Developing
a GIS For a Complex Site: U.S. Borax Inc.
By Barry A. Hillman
Introduction
GIS can serve as an excellent
management technology for the mining industry. One of the
most important considerations for company adoption of a
GIS is that industry professionals trained as engineers,
geologists, or other earth scientists, view GIS as a tool
to enhance and assist them in addressing their primary
technical or management function within the company.
This paper discusses the
development of a GIS for U.S. Borax Inc. (U.S. Borax)
Rather than undertake a separate, comprehensive, and
expensive GIS development project, engineering,
hydrological, hydrogeological and air quality projects
were used as a basis to develop individual GIS coverages
or themes as work products. Once several coverages were
completed, they were merged and presented to U.S. Borax to
demonstrate the capability to use GIS as a long term
management tool. Evolution of the GIS continues today in
the same manner. U.S. Borax is, therefore, realizing the
advantages of a GIS without having incurred high capital
and operating costs necessary to implement a system
independent of other technical programs.
Site Description
The U.S. Borax Mine (Figure 1) is located in the Upper
Mojave Desert in Kern County, Calif. between the towns of
Mojave and Barstow. It is the largest mine in the state of
California and one of the highest grade boron reserves in
the world. The mine and related processing facilities have
been in continuous operation since 1913. Exploration at
the site has established approximately 50 years of
reserves. The site complex as a result of the geology and
mineralogy, the long history of operation, diversity of
mining and processing technology, surface land ownership
constraints, and changing regulatory and operating
environment.
Operations at the U.S.
Borax facility can be divided into five categories;
Mining, Materials Processing, Mining Waste Management,
Environmental Management and Reclamation. Individual
departments are responsible for management of each
category of operation and report to a vice president of
operations who is responsible for coordinated facilities
management. The integrated operation is dependent upon
maintaining coordinated technical and geographic control
of site activities. For example, mine expansion planning
is constrained by waste rock storage availability while
processing operations must consider water consumption
requirements and the use of reclaim retention storage
ponds. Past underground operations must be considered when
planning new surface facilities. Management of
environmental compliance issues related to air, surface
and ground water must also be considered to provide
consistency and continuity with mine development and waste
management practices. Finally, reclamation is an ongoing
element of site activities that must coincide with overall
operations while remaining consistent with regulatory
requirements.
Development For A GIS For The Site
In 1990, U.S. Borax and its consultant, Condor Earth
Technologies Inc. initiated various long term site
environmental planning and other technical projects that
could be partially accomplished through and benefit by use
of a GIS. These activities included a study of the
hydrogeology of the site, closure of several large
retention ponds, placement of mine waste rock, combined
storage of waste rock and process by-product materials,
basin hydrology, and air quality. Despite the apparent
advantages of a GIS to address these complex issues, U.S.
Borax was unfamiliar with GIS and the costs for direct
implementation of a GIS could not be confidently
established. The company was, therefore, reluctant to
proceed with a direct conversion of data to immediately
build a comprehensive GIS. It was, therefore, recommended
that a plan of implementation as part of other on-going
required work activities at the site.
Some of the issues
considered in developing a GIS for the Borax operation
included the following:
1. Is a GIS warranted for the site?
2. Will site work assignments justify producing a product
in a GIS format?
3. What existing information and data can be used as a
platform for developing a GIS?
4. How will additional field data be efficiently and cost
effectively collected to update existing site information
and produce new coverages or themes?
5. A need for cost effective and consistent presentation
of data.
6. Better control of QA/QC.
7. Can the results of a GIS (including electronic format)
be effectively utilized on-site by staff?
Condor had developed
several GIS programs for other natural resources
companies. This experience had shown that GIS can best be
implemented by providing GIS as a support function to
other technical activities and to integrate development
with CAD work products. Condor, therefore, suggested that
deliverables for all site work require a GIS coverage or
theme, where reasonable, for all segments of work on the
site. In this way the marginal cost for developing the GIS
would be very small for any component of site work. When
the themes were eventually combined, U.S. Borax would be
provided with a GIS which could be used as a base and
updated in the future as the value of the system was
demonstrated during continuing operations.
Map, Survey Control, and System Requirements
All mines are dependent on maps and surveys to provide
control in the development of operations. U.S. Borax is no
exception. Aerial photography and ground survey control
have been developed for the entire site. The availability
of this information at mining operations provides
immediate advantages in establishing a GIS. First, no
additional costs are required for developing a base map.
Second, high accuracy is provided for establishing all
other map information. These map products and related
information formed the basis for the development of the
GIS for the facility.
ARC/INFO GIS Software
Condor had previously selected the ESRI group of GIS
products for mining and other natural resource GIS project
work. Experience with ARC/INFO and the knowledge that this
platform would meet the U.S. Borax needs led to a
recommendation to develop the GIS for the site on this
platform. The ArcView and ArcCad products provided the
ability to introduce U.S. Borax personnel to the value of
GIS with low-cost, easy-to-use, and immediately applicable
GIS examples while providing integration with existing
AutoCad products.
PenMap Real-Time Field Survey, Mapping and GIS Data
Collection Software
While existing base maps were available in digital format
at the U.S. Borax operation, the maintenance of the GIS
was dependent upon the ability to update existing maps and
create new coverages cost effectively. Condor's PenMap
software was selected to undertake field survey, mapping
and GIS data collection. The PenMap software operates on a
ruggedized field 486 Pen computer allowing the individual
doing the survey to use any of 20 different survey and
data collection methods and to see the map as it is being
created in the field. In addition, the program includes a
GIS forms generator to enable the creation of user defined
GIS forms for use in field data collection. These forms
can be attached to any point, symbol, or other graphic
feature on the map as it is created in the field. Once
attribute information is collected, it can then be
exported to ARC/INFO, ArcView, ArcCad or AutoCAD. A key
feature is the ability to import maps and GIS data from
any of these other platforms, as well as many others, so
that maps and database information can be taken to the
field for easy updating.
An extremely important use
of the PenMap system was made when maps of different
scales containing information for use in the GIS were
combined. Digital map data was imported to PenMap to be
taken to the field where it could be easily verified and
updated. The information could then be exported to
ARC/INFO or ArcView where it was used for GIS analysis or
delivered back to AutoCad for update of drawings. This
enabled the reconciliation of significant map information
and data that had been created during more than 50 years
of mine operation.
Project Activity and Resulting GIS Work Products
The following section provides a brief description of
engineering, geotechnical, hydrogeological and
hydrological projects that required several months, or in
some cases several years to complete and related GIS
products. It is important to emphasize that at no time was
the client anticipating development of the GIS. U.S. Borax
was instead interested in resolving technical issues
related to short and long-term profitable operations. The
GIS became both a tool for and by-product of the principal
work activity. Figure 3 is a graphic summary of projects
discussed below.
Project #1 Turning Liabilities Into Assets -
Evaporation Pond Reclamation
The future of mines are being redefined as their long term
asset value appreciates and environmental requirements
change. Materials once considered waste are now considered
ore. For example, residual materials retained in
evaporation ponds at the U.S. Borax facility contain boron
and other recoverable minerals. The incentive to reprocess
these materials is defined by both recoverable grades as
well as the high cost of in-place closure dictated by
changes in environmental regulations during the 1980s.
Large evaporation ponds at
the U.S. Borax facility are now planned for reclamation.
The project requirements included design and
implementation of pond dewatering, development of a
materials recovery system, design and implementation of a
process facility, and design and permitting of pond
closure.
AutoCad drawings of the
ponds were developed from aerial photography and site
survey. Pond materials were evaluated by collecting
samples during a comprehensive drilling program and
subsequently subjecting the sampled materials to physical
and chemical analysis. The analytical results were treated
as attributes of the pond and displayed in GIS coverages
for future evaluation. Total material volumes were
determined as well as recoverable quantities of valuable
minerals which could then be used in determining the
economics of recovery of the pond materials versus closure
in place. Because only a percentage of the materials can
be economically recovered, residual process materials must
be stored in an alternative location. The volumes of these
materials could be calculated and locations for their
disposal determined. U.S. Borax is now developing
reprocessing plans for mining the evaporation ponds.
Project #2 Ground Water Analysis
Vigilant monitoring and evaluation of site groundwater
conditions is undertaken at U.S. Borax. The complexity of
site geology and the indigenous mineralization combined
with current and past mining activities make the use of
GIS an extremely attractive tool for the hydrogeologist.
The site digital aerial map was used as a base to record
groundwater well locations which were surveyed with a
Total Station to establish accurate horizontal and
vertical control. Water quality information is then
collected from the wells from different geologic
formations. The information is used to determine the
location of various aquifers and groundwater gradients to
monitor water quality over time.
Project #3 Surface Water Analysis
The Federal Emergency Management Agency (FEMA) is
responsible for determining what areas will be considered
flood-plain and consequently subject to specific
regulation. New stormwater regulations combined with
recent flood related disasters throughout California and
the nation have resulted in re-evaluation of the
definition of floodplains. The area containing the U.S.
Borax open pit mine and waste piles include historic
drainages designated as FEMA flood plains. During recent
permitting review for future expansion, Kern County
requested that FEMA designated floodplains be re-evaluated
to determine the risk of flooding to the proposed
expansion. They also requested that a comprehensive
stormwater management plan be developed to mitigate
negative impacts.
A determination that the
operation was located within a flood- plain would have
required major modification and great costs to address
potential flood scenarios related to 10, 50, and 100 year
storm events. It was, therefore necessary to develop a
response that accurately depicted the site and enabled
quantitative analysis of variables associated with flood
analysis.
Maps including the U.S.
Borax site and surrounding area were generated in GIS
format to provide for the evaluation of surface water
drainage characteristics (Figure 5). Topography was
overlain with area geology, soils, and hydrologic basins
were identified. Storm water run-off coefficients were
calculated and site hydrology examined. Area background
maps were imported to PenMap and then taken to the field
for updating. Once map updating was completed, information
was exported to ArcView version 2.0 for analysis in
conjunction with the HEC 1 surface hydrology modeling
program.
The project established
that the developed stormwater management plan would
effectively mitigate and manage any potential flood
waters. It further established that FEMA floodplain
designation was not warranted. This use of GIS alone was
responsible for saving the company very high costs and
extensive time for site modifications that would otherwise
have been necessary to comply with FEMA flood plain
restrictions.
Project # 4 Scheduling and Placement of Mine Waste
Rock Materials
The U.S. Borax facility, like other property owners, has a
limited land area for conducting operations. The operation
generates large quantities of overburden and non-ore
bearing materials that require storage areas for
continuation of mining. Operations may be subject to
change from time to time due to changes in ore grade,
market demand for the products, geotechnical constraints
in the mine or other mine production or operating
conditions. The build-out of the overburden and waste rock
storage areas are dynamic and planning must accommodate
changes while adhering to land ownership boundary
constraints.
Figure 4 is an example of
how mine production of ore is used to develop GIS for
scheduling the timing and physical placement of waste rock
at the site.
Summary
In each of the projects discussed, limited data were
available at the beginning of the project activity.
Information that was available could not be provided in a
format appropriate for computer analysis. It was,
therefore, necessary to undertake data conversion and
updating prior to use for various project analysis. Using
the technologies discussed in this article, a cost
effective survey, mapping, GIS data collection and
analysis program was developed as part of other technical
work programs using the PenMap, ARC/INFO, ArcCad, and
ArcView software products. Much like CAD, GIS was used as
a tool to support engineers, geologists, and environmental
scientists to produce work products as one aspect of their
project activity. U.S. Borax benefited both by completion
of the technical work undertaken but also by the
development of a GIS that can now continue to be expanded
for a wide variety of site planning as well as operations
control and analysis. Potentially high capital and
operating costs for creating a GIS from scratch were
avoided and client confidence in the value of the GIS was
established.
About the Author:
Barry Hillman is president and CEO of
Condor Earth Technologies Inc. Condor would like to
express appreciation to Gerald M. Pepper, Arthur
Beckerman, Joseph Siefke, Tony Teske, Cliff Maddox and
the other members of the U.S. Borax operation who
participated in and contributed to the programs discussed
in this article. Condor personnel and associates
responsible for directing and participating in the
programs discussed here are Dr. Donald Bishop, vice
president and project manager, Ronald Skaggs, Scott Lewis,
Robert Hoagland, Debra Lewis, Glen Nunnelley, David Meade,
Michael Meade, and Howard Ericksen and Dr. Alvin Franks.
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