooling Design Criteria

• Virgin rock surface temperatures:• 90°F at upper campus

• 107°F at central campus

• 142°F at lower campus

• Projection of bore hole temperature readings

• Heat transfer coefficient• 0.098 Btu / hr-ft2 -°F after 720 days

• Based upon published data

• Mine ventilation air• Supplied to the central campus at 78°F

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Ventilation Systems

• Access & egress tunnel ventilation

• Normal Upper, Central & Lower campus ventilation• Interconnecting drifts ventilated using mine air (no A.C.)

• Caverns have conditioned air (chilled water coils, electric heating coils to control humidity, filtration)

• Clean space ventilation system

• Safety ventilation systems• Compartmentalization smoke ventilation

• Smothering gas ventilation

• Central exhaust system

• Special exhaust system• Special process exhaust, toilets, flammable liquid, etc.

• 10,000 cfm each at Central & Lower Campus

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Cooling

• Each campus will have a chilled water loop

• Estimated Immediate Cooling Load• Upper Campus 25 Tons

• Central Campus 85 Tons

• Lower Campus 175 Tons

• Estimated Future Cooling Load• Upper Campus 90 Tons

• Central Campus 395 Tons

• Lower Campus 430 Tons

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Plumbing

• Water systems• Potable via bottles

• Non potable from mine system, stored in tanks

• Sanitary waste• Lift station to a holding tank, periodic transfer to surface

• Gray water• 500 gpm total flow

• Sumps at Central, Midway and Lower Campus

• Pumped into the Henderson mine water system

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Process Utilities & Fire Protection System

• Process utilities• Central nitrogen gas system

• Compressed gas system

• Clean dry compressed air

• Cryogen relief

• De-ionized water system

• Fire protection system• Each campus will have a wet pipe sprinkler system

• Drift standpipe systems

• Fire protection water storage tanks

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Lighting

• Normal lighting• Caverns 30 foot-candles (either metal halide or fluorescent

depending upon height)

• Office, lunch, shops at 50 fc

• Miscellaneous at 20 fc

• Egress routes at 1 fc

• Emergency lighting

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Power

• New feed from the surface at 13,800 V

• Unit substations at each campus• 277/480V for lighting & power to mechanical systems

• 120/208V for receptacles

• Demand• All campuses, immediate: 2975 kVA

• All campuses, future increment: 3990 kVA

• All campuses, total: 6965 kVA

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Emergency Systems

• Emergency power

• Fire alarm system

• Surveillance cameras

• Access control

• Security

• Duress alarm

• Asset locator

• Personnel emergency device & tracking

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Communications

• Backbone cabling• Single-mode fiber

• 10-gigabit Ethernet

• 192 strands of fiber from surface and to each campus

• Campus cabling• Category 6 unshielded twisted pair

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Site Placement

• Visitor Center – Interface with Public

• Parking – Relationship to Office

• Offices, Laboratories, Warehouse and Shops – Achieve a campus grouping of buildings

• Dormitory & Cafeteria - Location to be determined, near campus

• Future Expansion - Post Mine closure

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Surface Buildings

• Surface Building Program• Visitor’s Center total 50,000 sf to yr 15 30,000 sf

• Admin/Offices/Laboratories total 85,000 sf to yr 15 65,000 sf

• Dormitory & Cafeteria total 35,000 sf to yr 15 35,000 sf

• Assembly, Shops & Storage total 25,000 sf to yr 15 25,000 sf

• Existing Facilities (available after about 2026)• Office Building 87,759 sf

• Surface Shop 26,000 sf

• Shaft Hoist House 9,600 sf

• Surface Warehouse 14,000 sf

• Building reuse issues• DUSEL program needs & phased buildout

• Existing building locations