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Article

Comminution Flowsheet Energy Requirements of a New Narrow-Vein Mining Method

1
Faculty of Engineering and Applied Science, Memorial University of Newfoundland, St. John’s, NL A1B 3X5, Canada
2
Novamera Inc., Oakville, ON L6H 5S9, Canada
*
Author to whom correspondence should be addressed.
Energies 2025, 18(12), 3119; https://doi.org/10.3390/en18123119
Submission received: 7 February 2025 / Revised: 22 April 2025 / Accepted: 7 May 2025 / Published: 13 June 2025
(This article belongs to the Topic New Advances in Mining Technology)

Abstract

Narrow-vein deposits have historically been valuable in producing gold, tin, copper, silver, lead, and zinc. Developing these mineral resources is sometimes challenging due to economic and safety concerns. Given the small to medium scale of production, narrow-vein mining could be labor-intensive with increased exposure of the miners to hazardous conditions. A safe, mechanized, efficient, and sustainable method can be invaluable to operators looking to develop narrow-vein mineral resources. The comminution circuit (consisting of crushing and grinding) is downstream of most mineral resources’ extraction processes. Comminution is significantly energy-intensive, consuming almost half of the energy supplied to a mineral-processing activity. Thus, several engineers have investigated the continued development of sustainable narrow-vein mining and comminution technologies. This journal article focuses on a developed innovative, safe, mechanized, and continuous narrow-vein mining technology that has further made accessing narrow-vein deposits more economically feasible and efficient while reducing dilution of ores. The article also extensively presents the impact of this new mining approach on the daily production of the operation and the observed particle size distributions of the day-to-day operational output. Subsequently, the article evaluates and presents the impact of the new procedure of mineral extraction on the resultant size of the cuttings generated as well as the expected energy input of the comminution process downstream of the mining operation. The novelty of the mining method upon which this work is based is improved capital expenditure and reduced dilution. With the new mining method, otherwise-uneconomic narrow-vein deposits can be accessed.

1. Introduction

Narrow-vein deposits are thin tabular orebodies which occur in intermediate and steeply dipping fissures and fractures. These veins are typically classified as seams whose widths lie between 0.1 and 3 m (sometimes up to 6 m) with dip ranging from 20–55° or exceeding 55° [1,2,3,4]. Narrow veins are sources of important minerals like silver, gold, tin, and uranium. Narrow-vein operations are located all over the world—Europe, Australia, Asia, South America, Canada, and Africa [5].
There are several narrow-vein mining methods which include cut-and-fill, mechanized cut-and-fill, room-and-pillar mining, shrinkage stoping, longitudinal retreat mining, sublevel longhole, and open-stope method [4,5]. Some are labour-intensive (e.g., shrinkage stoping), while others require high initial capital expenditure (e.g., sublevel longhole and cut-and-fill—mechanized) [4]. The dominant narrow-vein mining method in Australia and Canada is longhole stoping [2], while the recorded methods in South African mines are the conventional room-and-pillar and longhole stoping [6]. Over the last two decades, there has been a shifting trend from traditional small-scale narrow-vein mining methods to mechanized methods [2,6,7]. Longhole-stoping method, a highly mechanised method, results in reduced mining costs per tonne and increased rate of production; however, it leads to increased dilution, which impacts the ore grade as well as the overall cost of mineral processing. As such, careful consideration is given in the selection of the mining method. Narrow-vein mining methods can be classified into three categories: “conventional” labour-intensive methods, mechanized methods, and steep narrow coal longwall techniques [8]. The choice of the narrow-vein mining method depends on the nature of the orebody (geometry, depth, and orientation). It is also critical to select a mining method that minimizes dilution.
While the conventional narrow-vein mining methods result in reduced dilution of the produced ore and require low capital expenditure, they are associated with high operating expenditure. Dilution is the process by which non-ore materials contaminate ore pilot material during the mining process [9]. Hence, dilution lowers the recovered ore compared to the in-situ ore and increases the ore-processing cost. Development of narrow- vein deposits are thus considered challenging because of the small lateral extent of the deposit, the significant cost of evaluating the resources, the high cost of mining, and the resultant low profit margin [1]. Additional challenges to mining narrow-vein deposits arise from the width of the deposit, its geometry, and the interaction of the narrow-vein deposit with the neighbouring rock mass [7].
Recently, there has been an identified application of rotary drilling in the sustainable mining of narrow-vein deposits. Using this large-diameter rotary drilling method, selective extraction of narrow-vein deposits with resultant minimal dilution can be achieved. While every rotary drilling combines rock indentation and rotary cutting under a static applied compressive load to continually remove rock surfaces, the drilling setup varies according to the intended application. In a raise-boring operation, a vertical or inclined shaft is excavated. A pilot hole is drilled downward to achieve this, followed by back reaming. In a tunnel-boring application, the tunnel-boring machine excavates a horizontal underground tunnel. The difference in the drilling setups could explain why the research on large-diameter drilling performance falls under two main categories: raise boring machine or tunnel boring machine performance and optimization. Several studies have been conducted to investigate the drilling performance of tunnel boring machines and raise boring machines [10,11,12,13,14,15,16,17,18].
The recently proposed application of large-diameter drilling in mining narrow-vein deposits will result in the feasible development of otherwise uneconomic deposits. This ore-extraction method is a continuous, mechanized, safe, and sustainable method. This large-diameter drilling (LDD) method may be completed in one pass using a pile-top drilling rig; or in two passes using pilot-hole drilling with a diamond drilling rig (or coring) and large-diameter drilling (equivalent to forward reaming) with a pile-top drilling rig. Unlike the tunnel boring application, mining by drilling can be used for steep, narrow veins. Though the raise boring might resemble the LDD technique in its ability to produce a vertical or an inclined shaft, the large-diameter hole is created through back reaming. A patented steerable system has been developed to replace the pilot hole approach. Table 1 shows the cost comparison of the narrow-vein mining methods.
Three critical differences in these three different approaches of large-diameter drilling are the direction of the axis of the drilled hole, the source of the resultant normal force applied on the rock face, and the evacuation mode of the generated rock cuttings. Tunnel boring machines (TBMs) bore horizontal tunnels, raise boring machines (RBMs) bore vertical or inclined shafts through back reaming, while this LDD technique drills an inclined hole along the length of an ore body. The entire normal force applied on the rock face during rock excavation by the TBM or the RBM results from the applied machine thrust.
On the other hand, the effective normal force applied during the LDD technique for mining application depends on the applied machine thrust, the buoyed weight of the drilling assembly, and the frictional forces resulting from the axial and rotary motions of the drillstring. The rock excavated (muck) in tunnel boring is removed dry through a belt conveyor system. The excavated rock which is generated through raise boring is removed dry at the lower level of the mine using a conveyance system. In contrast, the rock cuttings resulting from the LDD drilling technique are circulated to the surface during the drilling operation through direct flush with water or airlift-assisted reverse circulation methods. This work delves into the size and shape of the cuttings resulting from this new narrow-vein mining method. Additionally, this work will present the observed impact of the size of the generated rock cuttings on the energy required for comminution during mineral processing.
Evaluation of size and shape of cuttings generated during rotary drilling gives valuable insight into the performance of the rock-cutting process. The cutting size increased with increasing weight-on-bit for all the bits used [20]. The researchers observed that the efficient drilling (identified by optimal specific energy consumption) produced large cuttings. The penetration rate using the degree of coarseness, cuttings dimensions, and mean particle size was estimated to understand the particle sizes [21]. Several drill cuttings samples collected during a percussive drilling operation were sieved to get particle size distribution.
Computed values of particles’ mean size, coarseness index (a non-dimensional index obtained with the sum of cumulative weight percentages of a particular size), and specific surface areas regressed against drilling penetration rates. The note shows that the rate of penetration increases as the coarseness index and mean size diameter increase. On the other hand, the penetration rate decreased as the specific surface area increased. Finally, using the multi-regression method, a relationship between penetration rate, coarseness index, and mean particle radius was established [21]. The measured rates of penetration were plotted against the estimated penetration rates, with the results showing a good fit, thus validating the predicted penetration rate model.
Through laboratory experiments, some researchers showed the relationship between coarseness index and the specific energy for cutting tests conducted on different rock samples with varying diameters of cutters (conical cutter, V-shape disc cutter, constant cross-section disc cutter, and chisel picker cutter) [22]. They showed that the specific energy decreased with increasing coarseness index for all considered rock samples. They also showed that the coarseness index increased as the depth of cut increased. Ultimately, the authors established relationships between specific energy and coarseness indices for different rocks and disc cutters.
The connection among the mechanical specific energy, cuttings morphology, and PDC cutter geometry was further illustrated [23]. Through experimental methodology, the authors sought to evaluate the effect of cutting geometry on mechanical specific energy and the relationship between the structure of the cuttings and drilling parameters. From the drill-off tests carried out on confined Carthage Marble rock at varying rotary speeds and depths of cuts, the authors showed an inverse relationship between the mechanical specific energy (MSE) and depth of cut. They also showed that the MSE decreased as the minimum particle size increased. However, they could not establish a relationship between MSE and maximum particle size.
Other researchers used photographic analysis to determine the particle size of cuttings generated during the boring of a 6.3 m diameter exploration tunnel in a hard rock using the open tunnel boring machine [24]. They then went on to show a relationship between the coarseness index and several drilling parameters (normal cutter force, penetration rate, specific energy, and field penetration index). In addition to being valuable in the prediction and evaluation of the rotary drilling performance, the results of cuttings size analyses provide key inputs for designing the milling circuit and predicting the required energy for the system.
This study presents the cuttings sampling strategy noting the various sources along the circulation circuit, the cutting inventory, the different applied methodologies of cuttings size analysis, the particle size distribution of all the cuttings samples, and the results of the compositional analyses of some fine samples.
Comminution consumes at least forty percent of the energy utilized in mineral processing activity [25]. These most-used size–energy models are premised on the dependence of comminution energy requirement on the effective particle size of the product of the milling device [15]. These models, shown in Equations (1)–(3), were developed by Rittinger, Bond, and Kick, respectively [25].
e = W 1 r p 1 r f
e = 10 × W 1 r p 1 r f
e = W L n r f r p
An updated model is shown in Equation (4) [25]. With published data, the researcher developed a relationship for the exponential function, f(r). Equation (5) shows how f(r) is computed.
e = W 1 r p f 1 r f f
f r = f = 1 2 r r o 1 + 1 3
where e = specific energy (enthalpy) (kilowatt hours per metric ton), W = Work Index (kilowatt hours per metric ton), rp = P80 (μm), rf = F80 (μm), and ro = model parameter = 60 μm.
After presenting the particle size analysis of the collected cuttings samples, this work will evaluate the impact of these cuttings’ sizes on comminution energy requirements during mineral processing.

2. Materials and Methods

Figure 1 shows the circulation system for the airlift-assisted cuttings evacuation method and rock cuttings sampled at various points along the circulation circuit—effluent line (1) ahead of the settling tank (2) and sedimentation tanks (3).
Figure 2 shows the effluent line (Sampling Point 1) and the settling pit tank (Sampling Point 2). The cuttings sampled from Point 1 (Effluent Line) represent the size of the produced cuttings at different depths; the research team mapped these depths to the lithology drilled, the applied drilling parameters, and the circulation mode. The field operations team collected these cuttings every 30 min during the daily drilling operation. Samples collected from Point 2 (Settling Pit) show the daily production (which would subsequently be the feed for mineral processing). The Geotube® system is only used at the end of the project if there is need to remove solids suspended in water before releasing the water to the environment.
The sedimentation tank, which is downstream of the settling pit, is presented in Figure 3. The cuttings obtained from the four compartments of the sedimentation tank spanned across the entire 4-month drilling campaign. These cuttings provide insight into the cuttings’ separation capacity of the settling pit and into the quality of water (including the size of the suspended fines) recirculated into the well for reuse.
Section 2.1 presents the inventory of all the sampled cuttings obtained during the drilling trial.

2.1. Cuttings Inventory

Table 2 presents the cuttings inventory showing the different sampling sources of the cuttings. The cuttings sampled from Point 1 (different boreholes), shown in Appendix A Table A1, Table A2 and Table A3, were labeled by the research team to indicate the time of collection, borehole number (from which they were generated), and circulation mode. With these indicators, the other parameters (e.g., collection depth, lithology, and drilling parameters) can be deduced from the drilling data record (like ROP, flow rate) and core description. Cuttings samples obtained from Sampling Point are in Table A4 while Table A5 shows the inventory of the cuttings from Point 3.
Figure 4 shows the samples collected from Sampling Points 1–3.

2.2. Methodology for Cuttings Size Analysis

The decision on the method of particle size analysis for each cuttings sample depended on the nature of the cuttings and the maximum size of the particles. Table 3 presents the adopted ASTM test protocol based on the maximum size of the particle in the cutting sample. ASTM D6913/D6913-17: Standard Methods for Particle-Size Distribution (Gradation) of Soils Using Sieve Analysis [27] provides the test method that employs the square sieve criterion in evaluating the particle size distribution of cuttings whose sizes range from 75 mm to 75 μm. The gradation, proportion by mass of various particle sizes, is presented as a table (sieve size and percent passing) or in graphical format (percent passing versus logarithm of the sieve size in mm).
This standard is vital for analysis of particle size distribution. The cuttings sample as required by the standard did not contain the following: fibrous peat, organic solvents, oil, asphalt, wood fragments, or cementitious components (e.g., cement, fly ash, and lime). ASTM D6913/D6913-17 documents the apparatus required for the test which include a standard sieve set, balances, mechanical sieve shakers, sieving containers, quartering accessories, and low-temperature drying oven. In this work, the US Standard Sieve Series was used. ASTM D6913/D6913-17 also stipulates guidelines for apparatus preparation, specimen preparation, sieving procedure, and results analyses and verification. The standard stipulates that no material should be retained on the top sieve in the finer sieve set (same size as the designated separating sieve). And when there is, the fractional percent retained shall not exceed 2%.
The sedimentation by hydrometer method is utilized to determine gradation for samples whose particle sizes lie between 75 μm and 0.2 μm. ASTM D7928-21e1: Standard Test Method for Particle-Size Distribution (Gradation) of Fine-Grained Soils Using the Sedimentation (Hydrometer) Analysis provides guidelines for the quantitative determination of the gradation of fine-grained soils [28]. The particle size analyses results of the sedimentation method are presented as mass percent finer of this fraction versus the logarithm of the particle diameter. The sedimentation results are combined with the sieve analysis results to get a complete gradation curve. The apparatus for the sedimentation method includes the hydrometer, sedimentation cylinder, separation sieve, thermometric device, timing device, balance, drying oven, plate, specimen-mixing container, temperature-maintaining device, and dispersion apparatus. Section 10 of ASTM D7928-21e1 provides additional steps for the verification and preparation of apparatus—hydrometer, sieves, and sedimentation cylinder. Section 11 presents the procedure for the test while Section 12 shows the computational steps underpinning the resultant gradation curve. Sieving precision is not accurately defined for sieves for which 99% or more of the specimen passes. Sieving precision is dependent on the quantity of the specimen retained on the given sieve. Sieve overloading, particle shape, and gradation curve affect sieving precision. For sedimentation, the estimate of precision is typically based on the results from interlaboratory test programs. There is no reference accepted for bias for sieve analysis, and for sedimentation method as such, bias cannot be determined.
Table 3. Cuttings size analysis protocol.
Table 3. Cuttings size analysis protocol.
Sample SourceCirculation ModeMaximum Particle
Size (mm)
Testing
Protocol
Type of Particle Size
Analysis Method
Sieve Sizes (mm)/
Principle
Sampling Point 1 Direct Flush
(Shallow Depth)
4.75ASTM D6913
/D6913-17
Single sieve-set sieving
(Dry Method)
Single Sieve Set
4.75, 2.00, 0.85, 0.452, 0.25, 0.15, 0.106 and 0.075 mm
Sampling Point 1Air Lift
Assisted Reverse Circulation
75.00ASTM D6913
/D6913-17
Composite
Sieving
(Dry Method)
Designated Separating Sieve
4.75 mm
Coarser Sieve Set
75, 50, 37.5, 25, 19, 9.5, 4.75 mm
Finer Sieve Set
4.75, 2.00, 0.85, 0.452, 0.25, 0.15, 0.106 and 0.075 mm
Sampling Point 2N/A75.00ASTM D6913
/D6913-17
ASTM C702
/C702 M-11 [29]
Composite Sieving
(Dry Method)
For Unbiased Quartering from large sample bag
Designated Separating Sieve
4.75 mm
Coarser Sieve Set
75, 50, 37.5, 25, 19, 9.5, 4.75 mm
Finer Sieve Set
4.75, 2.00, 0.85, 0.452, 0.25, 0.15, 0.106 and 0.075 mm
Sampling Point 3N/A<75 μmASTM D7928-21E1Sample was clumpy when dry but disintegrated on rubbing between two the thumb and the index fingerLeveraged terminal velocities based on Stoke’s law [28]
Figure 5 shows the setup of the single-sieve set sieving method, and it presents the different sieve sizes and the mechanical sieve shaker. As per the ASTM D6913/D6913-17 test standard, the pan and each sieve were first measured dry and empty, and their masses were recorded. Next, the sieves were arranged on the mechanical sieve shaker from coarsest to finest (top to down) with the empty pan below the finest sieve (75 μm). A known mass of cuttings sample, consistent with the recommended mass that will provide accurate results without overloading the sieve, was poured onto the topmost coarsest sieve (4.75 mm).
The sieve stack was covered with the lid and shaken (laterally and vertically) with the mechanical sieve shaker for 20 min. At the end of this sieving period, the mass of each sieve with the retained material was measured and documented. The percent passing for the single-sieve set sieving method was computed using the equation presented in page 23 of ASTM D6913/D6913M-17. The plot of percentage of the mass passing versus the logarithm of the sieve size (in mm) is the gradation of the cuttings sample. Samples obtained from Sampling Point 1 during air lift-assisted reverse circulation had particles whose sizes were up to 75 mm. In these instances, composite sieving was adopted with the designated sieve for splitting the sample into two fractions being 4.75 mm. Figure 6 shows the splitting of the sample ahead of the sieving of each sub-specimen. After the splitting of the specimen, each sub-specimen was sieved using a setup like that shown in Figure 5, with the difference being the size of the sieve in each sieve stack. Table 3 shows the size of sieves in the coarser sieve set and finer sieve set, respectively. The percent passing of the combined coarser and finer portions of the composite sieving method was computed using the equations presented on page 23 of ASTM D6913/D6913-17.
The cuttings samples collected from Sampling Point 2 (settling pit) over different days were quite large, and to obtain unbiased sample, ASTM C702/C702 M-11 was adopted. This standard recommended the use of a mechanical splitter as one of the methods for the unbiased reduction of large samples of cuttings to appropriate specimen size that can be tested utilizing the composite sieving method. Figure 7 presents the mechanical splitter that was used to obtain an unbiased specimen for composite sieve analysis. To test these samples, ASTM D6913/D6913-17 was also leveraged.
Two significant percentages are of note when quality-checking the results of a composite sieving process. These are the acceptable loss during washing or sieving and the acceptable fraction of finer portion retained. The acceptable loss during washing and sieving should be less than or equal to 0.5% of the original sieved mass. Without washing the coarser portion, this quantity corresponds to the mass of the coarser portion contained in the pan below the designated separating sieve (on completion of the sieving of the coarser portion). There should not be material retained on the topmost sieve of the finer sieve set (designated separating sieve). If there is, the fractional percentage retained should not be more than 2%. When this is the case, the percent passing data from the coarser sieve set will be accepted and used to determine the gradation of the cutting sample.
The samples collected from Sampling Point, the sedimentation tanks and Geotube®, were fines whose particle size analysis could not be obtained by sieving. For these samples, sedimentation by gravity method, ASTM D7928-21E1, was adopted for gradation. Figure 8 shows the setup for the sedimentation method.
The sedimentation analysis is premised on the concept that the larger particles fall through a fluid faster than smaller particles. The governing equation for calculating the terminal velocity of a spherical particle falling through a static liquid is provided by the Stokes’ Law. As the terminal velocity is proportional to the square of the particle diameter, the particles are sorted by size with respect to time and position when settling in a container of liquid.
Using a hydrometer, the density of the suspension of the rock cuttings was measured to determine the quantity of particles in suspension at a specific time and position. The density of the cuttings–water suspension was dependent on the concentration and specific gravity of the cuttings’ fine particles as well as on the amount of dispersant added. As such, each hydrometer measurement at an elapsed time was used to calculate the percentage of particles finer than the diameter given by Stokes’ Law. The series of readings provides the distribution of material mass as a function of particle size.

2.3. (Mineralogical) Composition Evaluation Using X-Ray Diffraction

In addition to the particle size analysis conducted on the fines, X-ray diffraction was carried out on the fine samples obtained from the sedimentation tanks and the Geotube®. This study was conducted at The Earth Resources Research and Analysis Facility (TERRA) at Memorial University of Newfoundland, St. John’s Campus to ascertain the (mineral) composition of these samples. X-ray diffraction is a non-destructive method of analyzing crystalline substances. In this setup, the X-rays are generated when copper was bombarded with focused electron beams. While the X-ray source was moved, the sample to be evaluated was kept in a fixed position. Additionally, the scintillation detector was moved. As per the XRD procedure, a powdered fine cuttings sample was irradiated with incident X-rays, and the intensities and scattering angles of the X-rays leaving the materials were subsequently measured. Based on the diffraction pattern, the composition of the sample was analyzed [30,31].
At the conclusion of the X-Ray Diffraction, the raw data was analyzed using MDI JADE version 9.3, a software provided by TERRA. We use ICDD PDF-2 database. To check the minerals whose peak signatures match those observed in the samples, RDB Minerals Database (which is appropriate for rocks) was used. As several minerals were suggested by MDI JADE, a knowledge of the geochemistry of the field test site was gathered from the literature. Additionally, knowledge of the water treatment process was required for complete interpretation of the XRD raw data as inorganic constituents which are foreign to rock deposits might be present as peaks in the XRD results.

3. Results

3.1. Results of the Cuttings Size Analyses

The results of the cuttings size analysis conducted on the three hundred and three (303) samples obtained during the field trial are shown in this section. Table A6, Table A7 and Table A8 present the results of the particle size analyses conducted on the cuttings obtained from Sampling Point 1. Table A9 presents the gradation of cuttings collected from Sampling Point 2 while Table A10 shows the particle size distributions of the cuttings obtained from Sampling Point 3. A screen was used in the effluent line (at Sampling Point 1) to obtain cuttings from the high-velocity hole effluent, leading to the possible loss of some fines from the obtained samples at Sampling Point 1. Sampling Point 2 provides a representation of the daily production and is an improvement over Sampling Point 1. Future studies will develop robust methodology to obtain cuttings samples from high-velocity hole effluent.
To evaluate the difference between the daily cuttings obtained from Sampling Point 1 and those collected from Sampling Point 2, a composite sample was created to represent the cumulative daily cuttings obtained from Sampling Point 1. The results of the gradation of these daily composite samples are shown in Table A11. Figure 9, Figure 10 and Figure 11 illustrate the gradation curves for cuttings collected from different sampling points. The cuttings collected from Sampling Point 1 during air lift-assisted reverse circulation were of similar particle size distribution as those obtained from the settling pit (Sampling Point 2) and the daily composite created for Sampling 1. This is because all the samples resulted from air lift-assisted reverse circulation mode.
Table 4 presents the mechanical properties of the drilled rock mass in the field based on the analyzed cores obtained from the pilot holes. Cuttings generated between 0 and 7 m were evacuated through direct flush while those generated from deeper intervals were cleaned using the air lift-assisted reverse circulation method.
To compare the grain sizes of the differing sources, percentiles, coarseness index (a non-dimensional index), coefficient of uniformity, and the coefficient of curvature of the gradation curves were computed for each particle size distribution. From the cumulative percentage retained of each mass, the coarseness indices were computed using documented methodology [22]. The uniformity coefficient (Cu), an important shape parameter, is defined as the ratio of the sixtieth percentile (D60) to the tenth percentile (D10). The uniformity coefficient implies that the smaller the quotient, the more uniform the gradation of the cutting sample.
Another important shape parameter is coefficient of curvature (Cc), which is calculated with the equation shown below (D30 is the thirtieth percentile). Equation (6) shows how Cc is computed.
C c = D 30 2 D 10 D 60
A sample with coefficient of curvature between 1 and 3 is considered well-graded provided the uniformity coefficient is more than 4 for gravel and more than 6 for sand. For mineral processing, the eightieth percentile (D80) is a valued size parameter for computing energy requirements for comminution. These computed values are presented in Table A12, Table A13, Table A14, Table A15 and Table A16 and Figure A1. For samples collected from Sampling Points 1 and 2, for the same mechanical energy expended, the following can be observed as is shown in Figure 12 and Figure 13.
D50quartz vein < D50 Mafic Massive Flow < D50Deep Mafic Ash Tuff < D50Shallower Mafic Ash Tuff
CI quartz vein < CI Mafic Massive Flow < CI Deep Mafic Ash Tuff < CI Shallower Mafic Ash Tuff
While it will be expected that the weaker fractured quartzite drilled in the shallower intervals will result in large-sized cuttings, the major determinant of the cuttings size was the mode of evacuations of the drilled rock. Use of direct flush circulation method in the shallow intervals resulted in fine-sized cuttings while with air lift-assisted reverse circulation applied in the deeper interval, large-sized cuttings were obtained. Table 5 shows the computed percentile and shape parameters for cuttings collected from Sampling Point 3.
Additional insight can be drawn from Figure 3 when reviewing the results in Table 5 as doing so enables the reader to compare the tabulated results with the tank layout and the direction of fluid flow during circulation. The mean grain sizes of the particles from Tanks 2 and 4 are slightly larger than those from Tanks 1 and 3. This can be attributed to the progression of flow. The Geotube® sample has larger particle sizes in all cases and this can possibly be due to flocculation of the grains resulting from water treatment.
In addition to the particle gradation analyses, the shape of some cuttings was analyzed. The shape and size of the cuttings have significant influence on cuttings transport, as the terminal velocity is proportional to the square of the particle diameter, where the particle is assumed to be spherical. As such, the degree of sphericity and the size of the cuttings are of importance. The geometry of the cuttings also enables the understanding of the efficiency of the drilling activity—hole cleaning and cuttings removal effectiveness and energy efficiency. The analysis of rock fragments produced in a laboratory cutting experiment showed that 85.6% of the selected cuttings were very platy and had very bladed shapes [32]. The longer the resident time of the cuttings in the hole, the longer they are reground with energy that would have otherwise been used for the cutting of fresh rock surface; and this newly applied energy is instead used to reduce the size of the previously produced rock fragments. Abrasion and selective transport during the drilling and cuttings transportation process affect the roundness and shape of the rock fragments [33]. The shape and roundness of some rock particles obtained during LDD were analyzed using Wadell’s rapid method for shape measurement [34,35]. Figure 14 shows the measurement of the particle diameters.
Subsequently, Zingg developed a system of classification of the particle shape as is shown in Table 6 below. This system was adopted to describe the shape of the sampled cuttings as is presented in Table 7. The classification shows that 57% of particles measured were formed in bladed shapes, 28.6% in rod-like shapes, and 14.3% in discoid shapes. Table 7 shows the outcome of the particle shapes evaluation.
The roundness of the rock fragment indicates the violence of transportation of the rock fragments [34]. The shape and roundness of rock particles, especially sediments, indicate the source of the deposit, as well as the transportation of the rock fragments to the final location [35].

3.2. Results of X-Ray Diffraction of Fine Cuttings Samples

The results of the composition analyses of these cuttings samples are shown in Figure A1, Figure A2, Figure A3 and Figure A4. The question marks besides the weight composition indicate that the user must be cautious in selecting the minerals from the suggested list. This was the reason why the authors of this article used the documented lithogeochemistry of the field test site prospect as well as the documented mineral occurrence in mafic and quartz veins to form the basis of the interpretation of the XRD results. Table 8 presents the summary of the results of the compositional analyses of these fine cuttings samples.

4. Discussion

The subsequent section provides the results of the particle size distribution analyses conducted on all the cuttings samples. To review the impact of these on mineral processing downstream of the mining site, the cuttings collected from the settling pit will be of interest. These cuttings represent the daily production and will eventually be transferred to the mineral processing plant. At the settling pit, effective separation is achieved as evidenced by the results of the gradation analysis conducted on the fines collected from the sedimentation tanks. As such, the particle size to be used will be those contained in Table A15. Table 9 shows that the jaw crusher can be bypassed entirely while the cone crusher can be used slightly. Alternatively, only the primary ball mill can be employed.
The calculated energy savings for the comminution is shown in Table 10. When the jaw crusher and the cone crusher are bypassed, the energy input savings will be 6.024 KWh/t. Based on the production rate of the LDD (100–400 tons/day), the estimated daily range of energy savings is 602–2410 KWh. This estimation adopts the Bond Work Index of quartz (13.57 KWh/t) and is based on Equations (4) and (5). At 95% availability of the comminution circuit and at 0.13 USD/KWh (average energy cost in Canada in 2023) [36], the estimated annual cost savings on energy will be USD 27,000–110,000.
While the authors of this technical work recognize that the energy had been applied in this new technology to drill the rock and evacuate the cuttings (including fluid circulation and air compression for air lift-assisted reverse circulation), they do not attempt to articulate the energy differential between conventional mining of the narrow-vein deposits and this proposed methodology for now, as that can be a subject of a future investigation. The value of this newly advanced method is its applicability in otherwise “uneconomical” narrow-vein deposits. This research demonstrates the additional value of this technology when mineral processing workflow is considered following the mining operations.

5. Conclusions

This study presented the justification for collecting drill cuttings during the drilling of the three large-diameter holes over the 4-month long field trial of the novel continuous mechanized narrow-vein mining method. The various sampling collection points along the circulation circuit and the inventory of three hundred and three (303) cuttings are shown presented. Next, the work delved into the adopted test standards applied in the particle size analyses of these cuttings’ samples. In addition to presenting these particle size distributions, the authors documented the relevant evaluation metrics of these cuttings’ gradations, e.g., percentiles (D10, D30, D50, D60, D80, D90), coefficients of uniformity and curvature, and coarseness index. From the results of these metrics, the efficiency of the cuttings separation system and water recycling were evaluated. The study concluded by demonstrating the impact of the resultant D80 size of cuttings on the energy requirement of the comminution process. Based on the results of the study, the comminution circuit does not need to include the jaw crusher. The estimated daily range of energy savings is 602–2410 KWh. At 95% availability of the comminution circuit and at 0.13 USD/KWh (average energy cost in Canada in 2023), the estimated annual cost savings on energy will be USD 27,000–110,000.
It is also worth mentioning that this study underlines the cost analysis presented for the large-diameter drilling in Table 1. Just as has been shown in Table 1, for relatively low capital expenditure, hitherto unrecoverable narrow-vein deposits can be mined continuously mechanically without a need for extensive mining infrastructure and without the need to send workers into the underground mine. This study demonstrates the additional value derivable from the use of large-diameter drilling technology in narrow-vein mining.

Author Contributions

Conceptualization, S.B. and J.G.; methodology, J.G.; software, J.G.; validation, S.B., A.C. and J.G.; formal analysis, J.G.; investigation, J.G.; resources, A.C.; data curation, J.G.; writing—original draft preparation, J.G.; writing—review and editing, A.C. and S.B.; visualization, J.G.; supervision, S.B.; project administration, S.B.; funding acquisition, S.B. All authors have read and agreed to the published version of the manuscript.

Funding

The funding was provided by Novamera through the NSERC, MITACS and disbursed by the university.

Data Availability Statement

The results of the cuttings size analyses are available in the Appendix A.

Acknowledgments

The authors acknowledge the tremendous support received from the members of the Drilling Technology Laboratory at the Memorial University of Newfoundland.

Conflicts of Interest

Author Allan Cramm was employed by the company Novamera Inc. The remaining authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.

Appendix A

Table A1. Inventory of cuttings from Sampling Point 1 in Large-Diameter Hole 1.
Table A1. Inventory of cuttings from Sampling Point 1 in Large-Diameter Hole 1.
LD#CirculationDepth (m Along Hole)Thrust (KN)Rotary Speed (rpm)Torque (KNm)ROP (m/h)Flow Rate (USgpm)Air Flow Rate (m3/h)
1DF0.9875.819.0032.640.8201938-
1DF1.0870.189.5032.640.3241718-
1DF3.1698.439.9037.390.3962045-
1RC4.0293.8513.0636.350.432510-
1RC4.1497.6413.1140.030.432509-
1RC4.45119.1413.0744.050.468510-
1RC4.56119.1013.1547.940.504514-
1RC5.26117.7210.4842.490.432515-
1RC6.08159.6014.2036.460.350815-
1RC6.16159.6013.0036.970.300813-
1RC6.23159.6013.9037.470.600812-
1RC6.31159.6013.506.870.430812-
1RC6.65155.6114.6046.590.510342-
1RC6.70159.6013.5049.120.270343-
1RC7.50195.5112.1038.490.270887-
1RC7.65211.4713.8040.010.220883-
1RC7.80219.4512.7040.010.220891-
1RC8.20219.4512.7040.010.220891-
1RC8.40239.4015.2042.030.220889-
1RC8.56259.3515.1042.540.360889-
1RC8.86279.3016.2049.630.440889-
1RC11.74339.1516.7049.120.8001158-
1RC12.10339.1516.4049.120.6801154-
1RC12.47339.1516.5049.120.7201158-
1RC12.83339.1514.7049.630.7601154-
1RC13.17339.1515.9050.640.5601154-
1RC13.53331.179.5044.060.180955-
1RC13.70339.1515.5054.180.5101129-
1RC14.02331.1714.8052.160.6401131-
1RC14.24359.1014.6051.150.1601132-
1RC14.75359.1016.0052.160.6801310-
1RC15.08279.3016.4049.630.660881-
1RC15.47275.3115.1049.631.000955-
1RC15.93275.3117.6051.650.920956-
1RC16.42279.3015.1050.641.040955-
1RC16.80279.3015.4050.640.800954-
1RC17.00279.3015.4050.640.800954.00-
1RC17.59295.2616.1056.211.060957-
1RC17.59295.2616.1056.211.060957-
1RC18.15279.3017.7052.671.240959-
1RC18.46279.3014.3055.700.6201078-
1RC19.01299.2515.9054.690.8001070-
1RC19.37295.2616.3052.160.7201129-
1RC19.68295.2615.1056.720.6201132-
1RC20.12303.2415.0051.150.7601129-
1RC20.16299.2510.0048.110.1201165-
1RC20.54295.2614.9057.220.7601155-
1RC20.79291.2715.1055.700.5001051-
1RC21.13315.2116.2052.670.6801053-
1RC21.13315.2116.2052.670.6801053-
1RC21.46323.1915.9052.160.6401120-
1RC21.81323.1915.9053.680.4701138-
1RC21.90323.1917.6051.650.3601138-
1RC22.18359.1017.0056.210.6001199-
1RC22.50359.1014.7055.700.6401201-
1RC22.72339.1513.9058.240.4401199-
1RC23.07359.1014.9053.170.5601199-
1RC23.36355.1114.9052.670.6001259-
1RC23.62351.1216.3052.160.5201262-
1RC23.88359.1015.5057.730.5201255-
1RC24.21359.1016.9057.730.5601251-
1RC24.61355.1115.1053.170.4801822-
1RC24.61355.1115.1053.170.4801822-
1RC24.85351.1217.7059.250.4801807-
1RC25.16339.1517.1055.700.6201829-
1RC25.45359.1017.3058.740.5601838-
1RC25.70355.1114.0055.200.5001831-
1RC26.00335.1614.0064.820.6001830-
1RC26.22355.1115.3055.200.1501876-
1RC26.49355.1117.4059.760.6401874-
1RC26.80363.0916.4061.780.6201867-
1RC27.11359.109.7068.870.6801865-
1RC27.24139.659.7056.210.1701892-
1RC27.31199.5010.2047.600.2801831-
1RC27.74319.2017.0058.240.8601867-
1RC28.20283.2915.4062.790.9601845-
1RC29.25303.2416.1060.770.6901866-
1RC29.53299.259.0058.241.1201856-
1RC29.82199.5011.9061.300.1001389-
1RC30.09195.5013.6051.700.5401386-
1RC30.09195.5013.6051.700.5401386-
1RC30.82259.4015.3056.700.7401392-
1RC30.82259.4015.3056.700.7401392-
1RC31.16279.3014.4057.200.7001395-
1RC31.46299.3016.1055.700.6701391-
1RC31.46299.3016.1055.700.6701391
1RC31.82299.3014.6050.100.7201386-
1RC31.95323.1916.0057.220.2101384-
1RC32.07319.2014.2056.700.6601386-
1RC32.54319.2013.2058.240.6401378-
1RC32.54319.2013.2058.240.6401378-
1RC32.97243.4010.1056.200.5001383-
1RC33.04279.3011.7060.260.2801458-
1RC33.40315.2014.4051.700.6501486-
1RC33.54319.209.7047.600.3001486-
1RC33.70335.169.7066.840.2701390-
1RC33.86355.1010.7066.800.2401390-
1RC33.95299.309.3063.300.1701382-
1RC34.01315.2011.9080.500.1001544-
1RC34.35355.1118.5056.720.4401545-
1RC34.57387.0316.0075.960.2001540-
1RC34.72399.0016.0087.100.1501950-
1RC34.74399.0016.0087.100.1501950-
1RC34.79395.0012.6099.800.1001920-
1RC34.87239.408.3037.980.0001548-
1RC35.12343.1416.3051.150.3761541-
1RC35.34355.1014.6053.200.5011541-
1RC35.63359.1021.0065.300.6551594-
1RC36.20355.1019.8059.200.5001602-
1RC36.57355.1120.6058.240.7141590-
1RC36.84355.1017.6057.200.1801391-
1RC36.84355.1017.6057.200.2001391-
1RC37.60363.1019.6056.700.7251391-
1RC38.00359.1019.5061.800.8001391-
1RC38.73359.1020.3068.900.7001392-
1RC39.13359.1018.6067.900.7001587-
1RC39.40363.0919.1057.730.6281391-
1RC39.60355.1119.4058.240.2931587-
1RC40.37359.1020.1065.300.6731533-
1RC40.63359.1021.9062.300.6121530-
1RC41.02359.1020.8064.300.8741535-
1RC41.41359.1023.6069.900.8001536-
1RC41.87359.1021.9072.400.7941532-
1RC42.22359.1021.1066.800.8101533-
1RC42.76359.1022.4069.900.4221674-
1RC43.61371.0722.0064.820.7441584-
1RC44.14359.1022.6067.901.0041584-
1RC44.94383.0422.0065.330.6551591-
1RC45.18359.1021.9064.300.4451590-
1RC45.38383.0421.1064.820.4831581-
1RC45.38359.1021.1064.800.4831581-
1RC45.60199.5020.6074.900.6001606-
1RC45.67379.0521.9080.520.0481394-
1RC46.21199.5021.6066.801.0071599-
1RC46.84199.5020.6066.800.6431686-
1RC47.16199.5020.1067.400.7171699-
1RC47.41199.5021.7080.500.5041696-
1RC48.70199.5022.6065.300.5561877-
1RC49.44199.5021.9069.400.8001878-
1RC50.71379.1019.6065.300.9701897-
1RC51.11379.1019.9068.400.8001892-
1RC51.35383.0019.8067.400.3001894-
1RC51.46383.0419.8067.350.2601886-
1RC51.77383.0019.8067.400.3001904-
1RC51.77383.0019.8067.400.3001904-
1RC52.25387.0020.5063.300.5111904-
1RC52.50395.0020.9066.800.5001911-
1RC52.73391.0024.0060.800.4131894-
1RC52.73391.0024.0060.800.4131894-
1RC53.11395.0021.6058.200.3501907
1RC53.39391.0222.2062.290.2651913-
1RC53.61379.1020.3058.200.1771899-
1RC53.70379.1020.5059.800.1662091-
1RC53.79379.1020.7058.200.1772088-
1RC53.93391.0023.5063.300.3812095-
1RC54.19395.0019.9054.200.2802002-
1RC54.21391.0010.1044.600.0001919-
1RC54.34395.0022.5059.200.15819142364
1RC54.44391.0021.4058.200.18719012478
1RC54.73387.0021.2059.800.25318142302
1RC55.03403.0028.6064.800.38218032506
1RC55.28403.0021.1061.300.5901810-
1RC55.60407.0020.4070.400.6421811-
1RC56.51419.0023.0058.700.52918072424
1RC56.51419.0023.0058.700.52918072424
1RC58.08434.9021.3068.400.8831784-
1RC59.29438.9022.2073.900.8491904-
1RC59.72438.9021.8080.000.8221885-
1RC60.09434.9022.4069.400.8392004-
1RC60.51442.9022.7068.400.81719972538
1RC60.56442.9021.9072.900.1151395-
1RC61.51438.9022.4072.900.93019952588
1RC61.99438.9022.5069.901.03119872416
1RC62.51438.9023.3076.000.98419942418
1RC63.01434.9023.9063.801.0001959-
1RC63.30434.9121.6065.830.49617802438
1RC63.39434.9119.4070.901.19320082327
1RC66.90430.9023.1077.001.09418032320
1RC67.43454.9022.6082.001.08718992560
1RC68.18379.1022.4086.600.77120062400
1RC69.20438.9023.4072.901.1261994-
1RC69.38367.0820.7083.050.1831994-
1RC70.82371.0721.6087.101.29319002518
1RC71.78399.0021.7073.431.0101831-
1RC73.30442.8923.3076.971.06717982516
1RC74.44434.9122.2073.930.93817692598
1RC76.02335.1622.1080.010.4091485-
1RC76.27259.3521.3081.530.4741813-
1RC76.66351.1222.2074.950.5661959-
1RC77.37418.9521.4077.481.0331963-
1RC78.21446.8822.1073.431.0161979-
1RC78.62295.2620.3083.050.1641351-
1RC81.31363.0920.7087.611.32219992568
Table A2. Inventory of cuttings from Sampling Point 1 in Large-Diameter Hole 2.
Table A2. Inventory of cuttings from Sampling Point 1 in Large-Diameter Hole 2.
LD#CirculationDepth (m AH)Thrust (KN)Rotary Speed (rpm)Torque (KNm)ROP (m/h)Flow Rate (USgpm)Air Flow Rate (m3/h)
2DF0.4210014.1039.500.5111770-
2DF0.7311213.9037.980.3581757-
2DF0.9811614.6043.550.5411837-
2DF1.6311213.4044.060.6301842-
2DF1.819616.8043.040.5521869-
2DF2.2311214.6042.540.4961869-
2RC2.258813.5040.000.39012741939
2RC2.385213.5034.440.381576-
2RC2.52929.7044.560.218575637
2RC2.654811.5031.900.2345762000
2RC2.8510013.4032.920.4545741999
2RC3.069613.3032.410.3895722000
2RC3.2316011.7033.420.4895692000
2RC3.2315613.4032.920.6895722000
2RC3.8210812.9043.550.5435721932
2RC4.1316012.4041.020.5885762000
2RC4.4312014.4041.020.6405742000
2RC4.6812014.9036.970.4975742000
2RC5.1223914.6095.201.0705762000
2RC5.391208.8075.450.2165772000
2RC5.46527.6095.710.0445762000
2RC6.0419222.2048.110.691573-
2RC6.420020.8048.610.7665732584
2RC6.420020.8048.610.7665732584
2RC6.819621.6052.160.7715712592
2RC6.8120321.9065.330.000572-
2RC7.0921521.4054.180.773568-
2RC7.6921921.0050.130.769475-
2RC7.9821925.4053.170.446475-
2RC8.0121120.8058.740.024475-
2RC8.2231120.9070.390.3924732600
2RC8.5133525.0052.670.7314722016
2RC8.8833521.7051.650.805470-
2RC9.1733922.5063.810.414473-
2RC9.946314.6058.740.564607-
2RC10.248313.5053.680.792609-
2RC10.6147913.9050.640.823609-
2RC10.9747913.6048.610.671613-
2RC11.7947912.7057.220.8596092568
2RC12.1443913.2047.100.6125402574
2RC12.4651514.7053.170.6685382602
2RC12.6651914.4056.720.688510-
2RC12.9151514.1048.110.5994262602
2RC13.3839514.8054.690.083806-
2RC13.6647913.8059.250.6547092238
2RC13.8847911.1050.640.2805902222
2RC14.2452313.5064.820.1545861662
2RC15.1851914.9050.640.7972861836
2RC15.1851914.9050.640.7972861836
2RC15.4551914.9055.700.6092861842
2RC15.7147913.4079.000.4554471858
2RC16.0832711.1051.650.3554551838
2RC16.3231912.7049.630.4535141854
2RC16.3231912.7049.630.4535141854
2RC16.5930313.5092.670.4875141840
2RC16.5925513.5052.670.3894822430
2RC16.6927915.8049.120.4044812414
2RC16.8329914.0050.130.5374812456
2RC17.1529513.2054.690.6584842464
2RC17.4532313.0044.560.7004862428
2RC17.8238713.0051.650.8294652494
Table A3. Inventory of cuttings from Sampling Point 1 in Large-Diameter Hole 3.
Table A3. Inventory of cuttings from Sampling Point 1 in Large-Diameter Hole 3.
LD#CirculationDepth (m Along Hole)Thrust (KN)Rotary Speed (rpm)Torque (KNm)ROP (m/h)DOC
(mm/rev)
Flow Rate (USgpm)
3DF1.9532.03.610.630.3361.556517
3DF2.1832.03.410.130.3001.4711895
3DF2.2432.03.510.630.0530.2521874
3DF2.3236.07.320.760.0260.0591470
3DF2.3760.06.720.760.1100.2742116
3DF2.4472.07.624.310.1200.2632616
3DF2.6156.07.421.780.1200.2702431
3DF2.952.05.520.760.2600.7882378
3DF3.3432.05.822.280.4201.2071859
3DF3.4964.06.925.320.1500.3622038
3DF3.8119.7827.85- 2400
3DF5.66111.76.329.370.1100.2912550
3DF5.74111.76.334.440.1100.2912200
3DF5.8799.89.830.380.1300.2212200
3DF6.11123.78.628.860.2200.4261850
3DF6.5135.78.629.370.2000.3882400
3DF6.6135.79.728.360.2000.3442307
3DF6.7135.79.728.360.2000.3442460
3DF6.8135.71129.880.2000.3032460
3DF6.88155.610.433.420.1700.2722400
3DF7.11147.615.430.890.1700.1842400
3DF7.2799.815.430.890.3900.4222400
Table A4. Inventory of cuttings from Sampling Point 2 in Large-Diameter Hole 1 and 2.
Table A4. Inventory of cuttings from Sampling Point 2 in Large-Diameter Hole 1 and 2.
Date of Daily ProductionLD#Mode
11 October 20211RC
12 October 2021
13 October 2021
14 October 2021
20 October 2021
21 October 2021
26 October 2021
27 October 2021
28 October 2021
29 October 2021
30 October 2021
1 November 2021
2 November 2021
3 November 2021
4 November 2021
28 November 20212
3 December 2021
Table A5. Inventory of cuttings from Sampling Point 3.
Table A5. Inventory of cuttings from Sampling Point 3.
S/N Remarks
1Tank 1Fine-sized
2Tank 2Fine-sized
3Tank 3Fine-sized
4Tank 4Fine-sized
5Geotube®Fine-sized
Table A6. Results of particle size analyses for cuttings from Sampling Point 1 (Large-Diameter Hole 1).
Table A6. Results of particle size analyses for cuttings from Sampling Point 1 (Large-Diameter Hole 1).
Depth
(m AH)
Cutting Size or Sieve Size (mm)
76.250.844.4538.10025.40022.22519.05011.1254.7502.0000.8500.4200.2500.1490.075
Cumulative Percent Passing
0.98--------100%78%5%1%1%1%0%
1.08--------100%81%3%1%1%1%0%
3.16------100%92%57%23%3%1%1%1%0%
4.02-100%100%100%100%97%95%69%4%1%1%1%1%1%1%
4.14--100%100%97%95%92%64%17%7%3%1%1%0%0%
4.45-100%100%100%97%97%94%64%7%4%2%1%1%1%0%
4.56---100%100%99%96%57%6%2%1%0%0%0%0%
5.26---100%100%98%97%72%26%15%8%4%3%2%1%
6.08-100%100%100%100%100%100%95%60%24%2%1%0%0%0%
6.16--100%100%100%100%100%95%63%27%4%2%1%1%0%
6.23-100%100%100%100%100%100%96%56%26%4%2%2%2%1%
6.31-100%100%100%100%100%100%95%47%22%4%2%1%1%0%
6.65---100%100%100%98%95%55%24%3%1%1%0%0%
6.70--100%100%100%100%100%95%60%24%2%1%0%0%0%
7.50---100%100%96%94%87%55%22%2%1%0%0%0%
7.65---100%100%100%100%93%59%26%5%3%2%2%2%
7.80--100%100%96%96%96%88%51%20%2%1%1%1%0%
8.20-100%100%100%100%97%97%90%60%27%6%3%3%2%2%
8.40--100%100%100%100%100%95%55%25%4%2%1%1%0%
8.56-100%100%100%97%97%97%91%53%22%5%3%2%2%1%
8.86-100%100%100%100%97%95%89%54%23%5%2%1%1%0%
11.74-100%100%100%100%100%100%93%61%29%7%4%3%2%1%
12.10--100%100%100%100%99%92%60%27%6%3%2%2%1%
12.47-100%100%100%100%100%100%91%51%21%6%4%3%3%3%
12.83-100%100%100%100%100%100%87%50%19%4%2%2%2%1%
13.17-100%100%100%100%98%98%87%49%18%5%3%3%2%2%
13.53--100%100%100%100%100%82%35%11%2%1%1%1%1%
13.70-100%100%100%94%93%91%79%47%21%7%5%4%3%2%
14.02---100%94%94%94%82%46%21%5%2%2%1%1%
14.24---100%100%100%100%88%47%20%4%2%2%2%1%
14.75---100%100%100%97%93%57%27%6%3%2%1%1%
15.08--100%100%100%100%100%87%35%14%3%2%1%1%1%
15.47-100%100%100%100%100%98%64%48%16%3%2%1%1%1%
15.93---100%100%100%100%85%46%20%4%2%2%2%1%
16.42--100%100%100%100%100%88%51%25%5%2%1%1%1%
16.80-100%100%100%100%100%97%85%47%22%5%3%2%2%1%
17.00---100%100%100%100%88%48%22%4%2%1%1%1%
17.59-- 100%97%97%94%83%46%19%5%3%3%2%2%
17.59---100%97%97%94%83%46%19%5%3%3%2%2%
18.15- 100%100%96%96%94%80%38%15%3%1%1%1%0%
18.46-100%100%100%71%67%62%51%25%12%4%3%2%2%2%
19.01- 100%100%79%79%72%59%28%9%1%0%0%0%0%
19.37-100%100%100%100%100%97%71%28%9%3%2%2%2%2%
19.68---100%88%88%88%68%30%8%1%1%0%0%0%
20.12---100%100%96%87%76%32%10%3%2%2%2%2%
20.16---100%92%87%87%71%32%12%3%2%2%2%1%
20.54---100%100%100%100%96%63%26%4%2%1%1%1%
20.79---86%80%80%79%62%34%15%5%4%3%3%2%
21.13---100%87%77%77%72%34%13%4%3%3%2%2%
21.13---100%100%100%100%88%39%15%5%3%3%2%1%
21.46---100%100%98%95%80%42%19%6%4%3%3%2%
21.81---100%100%100%100%83%38%16%5%3%3%3%1%
21.90--100%100%100%100%100%79%33%12%3%2%1%1%1%
22.18---100%100%100%93%78%39%15%5%3%3%3%1%
22.50---100%100%100%100%81%37%14%4%3%3%2%2%
22.72-100%100%100%83%83%83%73%43%17%6%4%4%3%3%
23.07---100%100%100%100%91%39%15%4%3%2%2%1%
23.36- 100%89%84%84%62%21%8%2%1%1%1%0%
23.62- 100%100%100%99%78%34%13%5%3%3%3%2%
23.88---100%100%100%100%84%37%15%4%3%2%2%1%
24.21---100%100%100%98%88%57%28%8%4%4%3%2%
24.61---100%100%100%100%88%46%19%5%3%3%2%1%
24.61---100%100%99%98%80%28%10%3%2%1%1%1%
24.85---100%81%81%80%75%46%18%6%4%4%3%2%
25.16---81%73%73%73%70%42%18%7%4%4%3%2%
25.45---100%100%100%100%91%50%20%6%4%3%3%1%
25.70---100%100%100%98%90%45%18%5%3%2%2%1%
26.00---100%94%94%94%85%54%22%6%3%3%2%2%
26.22---100%90%90%90%80%42%15%4%3%2%2%1%
26.49---100%93%85%81%70%38%14%3%2%1%1%0%
26.80---100%100%100%94%88%47%17%3%2%2%1%1%
27.11---100%89%87%87%78%50%22%5%2%1%1%1%
27.24---100%100%100%97%88%55%21%4%2%2%2%1%
27.31---100%100%100%100%99%62%23%4%2%2%2%1%
27.74---100%100%100%100%95%59%23%5%3%2%2%2%
28.20---100%100%100%100%90%50%19%4%3%2%2%2%
29.25---100%100%100%100%79%43%15%4%3%3%2%2%
29.53---100%100%95%95%76%45%15%4%2%2%2%1%
29.82---100%89%85%76%60%28%10%3%2%2%1%1%
30.09---100%100%95%95%77%31%10%2%1%1%1%0%
30.09---100%100%100%96%86%48%17%4%2%2%2%1%
30.82---100%80%72%72%70%38%13%3%2%2%1%1%
30.82---82%57%42%42%29%12%6%2%2%2%1%1%
31.16---100%100%93%93%78%35%14%4%2%2%1%1%
31.46---65%65%58%52%38%0%0%0%0%0%0%0%
31.46---72%72%66%61%49%19%5%1%1%1%1%0%
31.82---100%95%95%93%70%34%12%2%1%1%1%0%
31.95---86%86%86%81%62%32%13%4%3%2%2%2%
32.07---100%100%96%96%83%30%8%1%1%1%0%0%
32.54---100%100%96%96%82%42%17%6%4%3%3%3%
32.54---100%100%96%96%82%42%17%5%4%3%3%3%
32.97---100%94%94%94%80%36%11%2%2%1%1%1%
33.04---100%100%100%99%82%35%12%3%2%2%1%1%
33.40---87%78%76%76%64%40%16%5%3%3%3%2%
33.54---86%86%84%81%64%27%8%3%2%2%2%1%
33.70---100%100%98%94%70%31%9%2%2%1%1%1%
33.86---87%82%80%80%65%32%11%2%1%1%1%0%
33.95---100%100%100%100%86%41%15%4%3%2%2%2%
34.01---100%100%94%92%74%33%13%4%2%2%2%1%
34.35---100%100%96%93%77%32%12%4%3%2%2%2%
34.57---100%96%96%91%70%38%14%4%2%2%2%1%
34.72---100%100%93%93%79%42%17%5%4%3%3%1%
34.74---100%100%100%97%79%28%9%3%2%2%1%1%
34.79---100%100%97%94%79%29%8%2%2%1%1%1%
34.87 100%100%100%83%83%82%70%47%22%6%4%3%3%2%
35.12 100%100%100%100%100%100%87%48%20%5%3%2%2%1%
35.34---100%96%96%96%81%42%20%6%3%2%1%1%
35.63---100%100%97%97%84%37%13%2%1%1%0%0%
36.20 100%100%100%100%100%100%88%45%18%5%4%3%3%3%
36.57 100%100%100%100%100%100%78%42%15%3%2%2%1%1%
36.84---100%96%96%96%85%38%13%3%2%1%1%1%
36.84 100%100%100%97%97%97%83%41%15%5%3%3%3%2%
37.60---100%100%100%98%83%43%16%5%3%2%2%2%
38.00 100%100%100%93%93%92%79%41%15%3%2%2%1%1%
38.73 100%100%100%95%95%94%77%37%14%5%3%3%3%2%
39.13---91%88%87%87%72%37%14%4%3%2%2%2%
39.40 100%100%100%90%90%88%65%24%8%2%2%1%1%1%
39.60 100%100%100%100%100%98%82%38%16%4%2%2%2%1%
40.37 100%100%100%93%93%91%76%38%15%3%2%2%2%1%
40.63 100%100%100%84%82%80%71%39%17%4%3%2%2%1%
41.02 100%100%100%96%96%91%78%43%16%4%3%2%2%1%
41.41---81%81%81%81%72%42%19%5%3%3%2%2%
41.87 100%77%77%72%72%70%62%38%18%3%2%1%1%1%
42.22---88%88%88%88%76%49%24%5%2%2%1%1%
42.76 100%100%100%100%100%100%95%64%28%6%3%3%2%1%
43.61 100%100%84%63%63%63%53%37%20%4%2%2%1%1%
44.14 100%100%83%68%68%65%57%38%20%5%3%2%2%1%
44.94 100%100%100%100%100%97%88%50%24%5%2%2%1%1%
45.18 100%73%73%66%64%64%59%36%18%5%3%2%2%1%
45.38---89%89%89%87%80%47%20%5%3%3%3%2%
45.38 100%100%92%87%84%79%61%27%13%3%2%1%1%0%
45.60 100%100%100%100%100%95%76%40%15%4%3%2%2%2%
45.67 100%100%100%100%100%100%88%50%20%4%2%1%1%1%
46.21---100%100%97%94%78%40%14%3%2%2%2%1%
46.84---91%91%87%87%79%52%36%7%4%3%2%1%
47.16---73%73%69%69%62%62%13%5%3%3%2%2%
47.41---100%89%88%88%76%34%11%3%2%2%1%1%
48.70---100%100%100%100%86%38%16%6%5%2%1%1%
49.44 100%100%100%100%100%100%88%48%16%4%2%2%2%1%
50.71---100%100%100%70%57%51%25%7%4%4%3%1%
51.11-90%90%80%79%75%72%55%25%10%3%1%1%1%0%
51.35-100%100%89%89%88%88%71%35%15%4%2%1%1%1%
51.46 100%100%100%94%94%92%82%51%22%7%5%4%4%3%
51.77-100%100%100%100%98%97%84%38%15%5%3%3%3%2%
51.77 100%100%81%75%71%70%57%26%11%2%1%1%1%0%
52.25---100%98%93%91%74%28%9%2%1%1%1%1%
52.50 100%100%100%100%100%100%89%49%21%5%3%2%1%1%
52.73---87%80%80%79%65%25%8%2%2%1%1%1%
52.73---100%94%94%94%79%32%10%3%2%2%2%1%
53.11 100%100%100%79%79%78%66%36%15%4%2%2%1%1%
53.39---89%86%84%84%77%41%16%5%3%3%3%1%
53.61---100%100%98%96%79%34%13%5%3%3%3%2%
53.70 100%100%100%100%100%100%91%47%19%6%3%3%2%1%
53.79---76%69%69%67%54%23%8%3%2%2%2%1%
53.93---100%100%98%97%84%41%17%5%3%2%2%1%
54.19---100%90%90%86%74%27%10%4%3%3%3%2%
54.21---100%100%100%93%81%33%13%4%3%2%2%2%
54.34---100%100%100%98%84%31%11%3%2%1%1%1%
54.44---100%91%91%91%78%29%10%3%1%1%1%1%
54.73---100%100%100%95%84%39%9%2%1%1%1%1%
55.03---100%100%96%96%83%34%11%3%2%2%2%1%
55.28---100%100%100%95%67%17%6%3%2%2%2%2%
55.60---100%73%73%73%58%18%5%1%1%1%1%1%
56.51---100%100%99%97%82%32%10%2%2%1%1%1%
56.51---100%87%81%81%63%26%11%3%2%2%2%1%
58.08---100%100%100%100%82%32%11%2%1%1%1%1%
59.29 100%100%100%100%100%100%85%41%16%5%3%2%2%1%
59.72 100%100%100%100%100%100%91%42%17%5%3%3%3%2%
60.09 100%100%100%100%100%100%81%18%5%1%1%1%1%0%
60.51 100%100%100%100%97%96%80%21%8%3%2%2%2%1%
60.56 100%100%100%96%92%92%74%24%9%2%1%1%1%1%
61.51 100%100%100%94%94%94%77%25%9%4%3%2%2%2%
61.99 100%100%88%85%84%84%64%19%8%3%2%1%1%1%
62.51 100%100%100%89%86%86%56%20%7%2%1%1%1%1%
63.01 100%100%100%97%97%96%78%28%12%4%3%2%2%1%
63.30 100%100%100%100%100%99%83%31%12%5%4%3%3%2%
63.39 100%100%100%100%100%97%74%18%6%2%2%1%1%1%
66.90 100%100%100%83%83%83%71%36%13%4%3%3%2%2%
67.43 100%100%100%90%90%87%76%42%18%5%3%3%2%1%
68.18 100%100%100%90%90%88%81%39%13%2%1%1%1%0%
69.20 100%100%100%95%95%95%84%49%21%6%4%4%4%3%
69.38 100%100%100%100%95%93%84%46%17%3%2%1%1%1%
70.82 100%100%84%84%84%82%75%41%16%5%4%3%3%2%
71.78100%100%100%100%92%92%92%80%41%15%3%2%1%1%1%
73.30100%100%100%100%100%100%100%90%46%18%4%3%3%2%1%
74.44---100%100%100%100%86%35%12%3%2%2%2%1%
76.02---100%100%100%100%89%53%22%4%3%2%2%1%
76.27100%66%66%66%66%62%62%52%26%10%2%1%1%1%0%
76.66100%100%100%100%100%100%100%89%46%18%5%4%3%3%2%
77.37100%100%100%85%85%85%83%71%35%13%3%2%1%1%1%
78.21100%100%100%100%100%95%95%81%43%16%5%4%4%3%2%
78.62---100%100%100%100%85%41%17%4%3%2%2%2%
81.31100%100%100%75%75%75%75%64%34%12%3%2%1%1%1%
Table A7. Results of particle size analyses for cuttings from Sampling Point 1 (Large-Diameter Hole 2).
Table A7. Results of particle size analyses for cuttings from Sampling Point 1 (Large-Diameter Hole 2).
Depth (m AH)Cutting Size or Sieve Size (mm)
76.250.844.4538.10025.40022.22519.05011.1254.7502.0000.8500.4200.2500.1490.075
Cumulative Percent Passing
0.42100%100%100%100%100%100%100%100%99%76%3%1%1%0%0%
0.73100%100%100%100%100%100%100%100%99%78%4%1%0%0%0%
0.98100%100%100%100%100%100%100%100%100%78%5%1%1%1%0%
1.63100%100%100%100%100%100%100%100%99%76%3%1%1%0%0%
1.81100%100%100%100%100%100%100%100%99%97%20%6%3%1%1%
2.23100%100%100%100%100%100%100%98%94%93%20%4%2%2%1%
2.25 100%100%100%94%92%92%81%61%36%3%1%0%0%0%
2.38 100%100%100%100%91%87%66%31%11%2%1%1%0%0%
2.52 100%100%100%100%97%96%68%30%12%5%3%2%2%1%
2.65 100%100%100%89%86%73%51%18%6%2%1%0%0%0%
2.85 100%100%100%92%83%80%45%15%5%2%2%1%1%1%
3.06 100%100%100%91%80%77%50%15%5%1%0%0%0%0%
3.23 100%79%79%79%79%76%57%28%8%1%1%1%1%0%
3.23 100%100%77%70%66%63%54%32%13%4%2%1%1%0%
3.82 100%100%100%100%100%100%96%69%31%5%1%1%1%0%
4.13 100%100%100%100%100%97%90%62%28%6%2%1%1%1%
4.43 100%100%100%100%100%100%91%67%36%10%4%2%2%1%
4.68 100%100%100%100%99%99%92%61%28%6%2%1%1%0%
5.12 100%100%100%100%100%100%93%60%30%5%1%1%0%0%
5.39 100%100%100%100%98%98%92%62%30%6%3%2%1%1%
5.46 100%100%100%100%100%100%80%25%8%2%1%1%1%1%
6.04100%100%100%100%100%100%100%96%60%26%5%2%1%1%1%
6.4100%100%100%100%100%100%100%96%60%27%5%2%1%1%0%
6.4100%100%100%100%100%100%100%97%78%40%8%3%2%2%1%
6.8100%100%100%100%100%100%100%96%65%30%6%2%1%1%0%
6.81 100%100%100%100%100%100%99%76%39%7%3%2%1%1%
7.09 100%100%100%100%100%100%95%70%34%7%2%1%1%0%
7.69 100%100%100%100%100%100%99%75%35%6%3%2%1%1%
7.98 100%100%100%100%100%100%98%62%20%1%0%0%0%0%
8.01 100%100%100%100%100%100%100%90%49%5%2%1%1%1%
8.22 100%100%100%100%100%100%99%81%36%3%1%1%0%0%
8.51 100%100%100%100%100%100%99%88%56%11%4%2%2%1%
8.88 100%100%100%100%100%100%98%66%27%6%2%1%1%0%
9.17 100%100%100%100%100%100%99%82%44%7%3%2%1%0%
9.9 100%100%100%100%100%100%97%71%32%3%1%1%1%0%
10.2 100%100%100%100%100%100%97%70%33%5%2%1%1%1%
10.61 100%100%100%100%100%100%97%75%35%5%2%1%1%0%
10.97 100%100%100%100%100%99%94%72%36%7%3%2%2%1%
11.79 100%100%100%100%100%100%93%57%23%4%1%0%0%0%
12.14 100%100%100%100%96%96%91%57%21%3%1%0%0%0%
12.46 100%100%100%100%100%98%96%62%24%2%1%1%0%0%
12.66100%100%100%100%100%100%100%98%72%30%2%1%0%0%0%
12.91100%100%100%100%100%100%100%96%72%38%9%3%1%1%0%
13.38100%100%100%100%100%100%100%99%65%29%6%2%1%1%1%
13.66100%100%100%100%94%94%90%75%60%29%5%1%1%1%0%
13.88100%100%100%100%100%100%100%93%63%35%4%1%0%0%0%
14.24100%100%100%100%100%100%100%95%60%25%1%0%0%0%0%
15.18100%100%100%100%90%90%90%84%57%22%2%0%0%0%0%
15.18100%100%100%100%89%89%89%88%67%35%6%1%0%0%0%
15.45100%100%100%100%100%98%98%95%67%30%4%1%1%0%0%
15.71100%100%100%100%100%100%100%97%75%39%6%0%0%0%0%
16.08100%100%100%100%100%100%100%100%72%26%1%0%0%0%0%
16.32100%100%100%100%100%100%100%95%73%28%3%1%0%0%0%
16.32100%100%100%100%100%100%98%91%54%21%1%1%0%0%0%
16.59100%100%100%100%100%100%100%93%69%30%4%1%0%0%0%
16.59100%100%100%100%100%100%100%100%91%49%7%2%1%0%0%
16.69100%100%100%100%100%100%100%100%93%47%6%2%1%1%0%
16.83100%100%100%100%100%100%100%98%87%41%4%1%1%0%0%
17.15100%100%100%100%100%100%100%99%84%36%3%1%1%1%0%
17.45100%100%100%100%100%100%100%100%92%51%4%1%1%0%0%
17.82100%100%100%100%100%100%100%98%83%40%5%1%1%0%0%
Table A8. Results of particle size analyses for cuttings from Sampling Point 1 (Large-Diameter Hole 3).
Table A8. Results of particle size analyses for cuttings from Sampling Point 1 (Large-Diameter Hole 3).
Depth (m Along Hole)Cutting Size or Sieve Size (mm)
4.7502.0000.8500.4200.2500.1490.075
Cumulative Percent Passing
1.95100%93%40%3%1%0%0%
2.18100%93%31%1%0%0%0%
2.24100%89%27%2%0%0%0%
2.32100%78%21%1%0%0%0%
2.3797%54%9%2%1%1%1%
2.44100%79%18%3%1%1%0%
2.6198%43%6%1%0%0%0%
2.9100%88%22%1%0%0%0%
3.34100%95%31%1%0%0%0%
3.49100%90%13%1%0%0%0%
3.8100%100%54%1%1%1%1%
5.66100%99%42%4%2%2%1%
5.74100%100%52%2%1%1%0%
5.87100%99%36%1%1%0%0%
6.11100%99%43%3%1%1%0%
6.5100%100%79%8%2%1%1%
6.6100%100%79%6%3%2%1%
6.7100%100%76%4%2%1%1%
6.8100%100%61%1%1%0%0%
6.88100%99%50%3%1%1%1%
7.11100%100%78%5%1%1%1%
7.27100%100%67%15%2%2%1%
Table A9. Particles size distribution for cuttings from ampling Point 2 (settling pit).
Table A9. Particles size distribution for cuttings from ampling Point 2 (settling pit).
Cumulative Percent Passing Sieves of Size (mm) (Settling Pit)
76.250.844.4538.125.422.22519.0511.12524.7520.850.420.250.1490.075
3 December 2021_LD2100%98%97%94%83%80%78%68%32%7%2%1%1%1%0%
28 November 2021 (LD #2)100%100%100%100%100%100%100%97%78%51%28%14%9%4%1%
1 November 2021 (LD #1)100%100%98%98%97%97%96%86%57%38%24%15%11%7%3%
11 October 2021 (LD#1)100%100%100%100%100%100%100%96%74%48%26%13%8%5%2%
4 November 2021 (LD #1)100%100%100%100%100%100%99%89%55%30%15%9%6%5%2%
3 November 2021 (LD #1)100%100%100%100%100%99%98%92%65%42%23%12%7%4%1%
2 November 2021 (LD #1)100%100%100%100%100%100%99%94%66%40%22%14%11%7%3%
21 October 2021 (LD #1)100%100%100%100%100%99%97%90%64%42%27%16%10%6%3%
30 October 2021 (LD #1)100%100%100%100%100%99%99%89%44%22%11%6%5%4%2%
29 October 2021 (LD #1)100%100%100%100%100%99%98%85%48%23%10%5%4%3%2%
27 October 2021 (LD #1)100%100%100%100%100%100%97%85%53%29%15%9%7%6%3%
26 October 2021 (LD #1)100%100%100%100%99%99%95%85%58%39%25%14%10%6%3%
14 October 2021 (LD #1)100%100%100%100%99%98%97%90%62%39%23%13%8%5%2%
12 October 2021 (LD #1)100%100%97%97%96%96%95%88%61%35%17%8%5%4%2%
13 October 2021 (LD #1)100%100%100%100%97%95%94%86%69%57%45%33%25%17%10%
20 October 2021 (LD #1)100%100%100%100%92%92%88%79%52%27%12%6%4%3%2%
Table A10. Gradation of cuttings from Sampling Point 3.
Table A10. Gradation of cuttings from Sampling Point 3.
Sample SourceMass Percent Finer (%)Maximum Particle Diameter in Suspension, (mm)
Tank 1750.132
680.096
600.070
560.050
500.037
420.027
340.020
220.010
100.004
Tank 2620.140
570.101
520.073
470.052
410.039
360.027
300.020
190.010
100.004
Tank 3750.146
670.105
630.075
510.054
440.040
380.029
320.020
200.010
120.004
Tank 4630.145
600.103
570.074
500.053
440.039
380.028
320.020
220.010
90.004
Geotube540.145
490.104
460.074
380.054
330.040
280.028
220.020
140.010
80.004
Table A11. Particles size distribution for composite daily samples from Sampling Point 1 (effluent line).
Table A11. Particles size distribution for composite daily samples from Sampling Point 1 (effluent line).
Cumulative Percent Passing Sieves of Size (mm) (Effluent Line)
76.250.844.4538.125.422.22519.0511.12524.7520.850.420.250.1490.075
3 December 2021 (LD #2)No Collected Sample
28 November 2021 (LD #2)100%100%100%100%100%100%100%97%72%34%5%2%1%1%0%
1 November 2021 (LD #1)100%100%100%100%96%95%93%77%30%10%3%2%1%1%1%
11 October 2021 (LD #1)100%100%100%100%100%99%99%90%54%23%5%3%2%2%1%
4 November 2021 (LD #1)100%100%100%100%100%100%100%87%48%20%4%3%2%2%1%
3 November 2021 (LD #1)100%100%100%96%93%92%91%81%41%15%4%2%2%2%1%
2 November 2021 (LD #1)100%100%100%99%94%94%93%76%28%11%4%2%2%2%1%
21 October 2021 (LD #1)100%100%100%100%99%96%93%76%34%12%4%2%2%2%1%
30 October 2021 (LD #1)100%99%99%93%89%88%85%72%35%14%4%3%2%2%1%
29 October 2021 (LD #1)100%100%100%95%93%92%91%79%45%19%5%3%2%2%1%
27 October 2021 (LD #1)100%100%95%89%82%81%79%69%41%19%4%2%2%2%1%
26 October 2021 (LD #1)100%100%100%99%95%95%94%79%39%15%4%3%2%2%1%
14 October 2021 (LD #1)100%100%100%99%94%93%92%84%47%18%5%3%2%2%1%
12 October 2021 (LD #1)100%100%100%100%96%95%93%79%42%17%4%2%2%2%1%
13 October 2021 (LD #1)100%100%100%99%95%94%93%78%38%16%5%3%3%2%2%
20 October 2021 (LD #1)100%100%100%93%90%87%86%71%34%12%3%2%2%2%1%
Table A12. Coarseness index, percentiles, and shape coefficients for LD#1 (Sampling Point 1).
Table A12. Coarseness index, percentiles, and shape coefficients for LD#1 (Sampling Point 1).
CirculationDepth
(m Along Hole)
Percentiles of Cutting SizeCoarseness Index
D10 (mm)D30 (mm)D50 (mm)D60 (mm)D80 (mm)D90 (mm)CuCc
DF0.980.91.21.61.72.23.51.840.97513
DF1.081.01.21.51.72.03.31.770.97513
DF3.161.32.64.25.38.910.74.251.00622
RC4.025.47.39.310.214.517.61.910.97731
RC4.142.86.59.310.615.618.43.741.40723
RC4.455.17.39.610.715.418.02.110.99731
RC4.565.37.810.311.815.917.92.240.97740
RC5.261.25.48.19.513.716.97.982.53675
RC6.081.32.44.04.78.410.23.761.00617
RC6.161.12.23.74.58.010.03.920.98607
RC6.231.22.44.25.38.510.24.550.93611
RC6.311.32.95.26.59.110.55.181.04628
RC6.651.22.64.35.68.810.44.480.95624
RC6.701.12.54.45.78.710.24.980.98617
RC7.501.32.74.45.89.814.94.490.93644
RC7.651.12.44.04.98.610.54.361.01608
RC7.801.42.94.76.39.713.04.650.99648
RC8.201.12.33.94.89.011.34.411.02614
RC8.401.22.54.35.58.710.44.630.93617
RC8.561.22.74.55.99.310.95.031.06629
RC8.861.22.64.45.99.512.65.040.99632
RC11.741.02.13.84.78.610.64.760.91600
RC12.101.12.33.94.78.710.74.351.00608
RC12.471.12.84.76.29.411.05.451.12617
RC12.831.33.04.86.59.913.05.061.05633
RC13.171.33.15.06.610.013.35.101.10634
RC13.531.94.16.48.110.914.74.371.14666
RC13.701.12.95.37.312.018.36.671.07654
RC14.021.23.05.47.210.816.25.891.01656
RC14.241.33.05.36.89.812.25.301.05633
RC14.751.12.24.15.28.810.64.940.91612
RC15.081.64.16.67.910.313.14.901.35658
RC15.471.53.25.49.514.917.36.360.72666
RC15.931.33.15.47.010.313.65.481.04638
RC16.421.22.64.66.39.712.35.440.91626
RC16.801.22.95.26.910.314.55.671.00636
RC17.001.32.95.16.79.912.55.310.98635
RC17.591.33.15.57.210.716.45.621.07651
RC17.591.33.15.57.210.716.45.621.07651
RC18.151.53.86.68.111.116.85.301.18676
RC18.461.86.010.817.329.233.79.861.19799
RC19.012.25.29.311.825.932.05.391.04772
RC19.372.15.08.09.513.916.94.491.23684
RC19.682.34.88.19.815.927.94.321.05729
RC20.122.04.57.38.813.920.24.331.15689
RC20.161.84.57.79.315.524.35.241.22709
RC20.541.22.33.84.58.09.93.890.99606
RC20.791.44.28.410.721.440.07.441.16747
RC21.131.64.37.49.123.228.45.531.22727
RC21.131.43.76.17.410.012.35.191.27644
RC21.461.23.36.07.711.116.46.421.18648
RC21.811.43.86.57.910.714.35.791.33648
RC21.901.74.47.18.511.415.24.891.30668
RC22.181.43.76.58.212.417.45.701.15660
RC22.501.53.96.78.111.014.95.281.25655
RC22.721.23.36.28.316.430.46.711.08695
RC23.071.53.76.17.39.711.05.001.29642
RC23.362.36.19.310.917.626.14.671.47747
RC23.621.64.27.18.511.915.65.351.32661
RC23.881.53.86.57.810.614.15.341.28652
RC24.211.02.24.15.49.513.05.420.91610
RC24.611.23.15.36.89.912.35.481.13632
RC24.612.05.07.48.611.115.64.381.45677
RC24.851.23.25.67.818.731.36.311.05699
RC25.161.13.46.68.837.0 7.881.13749
RC25.451.22.94.86.39.410.95.291.15622
RC25.701.33.25.46.99.711.45.241.14636
RC26.001.22.74.46.010.115.55.151.04641
RC26.221.43.56.17.711.025.75.331.10681
RC26.491.63.87.19.118.624.15.761.01712
RC26.801.43.25.26.89.914.04.831.07645
RC27.111.22.84.87.013.026.25.830.92678
RC27.241.22.74.35.79.612.94.581.03626
RC27.311.22.53.94.67.99.63.781.11606
RC27.741.22.64.14.98.510.34.131.14609
RC28.201.33.04.76.39.511.14.901.08628
RC29.251.53.56.07.711.415.25.311.06649
RC29.531.53.45.87.912.817.05.270.97664
RC29.821.95.19.111.120.526.15.771.20742
RC30.092.04.77.48.712.316.94.391.25668
RC30.091.43.15.16.810.114.14.961.07641
RC30.821.63.87.19.225.231.65.600.99745
RC30.823.811.523.926.936.9 7.101.29922
RC31.161.54.17.08.512.417.45.621.31676
RC31.466.49.818.023.1 3.610.65921
RC31.463.07.111.718.6 6.270.93853
RC31.821.74.37.69.414.718.15.421.12695
RC31.951.64.48.510.718.8 6.741.14741
RC32.072.34.87.28.410.815.53.651.18685
RC32.541.33.46.07.610.815.65.911.19648
RC32.541.33.46.17.610.815.65.891.20649
RC32.971.94.16.88.211.116.64.451.12682
RC33.041.84.16.78.110.814.84.611.19663
RC33.401.43.67.410.028.0 7.370.95745
RC33.542.35.38.810.518.5 4.671.18755
RC33.702.14.67.99.514.517.94.591.07690
RC33.861.84.48.210.122.639.55.561.07757
RC33.951.53.66.07.410.213.24.871.15645
RC34.011.64.37.48.913.718.15.501.30682
RC34.351.74.57.38.812.817.75.111.34678
RC34.571.53.87.29.215.018.65.961.03686
RC34.721.33.46.17.811.517.56.031.15659
RC34.742.25.07.58.811.816.24.031.29680
RC34.792.34.97.48.711.816.83.831.20685
RC34.871.12.95.78.317.830.67.440.89696
RC35.121.23.05.16.810.012.95.581.08632
RC35.341.23.26.07.610.915.96.421.14656
RC35.631.73.96.57.910.614.84.621.16668
RC36.201.33.25.57.010.012.55.511.16631
RC36.571.53.56.17.911.715.45.291.04655
RC36.841.63.96.47.810.514.84.701.17667
RC36.841.53.66.17.610.715.35.261.16656
RC37.601.33.45.97.510.715.05.571.16646
RC38.001.53.66.27.911.817.75.341.07678
RC38.731.53.96.98.412.517.35.611.23673
RC39.131.53.97.18.915.532.55.891.11710
RC39.402.35.78.710.316.221.74.491.36726
RC39.601.43.76.57.910.915.35.551.23656
RC40.371.53.86.88.513.318.45.521.13685
RC40.631.43.66.98.919.430.26.471.06715
RC41.021.43.46.07.812.418.65.541.05668
RC41.411.33.36.48.618.1 6.751.01729
RC41.871.43.67.810.545.348.17.680.91805
RC42.221.22.75.07.413.7 6.360.85686
RC42.761.12.13.74.48.010.04.210.98597
RC43.611.33.69.816.535.740.513.030.63806
RC44.141.23.68.914.435.340.611.630.72789
RC44.941.22.64.76.49.813.05.510.90630
RC45.181.33.98.713.046.248.59.950.87834
RC45.381.23.05.37.211.6 5.961.02684
RC45.381.75.39.111.019.934.06.501.49751
RC45.601.53.66.58.312.816.95.641.08661
RC45.671.32.94.76.49.812.55.031.02633
RC46.211.63.76.58.111.916.95.191.09667
RC46.841.01.84.46.611.724.56.760.48659
RC47.161.63.04.14.7 2.911.18763
RC47.411.84.27.18.713.926.34.791.13705
RC48.701.33.76.37.610.313.25.931.42644
RC49.441.43.25.16.79.912.74.671.06638
RC50.711.02.54.612.920.121.112.630.47676
RC51.112.15.910.013.335.044.46.471.26797
RC51.351.54.07.49.215.338.66.301.21715
RC51.461.12.84.66.610.817.85.991.05643
RC51.771.53.86.47.810.614.85.301.25653
RC51.771.85.59.612.836.041.16.991.28803
RC52.252.15.07.79.113.818.54.271.27701
RC52.501.22.84.96.59.712.15.401.03629
RC52.732.35.58.710.422.7 4.521.27769
RC52.732.04.57.28.511.716.94.321.18686
RC53.111.54.07.79.926.132.16.561.06738
RC53.391.43.56.38.114.2 5.741.11707
RC53.611.64.27.08.411.616.45.401.33663
RC53.701.23.15.26.69.59.85.311.17628
RC53.792.36.210.314.7 6.271.11823
RC53.931.33.56.17.610.514.85.651.20650
RC54.191.95.27.99.215.126.04.741.48709
RC54.211.64.37.08.411.017.15.141.38668
RC54.341.94.67.08.210.614.44.281.37668
RC54.442.14.97.58.812.218.24.231.34703
RC54.732.13.96.37.710.615.33.660.94666
RC55.031.84.36.88.110.815.34.531.24668
RC55.283.06.49.010.314.817.63.461.35704
RC55.603.16.79.912.128.633.33.941.21795
RC56.512.04.57.08.310.915.44.181.21673
RC56.511.95.58.910.618.728.15.521.47742
RC58.081.94.57.08.310.914.74.481.30669
RC59.291.43.56.07.510.413.95.401.19646
RC59.721.33.45.87.19.711.05.491.27634
RC60.093.16.08.09.011.014.82.881.28692
RC60.512.55.77.99.011.116.23.591.45689
RC60.562.25.58.09.313.718.24.201.45706
RC61.512.25.47.89.012.517.24.071.43695
RC61.992.56.39.110.617.639.34.141.47761
RC62.512.66.510.112.317.526.44.641.31751
RC63.011.75.17.68.912.116.45.271.72680
RC63.301.64.67.18.310.714.45.141.62658
RC63.392.96.18.49.513.116.63.241.35698
RC66.901.64.07.39.116.930.55.671.11716
RC67.431.33.46.38.214.322.26.201.06684
RC68.181.73.86.48.011.025.74.631.06695
RC69.201.22.94.96.710.515.45.761.07640
RC69.381.43.25.47.010.416.34.981.03656
RC70.821.43.66.58.417.040.46.141.11716
RC71.781.53.56.27.911.418.05.241.07681
RC73.301.33.25.36.89.711.55.131.12632
RC74.441.74.16.67.910.413.54.591.26657
RC76.021.22.74.56.09.612.14.861.00624
RC76.272.15.710.717.461.368.78.410.92919
RC76.661.33.25.36.89.811.75.281.15629
RC77.371.74.17.49.217.140.35.541.12736
RC78.211.33.46.07.610.916.05.721.16651
RC78.621.43.56.07.510.413.95.491.18644
RC81.314.14.38.210.339.441.92.510.43784
Table A13. Coarseness index, percentiles, and shape coefficients for LD#2 (Sampling Point 1).
Table A13. Coarseness index, percentiles, and shape coefficients for LD#2 (Sampling Point 1).
CirculationDepth (m AH)Percentiles of Cutting SizeCoarseness Index (%)
D10 (mm)D30 (mm)D50 (mm)D60 (mm)D80 (mm)D90 (mm)CuCc
DF0.420.9631.7461.7461.7462.4603.6691.811.81520.00
DF0.730.9481.2591.5711.7262.3053.5801.820.97517.80
DF0.980.9391.2531.5671.7242.3153.6061.840.97513.10
DF1.630.5981.0291.3281.4781.7781.9282.471.20520.00
DF1.810.5490.9951.2941.4441.7441.8942.631.25473.80
DF2.230.5781.0101.3241.4801.7931.9502.561.19485.90
RC2.251.1011.8033.5414.61310.94617.7384.190.64640.60
RC2.381.8694.6178.24710.08416.55421.5635.401.13709.80
RC2.521.6394.6778.0399.72314.49117.3735.931.37683.00
RC2.652.8747.08610.96614.36120.73326.6995.001.22773.90
RC2.853.3537.93012.19314.45718.98624.7234.311.30772.00
RC3.063.3817.40211.04613.95122.28325.0844.131.16779.90
RC3.232.2585.2589.63712.47844.79347.7965.530.98817.80
RC3.231.6384.48910.08316.47938.88841.66910.060.75817.80
RC3.821.081.973.384.107.339.713.810.88596.10
RC4.131.0502.1823.8054.6168.86111.1014.390.98611.40
RC4.430.8281.7223.2324.1308.17410.7894.990.87586.30
RC4.681.0462.1523.8454.6928.68610.7254.490.94610.90
RC5.121.071.993.864.848.6210.514.550.77609.10
RC5.391.032.013.744.608.5510.644.450.85607.00
RC5.462.3755.3767.6748.82311.12215.0813.721.38681.20
RC6.041.1292.2903.9274.7458.33310.1304.200.98609.00
RC6.41.1272.2673.8984.7148.26810.0674.180.97608.70
RC6.40.9371.6422.7063.4235.2798.7623.650.84569.60
RC6.81.0432.0143.5834.3677.8009.8184.190.89598.60
RC6.810.951.672.803.545.788.583.720.83571.30
RC7.090.991.823.213.987.269.774.030.84589.80
RC7.690.991.793.013.705.978.633.730.88577.60
RC7.981.4102.6743.9764.6277.9609.7323.281.10619.20
RC8.010.9801.5032.0682.7444.0984.9762.800.84551.10
RC8.221.101.792.873.484.717.953.160.84579.30
RC8.510.831.341.852.364.075.962.860.92537.90
RC8.881.082.213.624.327.539.523.991.04599.00
RC9.170.941.572.453.174.607.793.380.83562.40
RC9.91.1181.9283.2643.9576.9059.4203.540.84593.80
RC10.20.951.672.803.545.788.583.720.83589.40
RC10.611.041.803.003.696.129.053.530.84583.60
RC10.970.981.773.073.836.989.853.920.84584.50
RC11.791.2252.5304.1455.1978.75910.5404.241.01620.60
RC12.141.3032.6874.2415.3809.02910.8534.131.03635.50
RC12.461.2582.4063.8614.5888.13210.0343.651.00615.60
RC12.661.1721.9973.3103.9676.7289.1733.390.86596.60
RC12.910.8711.6832.9783.7816.8979.6014.340.86579.40
RC13.381.0442.0843.6034.3637.5809.4794.180.95596.40
RC13.661.0782.0483.8484.74713.82519.2194.400.82650.20
RC13.881.0601.8053.4694.4648.32810.4174.210.69602.20
RC14.241.2972.4243.9814.7728.41110.2313.680.95619.50
RC15.181.3192.6124.1695.35810.15518.6584.060.97662.90
RC15.181.0041.7873.2644.1328.73526.9794.120.77636.20
RC15.451.1232.0043.4734.2077.6129.8823.750.85605.10
RC15.710.9971.6782.8163.5926.2379.1693.600.79582.60
RC16.081.2562.2473.4534.0566.6768.9433.230.99601.00
RC16.321.1702.0983.3243.9366.7109.6253.370.96599.40
RC16.321.3472.7274.3955.7599.27211.0284.280.96632.30
RC16.591.1211.9923.3894.0907.61910.3293.650.87602.20
RC16.590.9241.4822.0942.7484.0554.7092.970.87550.30
RC16.690.9731.5342.2022.7963.9844.5782.870.87551.60
RC16.831.0351.6662.5583.1514.3386.4393.040.85567.60
RC17.151.0821.7882.7983.3694.5117.2613.110.88574.90
RC17.450.9861.4781.9702.5893.9324.6032.630.86550.20
RC17.821.0271.6842.6653.3054.5847.7743.220.84572.30
Table A14. Coarseness index, percentiles, and shape coefficients for LD#3 (Sampling Point 1).
Table A14. Coarseness index, percentiles, and shape coefficients for LD#3 (Sampling Point 1).
Depth (m Along Hole)Percentiles of Cutting SizeCoarseness Index (%)
D10 (mm)D30 (mm)D50 (mm)D60 (mm)D80 (mm)D90 (mm)CuCc
1.950.510.741.071.291.711.932.530.84463
2.180.550.831.201.381.751.942.510.91474
2.240.560.901.271.461.832.202.590.99499
2.320.611.031.441.642.273.512.681.06482
2.370.871.381.902.393.664.302.760.92500
2.440.631.081.451.642.093.422.601.12499
2.610.961.582.332.843.854.362.950.92552
2.90.610.991.341.511.852.372.471.06489
3.340.550.841.191.371.721.902.490.93472
3.490.741.101.401.551.852.002.111.06496
3.80.500.660.821.001.501.752.020.87443
5.660.500.721.021.221.621.822.460.86451
5.740.490.660.831.041.531.772.100.86444
5.870.530.781.111.291.661.842.420.88463
6.110.500.680.951.09 1.602.180.85453
6.50.440.560.670.730.881.441.690.96408
6.60.450.560.680.740.901.461.650.96409
6.70.460.580.700.761.051.521.640.96417
6.80.490.630.770.841.411.711.730.96436
6.880.490.670.851.091.551.782.220.85445
7.110.460.570.690.740.931.471.630.96413
7.270.360.550.710.791.301.652.231.06413
Table A15. Percentiles, coefficients and coarseness index—settling pit (Sampling Point 2).
Table A15. Percentiles, coefficients and coarseness index—settling pit (Sampling Point 2).
Particle Size (mm) LD#Mode
Settling Pit—Daily ProductionD10D30D50D60D80D90CuCcCoarseness Index (%)
11 October 20210.331.062.183.246.409.299.941.07528.801RC
12 October 20210.511.673.554.609.1313.008.991.18598.70
13 October 20210.070.351.352.728.7414.7837.740.63471.20
14 October 20210.311.343.314.528.9311.6014.481.28564.00
20 October 20210.682.354.536.6311.7720.589.821.24641.60
21 October 20210.241.093.004.278.7211.3317.821.16546.00
26 October 20210.261.273.575.2410.0315.1920.101.18567.50
27 October 20210.462.104.426.1510.1014.4713.361.56595.70
28 October 20211.233.636.828.6915.3033.097.051.23
29 October 20210.852.795.136.8210.2113.988.071.35622.50
30 October 20210.793.025.566.999.8612.048.871.65618.40
1 November 20210.221.323.685.339.7214.0523.711.47571.60
2 November 20210.221.353.084.137.9410.1918.571.99542.70
3 November 20210.361.272.984.168.2310.5511.471.07556.70
4 November 20210.532.024.175.639.4011.8210.711.38590.60
28 November 20210.290.941.892.925.458.749.911.02517.802
3 December 20212.314.567.979.7321.7633.884.220.93759.50
Table A16. Percentiles, coefficients and coarseness index—composite from effluent Line-Sampling Point 1.
Table A16. Percentiles, coefficients and coarseness index—composite from effluent Line-Sampling Point 1.
Particle Size (mm) LD#Mode
Effluent Line—Daily ProductionD10D30D50D60D80D90CuCcCoarseness Index (%)
11 October 20211.152.634.405.829.3311.085.041.03621.801RC
12 October 20211.383.436.177.9011.8917.385.731.08668.20
13 October 20211.413.746.618.2011.9917.395.801.21672.20
14 October 20211.303.115.257.0010.5117.055.401.06659.40
20 October 20211.734.287.559.2716.0425.295.351.14717.50
21 October 20211.704.287.228.7313.0417.645.121.23679.20
26 October 20211.453.686.478.0711.6316.805.581.16670.20
27 October 20211.283.336.708.9720.4139.586.990.97732.90
28 October 2021No Available Cuttings from the Effluent Line
29 October 20211.303.195.697.5411.5518.405.811.04673.30
30 October 20211.564.157.419.1416.1027.355.841.20714.80
1 November 20212.034.807.478.8012.4417.514.331.28691.00
2 November 20211.885.037.709.0413.1617.804.801.49695.80
3 November 20211.493.586.167.7510.9218.315.201.11678.60
4 November 20211.283.025.146.7710.0413.105.291.05633.80
28 November 20211.041.843.153.876.749.303.710.84587.902
Figure A1. XRD for sample from Tank 1 (Sampling Point 3).
Figure A1. XRD for sample from Tank 1 (Sampling Point 3).
Energies 18 03119 g0a1
Figure A2. XRD for sample from Tank 2 (Sampling Point 3).
Figure A2. XRD for sample from Tank 2 (Sampling Point 3).
Energies 18 03119 g0a2
Figure A3. XRD for sample from Tank 3 (Sampling Point 3).
Figure A3. XRD for sample from Tank 3 (Sampling Point 3).
Energies 18 03119 g0a3
Figure A4. XRD for sample from Tank 4 (Sampling Point 3).
Figure A4. XRD for sample from Tank 4 (Sampling Point 3).
Energies 18 03119 g0a4
Figure A5. XRD for sample from Geotube® (Sampling Point 3).
Figure A5. XRD for sample from Geotube® (Sampling Point 3).
Energies 18 03119 g0a5
Table A17. Energy requirements calculations.
Table A17. Energy requirements calculations.
Settling Pit—Daily ProductionD80Comminution Circuitr060Microns
Jaw Crusher
(from 300 mm to 100 mm)
Cone Crusher
(from 100 mm to 10 mm)
Priamary Ball Mill
(from 10 mm to 150 Microns)
f@F80f@300 mmf@100 mmf@10 mmEnergy Requirement for Jaw Crusher @ W = 13.57 kWht−1)Energy Requirement for Cone Crusher @ W = 13.57 kWht−1)Energy Requirement for Cone Crusher @ W = 13.57 kWht−1)
11 October 20216N/AN/AYes5.020.430.633.33−0.030−0.0540.0003746
12 October 20219N/AN/AYes3.620.430.633.33−0.030−0.0540.0001301
13 October 20219N/AN/AYes3.770.430.633.33−0.030−0.0540.0001794
14 October 20219N/AN/AYes3.690.430.633.33−0.030−0.0540.0001561
20 October 202112N/AYesYes2.880.430.633.33−0.030−0.054−0.0003559
21 October 20219N/AN/AYes3.770.430.633.33−0.030−0.0540.0001818
26 October 202110N/AN/AYes3.320.430.633.33−0.030−0.054−0.0000050
27 October 202110N/AN/AYes3.300.430.633.33−0.030−0.054−0.0000168
28 October 202115N/AYesYes2.290.430.633.33−0.030−0.054−0.0014509
29 October 202110N/AN/AYes3.270.430.633.33−0.030−0.054−0.0000357
30 October 202110N/AN/AYes3.380.430.633.33−0.030−0.0540.0000229
1 November 202110N/AN/AYes3.420.430.633.33−0.030−0.0540.0000450
2 November 20218N/AN/AYes4.110.430.633.33−0.030−0.0540.0002645
3 November 20218N/AN/AYes3.980.430.633.33−0.030−0.0540.0002361
4 November 20219N/AN/AYes3.520.430.633.33−0.030−0.0540.0000927
28 November 20215N/AN/AYes5.840.430.633.33−0.030−0.0540.0004139
3 December 202122N/AYesYes1.710.430.633.33−0.030−0.054−0.0046634
Total Specific Enthalpy (KWh/t)−1.140

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Figure 1. Airlift-assisted reverse circulation [26].
Figure 1. Airlift-assisted reverse circulation [26].
Energies 18 03119 g001
Figure 2. Cuttings Sampling Points 1 and 2.
Figure 2. Cuttings Sampling Points 1 and 2.
Energies 18 03119 g002
Figure 3. Cuttings Sampling Point 3.
Figure 3. Cuttings Sampling Point 3.
Energies 18 03119 g003
Figure 4. Cuttings collected from different sampling points: effluent line (1), settling pit (2), and sedimentation tank (3).
Figure 4. Cuttings collected from different sampling points: effluent line (1), settling pit (2), and sedimentation tank (3).
Energies 18 03119 g004
Figure 5. Setup for single-ieve set sieving method.
Figure 5. Setup for single-ieve set sieving method.
Energies 18 03119 g005
Figure 6. Specimen-splitting setup for composite sieving.
Figure 6. Specimen-splitting setup for composite sieving.
Energies 18 03119 g006
Figure 7. Mechanical splitter: (1) ASTM C702/C702 M-11. (2) Picture of the mechanical splitter used.
Figure 7. Mechanical splitter: (1) ASTM C702/C702 M-11. (2) Picture of the mechanical splitter used.
Energies 18 03119 g007
Figure 8. Sedimentation cylinders during the sedimentation analysis (ASTM D7928-21E1).
Figure 8. Sedimentation cylinders during the sedimentation analysis (ASTM D7928-21E1).
Energies 18 03119 g008
Figure 9. Particle size distributions for cuttings (Sampling Point 1, Direct Flush, Large Diameter Hole 3).
Figure 9. Particle size distributions for cuttings (Sampling Point 1, Direct Flush, Large Diameter Hole 3).
Energies 18 03119 g009
Figure 10. Particle size distributions for cuttings (Sampling Point 1, Reverse Circulation, Large Diameter Hole 1).
Figure 10. Particle size distributions for cuttings (Sampling Point 1, Reverse Circulation, Large Diameter Hole 1).
Energies 18 03119 g010
Figure 11. Particle size distributions for cuttings (Sampling Point 3).
Figure 11. Particle size distributions for cuttings (Sampling Point 3).
Energies 18 03119 g011
Figure 12. MSE vs. d50 (All Lithology).
Figure 12. MSE vs. d50 (All Lithology).
Energies 18 03119 g012
Figure 13. MSE vs. CI (All Lithology).
Figure 13. MSE vs. CI (All Lithology).
Energies 18 03119 g013
Figure 14. Particle shape measurement [33].
Figure 14. Particle shape measurement [33].
Energies 18 03119 g014
Table 1. Cost summary for each Model, in 2019 US dollars [4,19].
Table 1. Cost summary for each Model, in 2019 US dollars [4,19].
Mining MethodProduction Range
(Ton/Day)
Operating Cost
(USD/Ton)
Capital Cost
(mln USD)
LDD100–400150–1285–30
Cut & Fill (Mechanized)–Adit200–200095.21–44.2424.5–61.6
Cut & Fill (Mechanized)–Shaft200–2000100.57–45.7933.8–70.3
Cut & Fill (Jackleg)–Adit200–2000139.33–63.1219.0–48.3
Cut & Fill (Jackleg)–Shaft200–2000145.36–65.1627.1–59.2
Room & Pillar–Adit1200–14,00045.26–17.1546.2–156.0
Room & Pillar–Shaft1200–14,00049.53–18.3158.7–184.9
Shrinkage Stoping–Adit200–2000114.74–54.9917.9–50.6
Shrinkage Stoping–Shaft200–2000119.61–57.4726.6–63.5
Sublevel Longhole–Adit800–800039.08–20.1127.1–94.5
Sublevel Longhole–Shaft800–800042.90–21.2137.2–132.0
Table 2. Cuttings’ Inventory.
Table 2. Cuttings’ Inventory.
Circulation ModeSampling Point 1
(Effluent Line)
Sampling Point 2 (Settling Pit)Sampling Point 3 (Sedimentation Tanks
and Geotube®)
LD Hole 1LD Hole 2LD Hole 3LD Hole 1LD Hole 2Tank 1Tank 2Tank 3Tank 4Geotube®
Direct Flush3522-------
Air Lift Assist Reverse Circulation19061-------
N/A (Daily Production)---15211111
Total303
Table 4. Mechanical properties of the rock mass (based on cores obtained from a pilot hole).
Table 4. Mechanical properties of the rock mass (based on cores obtained from a pilot hole).
Depth (m)LithologyUCS of Rock Mass (MPa)Tensile Strength of Rock Mass (MPa)Range of Elastic Modulus for Rock Mass (MPa)Poisson Ratio for Rock Mass
0.7–3Quartz (Highly fractured)1.9–2.40.03–0.0041.4–4.80.195
8.65–11.6Quartz54.2–66.22.00–2.4470.5–75.60.195
11.6–12.5Mafic ash tuff35.4–88.71.18–2.9680.5–80.80.247–0.286
20.7–21.4Mafic ash tuff (transition)1.3–1.30.02–0.042.3–7.30.247–0.286
21.5–25.3Quartz20.6–55.50.72–1.9554.2–65.70.143
25.3–26Quartz20.6–55.50.72–1.9552.5–65.70.143
26–29.6Green, grey mafic ash tuff12.10.2324.8–59.70.299
42.5–46.7Green, grey mafic ash tuff34.30.9563.9–91.70.299
67.8–72.2Mafic massive flow17.6–51.70.56–1.6577.5–83.70.312
Table 5. Mean size and shape parameters.
Table 5. Mean size and shape parameters.
D10 (mm)D30 (mm)D50 (mm)D60 (mm)CcCuRemarks
Tank 10.00440.01660.0380.0680.9115.3Smallest mean size of particle
Tank 2-0.0200.0650.123--
Tank 3-0.0190.0510.069--
Tank 40.0050.0190.0520.1040.7223
Geotube®0.0060.0330.113---Largest mean size of particle
Table 6. Classification of particle shape by Zingg [33].
Table 6. Classification of particle shape by Zingg [33].
Classb/ac/bShape
I>2/3<2/3Disks
II>2/3>2/3Spherical
III<2/3<2/3Blades
IV<2/3>2/3Rod-like
Table 7. Cuttings shape classification.
Table 7. Cuttings shape classification.
Cuttings SampleLong
Diameter, mm. (a)
Intermediate
Diameter, mm (b)
Short
Diameter, mm (c)
b/ac/bShape
142.1028.7316.500.680.57Disc
240.0324.477.110.610.29Blade
334.1218.2611.300.540.62Blade
427.7121.617.680.780.36Disc
534.8519.734.090.570.21Blade
633.5016.765.800.500.35Blade
722.5213.8012.750.610.92Rod-like
Table 8. Composition of the cuttings samples obtained from Sampling Point 3.
Table 8. Composition of the cuttings samples obtained from Sampling Point 3.
% Composition by Weight
Phase IDTank 1Tank 2Tank 3Tank 4Geotube®Remarks
Quartz25.719.032.831.443.6Oxide of silicon
Albite48.648.039.733.434.7Clay mineral
Kaolinite15.223.318.820.315.5Clay mineral
Strontianite3.74.31.56.51.2Carbonates of strontium present in veins of quartz
Vaterite0.40.30.50.40.3Carbonate of Calcium
Muscovite3.62.93.65.14.0Clay mineral
Strontium thiosulphate pentahydrate2.82.23.22.90.9Inorganic compound that finds application in areas like gold mining and water treatment
Mean
Particle Size (mm)
0.0380.0650.0510.0520.113
Table 9. Required milling based on D80 size.
Table 9. Required milling based on D80 size.
Settling Pit—Daily ProductionD80Comminution CircuitLD Hole #Circulation Mode
Jaw Crusher (from 300 mm to 100 mm)Cone Crusher (from 100 mm to 10 mm)Primary Ball Mill (from 10 mm to 150 Microns)
11 October 20216N/A *N/AYes1RC
12 October 20219N/AN/AYes
13 October 20219N/AN/AYes
14 October 20219N/AN/AYes
20 October 202112N/AYesYes
21 October 20219N/AN/AYes
26 October 202110N/AN/AYes
27 October 202110N/AN/AYes
28 October 202115N/AYesYes
29 October 202110N/AN/AYes
30 October 202110N/AN/AYes
1 November 202110N/AN/AYes
2 November 20218N/AN/AYes
3 November 20218N/AN/AYes
4 November 20219N/AN/AYes
28 November 20215N/AN/AYes2
3 December 202122N/AYesYes
* The need for the jaw crusher and cone crusher has been eliminated by the reduction of the rock cuttings during the drilling process.
Table 10. Energy and cost savings due to bypass of jaw crusher and cone crusher.
Table 10. Energy and cost savings due to bypass of jaw crusher and cone crusher.
Settling Pit—Daily Production Comminution CircuitEnergy
Requirement for Jaw Crusher @ W = 13.57 kWh/t)
Energy Requirement for Cone Crusher @ W = 13.57 kWh/t)Energy Requirement for Cone Crusher @ W = 13.57 kWh/t)
D80 (Microns)Jaw Crusher
(from 300 mm to 100 mm)
Cone Crusher
(from 100 mm to 10 mm)
Primary Ball Mill
(from 10 mm to 150 Microns)
14 October 20218930N/AN/AYes0.0070.024−0.0019009
20 October 202111,770N/AYesYes0.0070.0240.0025962
21 October 20218720N/AN/AYes0.0070.024−0.0023113
26 October 202110,030N/AN/AYes0.0070.0240.0000492
27 October 202110,100N/AN/AYes0.0070.0240.0001632
28 October 202115,300N/AYesYes0.0070.0240.0064517
29 October 202110,210N/AN/AYes0.0070.0240.0003402
30 October 20219860N/AN/AYes0.0070.024−0.0002323
1 November 20219720N/AN/AYes0.0070.024−0.0004693
2 November 20217940N/AN/AYes0.0070.024−0.0039649
3 November 20218230N/AN/AYes0.0070.024−0.0033247
4 November 20219400N/AN/AYes0.0070.024−0.0010290
28 November 20215450N/AN/AYes0.0070.024−0.0112552
3 December 202121,760N/AYesYes0.0070.0240.0110685
0.0920.3320.0206690
Energy Requirement (KWh/ton)6.024
Minimum Production Rate (tons)400
Maximum Production Rate (tons)100
Daily Energy Requirement (KWh)602–2410
Annual Energy Cost Savings (USD)
@0.13 USD/kWh, at 95% Comminution Circuit Availability
27,000–110,000
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MDPI and ACS Style

George, J.; Cramm, A.; Butt, S. Comminution Flowsheet Energy Requirements of a New Narrow-Vein Mining Method. Energies 2025, 18, 3119. https://doi.org/10.3390/en18123119

AMA Style

George J, Cramm A, Butt S. Comminution Flowsheet Energy Requirements of a New Narrow-Vein Mining Method. Energies. 2025; 18(12):3119. https://doi.org/10.3390/en18123119

Chicago/Turabian Style

George, Judith, Allan Cramm, and Stephen Butt. 2025. "Comminution Flowsheet Energy Requirements of a New Narrow-Vein Mining Method" Energies 18, no. 12: 3119. https://doi.org/10.3390/en18123119

APA Style

George, J., Cramm, A., & Butt, S. (2025). Comminution Flowsheet Energy Requirements of a New Narrow-Vein Mining Method. Energies, 18(12), 3119. https://doi.org/10.3390/en18123119

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