Method of extracting ore using tunnel boring machine

Abstract

A method of extracting mineral ore with a tunnel boring machine can include positioning the TBM in an initial chamber adjacent to a mineral field; boring a first tunnel into the mineral field aligned with the initial chamber, while transporting muck containing the ore away from the first tunnel; and retracting the TBM out of the first tunnel and back into the initial chamber. The method can further include pouring a grout plug at a proximal end of the first tunnel, and boring a second tunnel with the TBM through the grout plug and into the mineral field laterally offset from the initial chamber. The second tunnel can be bored by advancing the TBM from the initial chamber along an S-curve path having a first curve away from the first tunnel and a second curve toward the first tunnel, after which the second tunnel is parallel with the first tunnel.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A method of extracting mineral ore from a mineral field with a tunnel boring machine, the method comprising:
 positioning the tunnel boring machine in an initial chamber adjacent to the mineral field;   boring a first tunnel into the mineral field with the tunnel boring machine, the first tunnel being laterally aligned with the initial chamber, wherein during the boring of the first tunnel, muck produced from the boring containing the mineral ore is transported away from the first tunnel and through the initial chamber;   after the tunnel boring machine bores the extent of the first tunnel, retracting the tunnel boring machine out of the first tunnel and back into the initial chamber;   pouring a first grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the first tunnel;   boring a second tunnel through the first grout plug into the mineral field with the tunnel boring machine, the second tunnel being laterally offset from the initial chamber, wherein:
 the tunnel boring machine bores the second tunnel by advancing from the initial chamber along a first S-curve path having a first curve away from the first tunnel and a second curve toward the first tunnel; 
 after traveling along the first S-curve path, the tunnel boring machine is advanced parallel to the first tunnel to the extent of the second tunnel; and 
 during the boring of the second tunnel, muck produced from the boring containing the mineral ore is transported away from the second tunnel and through the initial chamber; and 
   after the tunnel boring machine bores the extent of the second tunnel, retracting the tunnel boring machine out of the second tunnel and back into the initial chamber.   
     
     
         2 . The method of  claim 1 , further comprising:
 after the tunnel boring machine is retracted out of the second tunnel and back into the initial chamber, pouring a second grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the second tunnel;   boring a third tunnel through the second grout plug into the mineral field with the tunnel boring machine, the third tunnel being laterally offset from the initial chamber on an opposite side of the first tunnel from the second tunnel, wherein:
 the tunnel boring machine bores the third tunnel by advancing from the initial chamber along a second S-curve path having a first curve away from the first tunnel and a second curve toward the first tunnel; 
 after traveling along the second S-curve path, the tunnel boring machine is advanced parallel to the first tunnel to the extent of the third tunnel; and 
 during the boring of the third tunnel, muck produced from the boring containing the mineral ore is transported away from the third tunnel and through the initial chamber; and 
   after the tunnel boring machine bores the extent of the third tunnel, retracting the tunnel boring machine out of the third tunnel and back into the initial chamber.   
     
     
         3 . The method of  claim 2 , further comprising:
 after the tunnel boring machine is retracted out of the third tunnel and back into the initial chamber, pouring a third grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the third tunnel;   boring a fourth tunnel through the third grout plug into the mineral field with the tunnel boring machine, the fourth tunnel being laterally offset from the initial chamber on an opposite side of the second tunnel from the first tunnel, wherein:
 the tunnel boring machine bores the fourth tunnel by advancing from the initial chamber along a third S-curve path having a first curve away from the first and second tunnels and a second curve toward the first and second tunnels; 
 after traveling along the third S-curve path, the tunnel boring machine is advanced parallel to the first and second tunnels to the extent of the fourth tunnel; and 
 during the boring of the fourth tunnel, muck produced from the boring containing the mineral ore is transported away from the fourth tunnel and through the initial chamber; and 
   after the tunnel boring machine bores the extent of the fourth tunnel, retracting the tunnel boring machine out of the fourth tunnel and back into the initial chamber.   
     
     
         4 . The method of  claim 3 , further comprising:
 after the tunnel boring machine is retracted out of the fourth tunnel and back into the initial chamber, pouring a fourth grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the fourth tunnel;   boring a fifth tunnel through the fourth grout plug into the mineral field with the tunnel boring machine, the fifth tunnel being laterally offset from the initial chamber on an opposite side of the third tunnel from the first tunnel, wherein:
 the tunnel boring machine bores the fifth tunnel by advancing from the initial chamber along a fourth S-curve path having a first curve away from the first and third tunnels and a second curve toward the first and third tunnels; 
 after traveling along the fourth S-curve path, the tunnel boring machine is advanced parallel to the first and third tunnels to the extent of the fifth tunnel; and 
 during the boring of the fifth tunnel, muck produced from the boring containing the mineral ore is transported away from the fifth tunnel and through the initial chamber; and 
   after the tunnel boring machine bores the extent of the fifth tunnel, retracting the tunnel boring machine out of the fifth tunnel and back into the initial chamber.   
     
     
         5 . The method of  claim 1 , wherein the first and second tunnels are bored to a length from about 1500 m to about 3000 m from a distal end of the initial chamber. 
     
     
         6 . The method of  claim 1 , wherein the mineral ore extracted from the first and second tunnels is transported through the initial chamber by a muck conveyor system operably coupled to the tunnel boring machine. 
     
     
         7 . The method of  claim 1 , wherein the mineral ore extracted from the first and second tunnels is transported from the initial chamber out of a production shaft extending from the ground into the initial chamber. 
     
     
         8 . The method of  claim 1 , wherein the first and second curves each have a radius of about 300 m. 
     
     
         9 . The method of  claim 1 , wherein the initial chamber has a length of about 400 m or greater. 
     
     
         10 . The method of  claim 1 , wherein a vertical height of the first tunnel is different than a vertical height of the second tunnel. 
     
     
         11 . The method of  claim 3 , wherein a vertical position of the first tunnel with respect to the initial chamber is different than a vertical position of the second tunnel, wherein a vertical position of the third tunnel with respect to the initial chamber is different than a vertical position of the fourth tunnel, wherein the first and fourth tunnels have the same vertical position with respect to the initial chamber, and wherein the second and third tunnels have the same vertical position with respect to the initial chamber. 
     
     
         12 . The method of  claim 1 , wherein the first tunnel has a full bore portion positioned above a benched bore portion in a stacked configuration. 
     
     
         13 . A method of extracting mineral ore from a mineral field with a tunnel boring machine, the method comprising:
 positioning the tunnel boring machine in an initial chamber adjacent to the mineral field;   boring a first tunnel into the mineral field with the tunnel boring machine, the first tunnel being laterally aligned with the initial chamber;   after the tunnel boring machine bores the extent of the first tunnel, retracting the tunnel boring machine out of the first tunnel and back into the initial chamber;   pouring a first grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the first tunnel;   boring a second tunnel through the first grout plug into the mineral field with the tunnel boring machine, the second tunnel being laterally offset from the initial chamber, wherein:
 the tunnel boring machine bores the second tunnel by advancing from the initial chamber along a first S-curve path having a first curve away from the first tunnel and a second curve toward the first tunnel; and 
 after traveling along the first S-curve path, the tunnel boring machine is advanced parallel to the first tunnel to the extent of the second tunnel; 
   after the tunnel boring machine bores the extent of the second tunnel, retracting the tunnel boring machine out of the second tunnel and back into the initial chamber;   pouring a second grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the second tunnel;   boring a third tunnel through the second grout plug into the mineral field with the tunnel boring machine, the third tunnel being laterally offset from the initial chamber on an opposite side of the first tunnel from the second tunnel, wherein:
 the tunnel boring machine bores the third tunnel by advancing from the initial chamber along a second S-curve path having a first curve away from the first tunnel and a second curve toward the first tunnel; and 
 after traveling along the second S-curve path, the tunnel boring machine is advanced parallel to the first tunnel to the extent of the third tunnel; and 
   after the tunnel boring machine bores the extent of the third tunnel, retracting the tunnel boring machine out of the third tunnel and back into the initial chamber,   wherein during the boring of the first, second, and third tunnels, muck produced from the boring containing the mineral ore is transported away from the respective tunnel and through the initial chamber.   
     
     
         14 . The method of  claim 13 , further comprising:
 after the tunnel boring machine is retracted out of the third tunnel and back into the initial chamber, pouring a third grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the third tunnel;   boring a fourth tunnel through the third grout plug into the mineral field with the tunnel boring machine, the fourth tunnel being laterally offset from the initial chamber on an opposite side of the second tunnel from the first tunnel, wherein:
 the tunnel boring machine bores the fourth tunnel by advancing from the initial chamber along a third S-curve path having a first curve away from the first and second tunnels and a second curve toward the first and second tunnels; 
 after traveling along the third S-curve path, the tunnel boring machine is advanced parallel to the first and second tunnels to the extent of the fourth tunnel; and 
 during the boring of the fourth tunnel, muck produced from the boring containing the mineral ore is transported away from the fourth tunnel and through the initial chamber; and 
   after the tunnel boring machine bores the extent of the fourth tunnel, retracting the tunnel boring machine out of the fourth tunnel and back into the initial chamber.   
     
     
         15 . The method of  claim 14 , further comprising:
 after the tunnel boring machine is retracted out of the fourth tunnel and back into the initial chamber, pouring a fourth grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the fourth tunnel;   boring a fifth tunnel through the fourth grout plug into the mineral field with the tunnel boring machine, the fifth tunnel being laterally offset from the initial chamber on an opposite side of the third tunnel from the first tunnel, wherein:
 the tunnel boring machine bores the fifth tunnel by advancing from the initial chamber along a fourth S-curve path having a first curve away from the first and third tunnels and a second curve toward the first and third tunnels; 
 after traveling along the fourth S-curve path, the tunnel boring machine is advanced parallel to the first and third tunnels to the extent of the fifth tunnel; and 
 during the boring of the fifth tunnel, muck produced from the boring containing the mineral ore is transported away from the fifth tunnel and through the initial chamber; and 
   after the tunnel boring machine bores the extent of the fifth tunnel, retracting the tunnel boring machine out of the fifth tunnel and back into the initial chamber.   
     
     
         16 . The method of  claim 13 , wherein the first, second, and third tunnels are bored at a first mining tunnel layer at a first height above the initial chamber, and wherein the method further comprises:
 pouring a third grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the third tunnel;   boring a fourth tunnel into the mineral field with the tunnel boring machine, the fourth tunnel being laterally aligned with the initial chamber;   after the tunnel boring machine bores the extent of the fourth tunnel, retracting the tunnel boring machine out of the fourth tunnel and back into the initial chamber;   pouring a fourth grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the fourth tunnel;   boring a fifth tunnel through the fourth grout plug into the mineral field with the tunnel boring machine, the fifth tunnel being laterally offset from the initial chamber, wherein:
 the tunnel boring machine bores the fifth tunnel by advancing from the initial chamber along a third S-curve path having a first curve away from the fourth tunnel and a second curve toward the fourth tunnel; and 
 after traveling along the third S-curve path, the tunnel boring machine is advanced parallel to the fourth tunnel to the extent of the fifth tunnel; 
   after the tunnel boring machine bores the extent of the fifth tunnel, retracting the tunnel boring machine out of the fifth tunnel and back into the initial chamber;   pouring a fifth grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the fifth tunnel;   boring a sixth tunnel through the fifth grout plug into the mineral field with the tunnel boring machine, the sixth tunnel being laterally offset from the initial chamber on an opposite side of the fourth tunnel from the fifth tunnel, wherein:
 the tunnel boring machine bores the sixth tunnel by advancing from the initial chamber along a fourth S-curve path having a first curve away from the fourth tunnel and a second curve toward the fourth tunnel; and 
 after traveling along the fourth S-curve path, the tunnel boring machine is advanced parallel to the fourth tunnel to the extent of the sixth tunnel; and 
   after the tunnel boring machine bores the extent of the sixth tunnel, retracting the tunnel boring machine out of the sixth tunnel and back into the initial chamber,   wherein during the boring of the fourth, fifth, and sixth tunnels, muck produced from the boring containing the mineral ore is transported away from the respective tunnel and through the initial chamber, and   wherein the fourth, fifth, and sixth tunnels are bored at a second mining tunnel layer at a second height above the initial chamber lower than the first height.   
     
     
         17 . The method of  claim 16 , further comprising:
 pouring a sixth grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the sixth tunnel   boring a seventh tunnel into the mineral field with the tunnel boring machine, the seventh tunnel being laterally aligned with the initial chamber;   after the tunnel boring machine bores the extent of the seventh tunnel, retracting the tunnel boring machine out of the seventh tunnel and back into the initial chamber;   pouring a seventh grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the seventh tunnel;   boring an eighth tunnel through the seventh grout plug into the mineral field with the tunnel boring machine, the eighth tunnel being laterally offset from the initial chamber, wherein:
 the tunnel boring machine bores the eighth tunnel by advancing from the initial chamber along a fifth S-curve path having a first curve away from the seventh tunnel and a second curve toward the seventh tunnel; and 
 after traveling along the fifth S-curve path, the tunnel boring machine is advanced parallel to the seventh tunnel to the extent of the eighth tunnel; 
   after the tunnel boring machine bores the extent of the eighth tunnel, retracting the tunnel boring machine out of the eighth tunnel and back into the initial chamber;   pouring an eighth grout plug ahead of the tunnel boring machine in at least a portion of a proximal end of the eighth tunnel;   boring a ninth tunnel through the eighth grout plug into the mineral field with the tunnel boring machine, the ninth tunnel being laterally offset from the initial chamber on an opposite side of the seventh tunnel from the eighth tunnel, wherein:
 the tunnel boring machine bores the ninth tunnel by advancing from the initial chamber along a sixth S-curve path having a first curve away from the seventh tunnel and a second curve toward the seventh tunnel; and 
 after traveling along the sixth S-curve path, the tunnel boring machine is advanced parallel to the seventh tunnel to the extent of the ninth tunnel; and 
   after the tunnel boring machine bores the extent of the ninth tunnel, retracting the tunnel boring machine out of the ninth tunnel and back into the initial chamber,   wherein during the boring of the seventh, eighth, and ninth tunnels, muck produced from the boring containing the mineral ore is transported away from the respective tunnel and through the initial chamber, and   wherein the seventh, eighth, and ninth tunnels are bored at a third mining tunnel layer at a third height above the initial chamber lower than the first and second heights.   
     
     
         18 . The method of  claim 16 , wherein the proximal position of the first, second, and third tunnels is further from the initial chamber than the proximal position of the fourth, fifth, sixth, seventh, eighth, and ninth tunnels. 
     
     
         19 . The method of  claim 17 , wherein the proximal position of the fourth, fifth, and sixth tunnels is further from the initial chamber than the proximal position of the seventh, eighth, and ninth tunnels.