AU2021106881A4

AU2021106881A4 - Underground cementitious material pumping system and method thereof

Info

Publication number: AU2021106881A4
Application number: AU2021106881A
Authority: AU
Inventors: Nathan Phie
Original assignee: FCI Holdings Delaware Inc
Current assignee: FCI Holdings Delaware Inc
Priority date: 2021-08-24
Filing date: 2021-08-24
Publication date: 2021-11-25
Anticipated expiration: 2029-08-24

Abstract

Disclosed is an underground pumping system for dispensing cementitious material in an underground environment. The pumping system comprising one or more cement dispensers positioned in the underground environment configured to 5 hold at least one tonne of the cementitious material, and one or more batching stations configured to receive a predetermined quantity of the cementitious material respectively from the one or more dispensers. The one or more batching stations are configured to dispense the predetermined quantity cementitious material to an underground mine application via a delivery pump station. Also 10 disclosed is a method of dispensing cementitious material in an underground mine. Also disclosed is an underground pumping system integrated with a dust extraction system. [Fig. 2] 18000426_1 (GHMatters) P105058.AU 2/4 C ~ 00 (n r14N cn r-4 C* (N (

Description

2/4

C ~ 00

(n

r14N

cn r-4

C* (N ( UNDERGROUND CEMENTITIOUS MATERIAL PUMPING SYSTEM AND METHOD THEREOF TECHNICAL FIELD

This disclosure relates an underground dispenser system and method for cementitious material.

BACKGROUND ART

Cementitious material is used in underground mines for various applications. For example, mine roof support may be provided by various kinds of cribbing, such as wooden cribbing and pumpable cribbing. Pumpable cribs include a pumpable cementitious material pumped into a collapsible columnar containment bag. Also known in underground mines is erecting walls using formwork and cementitious material for isolating areas of the mine from gases, water, fires etc.

Some mines only utilise underground operations due to their topography. Within these known mines applications of utilising cementitious material, the cementitious material is transported underground manually by the operators. Manual handling of the cementitious material is labour intensive and can cause injuries to the operators.

It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.

SUMMARY

According to an aspect, disclosed is an underground pumping system for dispensing cementitious material in an underground environment. The pumping system comprising one or more cement dispensers positioned in the underground environment configured to hold at least one tonne of the cementitious material; one or more batching stations configured to receive a predetermined quantity of the cementitious material respectively from the one or more dispensers; and

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18000426_1(GHMatters) P105058.AU wherein the one or more batching stations are configured to dispense the predetermined quantity cementitious material to an underground environment application via a delivery pump station. The one or more cement dispensers holding large volume of the cementitious material allows for a continuous dispensing system. The one or more cement dispensers may be positioned on a vehicle which is connected to the one or more batching stations underground, or the cementitious material may be transported underground by a vehicle and machine loaded into the one or more cement dispensers. Manual handling of the cementitious material is eliminated, and thus injuries of the operators associated with manual handling of the cementitious material of the prior art is also eliminated.

In some embodiments, the underground dispenser system further comprising a conveying system arranged to convey the predetermined quantity of cementitious material from the one or more dispensers respectively to the one or more batching stations. In some embodiments, the conveying system comprises one or more augers to pump the cementitious material to the one or more batching stations. In some embodiments, the conveying system automatically stops conveying the cementitious material to the one or more batching stations when the quantity of the cementitious material reaches the predetermined quantity of cementitious material. In some embodiments, the conveying system automatically stops pumping the cementitious material to the one or more batching stations when the predetermined quantity of cementitious material is contained in the one or more batching stations. In some embodiments, the one or more cement dispensers include respective one or more sensors to determine the deduction of the predetermined quantity (e.g., volume) of the cementitious material from the tare weight. The automatic dispensing system results in increased production by stopping when the tare weight of the cementitious material equals the predetermined quantity and pumping when the tare weight of the cementitious material is less than the predetermined quantity. The predetermined quantity is determined by the batch size required for the particular underground application.

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18000426_1 (GHMatters) P105058.AU

The one or more cement dispensers are filled with a further bulk bag of cementitious material when the tare weight of the cementitious material remaining in the one or more dispensers indicates that there is available holding space in the one or more dispensers for the new bulk bag of cementitious material.

In some embodiments, each of the one or more batching stations comprises a batching tank for receiving the predetermined quantity of cementitious material. In some embodiments, the batching tank further comprises a predetermined quantity of fluid for mixing with the predetermined quantity of cementitious material. In some embodiments, the fluid is water.

In some embodiments, each batching station comprises a holding tank for holding the predetermined mixed cementitious material for dispensing to the underground environment application.

In some embodiments, the underground dispenser system further comprises one or more delivery pump stations for delivering the mixed cementitious material to the underground environment application. In some embodiments, each delivery pump station includes a first line and a second line, the first line draws the mixed material respectively from one of the batching stations, and the second line includes a catalyst which activates the mixed cementitious material from the first container. The first line may draw the mixed cementitious material from the holding tank. The second line may draw the catalyst from a second holding tank. The second line 38 is arranged in fluid communication with the second holding tank to draw mixed catalysing material from the one of the batching stations. In some embodiments, each delivery station includes a separate delivery line for the first line and the second line to the underground environment application. In some embodiments, the cementitious material contained in the first line and the catalyst in the second line is delivered via the separate delivery lines in a ratio of 1 to 1.

According to a further aspect, disclosed is an underground environment dispensing container comprising one or more cement dispensers positioned in the underground environment configured to hold a quantity of cementitious material; 3

18000426_1 (GHMatters) P105058.AU and a dust extraction system integrated with the one or more cement dispensers, the dust extraction system arranged to extract airborne dust from the one or more dispensers to reduce amount of the airborne dust in the underground environment.

In some embodiments, the airborne dust includes silica. In some embodiments, the dust extractor system is positioned proximate the one or more cement dispensers, and the dust extractor system includes an extractor respectively connecting the dust extractor system and the one or more dispensers. The dust extractor system reduces dust hazards that are typical of these types of operations. The dust extractor system being integrated with the one or more cement dispensers reduces the airborne dust in the working environment which improves air quality for the operators working underground.

According to a further aspect, disclosed is a method of dispensing cementitious material in an underground environment. The method comprising positioning one or more cement dispensers in the underground environment, the one or more cement dispensers being configured to hold at least one tonne of the cementitious material; positioning one or more batching stations in the underground mine, arranged to receive a predetermined quantity of the cementitious material from the one or more cement dispensers; and dispersing the predetermined quantity of cementitious material to an underground mine application via a delivery pump station.

In some embodiments, the method further comprises conveying the predetermined quantity of cementitious material from the one or more cement dispensers to the one or more batching stations via a conveying system. In some embodiments, the conveying system comprises one or more augers and the method further comprises pumping the cementitious material via the one or more augers to the one or more batching stations. In some embodiments, the method further comprises automatically stopping pumping of the cementitious material to the one or more batching stations when the predetermine quantity of cementitious material is contained in the one or more batching stations. In some embodiments, the

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18000426_1 (GHMatters) P105058.AU method further comprises determining the predetermined quantity of cementitious material from the tare weight. Determining the predetermined quantity of cementitious material may be performed by one or more sensors. Automatically dispensing the cementitious material may be performed by the deductive weight system using the one or more sensors and the tare weight of the cementitious material.

The disclosed underground pumping system and method of dispensing cementitious material in an underground environment has significant efficiencies. The disclosure is directed to underground operations rather than surface operations. Some underground mines can only employ underground operations due to their topography. Within these underground environments having this topography, the prior art systems allow for 20kg bags as a means of feeding the materials into the systems, which requires manual handling of the 20kg bags to feed the cementitious materials into the system. Operators experience injuries associated with this manual handling.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described by way of example only, with reference to the accompanying drawings in which

Figs. 1 is an isometric view of an embodiment of an underground pumping system for cementitious material;

Fig. 2 is side view of the underground pumping system of Fig. 1;

Fig. 3 is an isometric view of an embodiment of a cement dispenser station of the underground pumping system of Fig. 1; and

Fig. 4 is a plan view of the underground pumping system of Fig. 1.

DETAILED DESCRIPTION

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In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

Referring to Figures 1-4, illustrated is an embodiment of an underground pumping system 10 and methods of dispensing cementitious material in an underground environment. The underground pumping system 10 is used to provide automated accurate dispensing of predetermined quantities of bulk cementitious material for the underground environment. In the illustrated embodiment, the underground environment is an underground mine, but may be used in other applications such as tunnelling environments (e.g., underground road or train tunnels), and underground infrastructure environments. Cementitious material is used for various applications in the underground mine environment. The underground pumping system 10 includes one or more cement dispensers 12, one or more batching stations 14, one or more delivery stations 16 and one or more starter stations 18. The underground pumping system 10 is positioned in the underground environment, for example, the underground mine.

The one or more cement dispensers 12 are configured to hold at least one tonne of the cementitious material. The one or more batching stations 14 are configured to receive a predetermined quantity of the cementitious material respectively from the one or more cement dispensers 12, and dispense the predetermined quantity of cementitious material to an underground mine application via a delivery pump station.

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In the illustrated embodiment, two cement dispensers are positioned adjacent one another 12 are illustrated. Each cement dispenser 12 is able to hold up to 2.4 tonnes of dry cementitious material, which is arranged to be conveyed to the batching station 14 in predetermined amounts. The cement dispenser 12 is travelled underground for use with a batching station 14 and 1 or 1.2 tonne bulk bags of cementitious material are travelled underground in a vehicle/front end loader. The cement dispenser 12 is configured with a large hopper 26 for receiving dry cementitious material. A bulk bag support frame 28 is positioned adjacent the hopper for supporting the bulk bags of cementitious material during dispensation into the hopper 26. A lid of the hopper may also be configured as the support frame 28. It is configured to engineered to support a 1.2T bulk bag.

In some embodiments, a jib (not shown) attached to an underground loader is utilised to lift bulk bags of the dry cementitious material over the hopper 26 and lower onto a bulk bag support frame 28 of the cement dispenser 12. The bulk bags of the dry cementitious material hold at least one tonne, such as 1 tonne to 1.2 tonne bulk bags. Each cement dispenser is able to hold up to 2.4 tonnes. A bulk bag chute is undone to release the cementitious material into the hopper 26 of the dispenser 12 via an inlet 46. The bulk bag chute forms part of the design of the bulk bag itself. In further embodiments, the bulk bags may be lifted via an overhead rail system. Further, in non-illustrated alternative embodiments, the vehicle may include the cement dispenser and moved into position relative to the other components of the underground pumping system. In this way, the other components may be connected directly to the cement dispenser on the vehicle.

It is understood that any number of cement dispensers may be positioned in the underground mine depending on the required amount/volume of cementitious material required for the various applications and space available.

The underground pumping system 10 further comprises a conveying system 30 arranged to convey a predetermined quantity of cementitious material from each cement dispenser 12 to each batching station 14. Further, the conveying system 30

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18000426_1 (GHMatters) P105058.AU comprises one incline auger 20 and one horizontal auger 44 to pump the cementitious material from each cement dispenser 12 to each batching station 14. Each incline auger 20 extends between an inlet 22 and an outlet 24.

As illustrated in Fig. 2, each cement dispenser 12 is arranged alongside the respective batching station 14. The inlet 22 of the incline auger 20 is connected at the outlet of the horizontal auger, and the outlet 24 of the incline auger 20 is disposed overtop of the desired catchment area of the batching station 14. The batching station includes a batching tank 14. The incline auger 20 conveys the cementitious material from the outlet 24 of the incline auger 20 into the catchment area of the batching tank 14. The incline auger is inclined from the cement dispenser 12 over the top of the batching tank and is adjustable via a hydraulic mechanism. The incline auger 20 includes a transition region between the incline auger extending from the cement dispenser to the batching tank and the outlet 24 extending downwards towards the catchment area of the batching tank. The positioning of the conveying system over the batching tank allows both the batching tank to contain fluids and the downward portion of the incline auger to dispense the dry cementitious material into the batching tank by gravity and in some embodiments the incline auger includes an auger.

In the prior art, 20kg bulk bags of cementitious material are manually loaded into a batching station, and then the mixing rations are manually calculated. The underground pumping system 10 is automated such that the cement dispenser 12 dispenses any predetermined quantity of cementitious material up to 2.4 tonnes to the batching station 14 upon being activated by the operator, for example, at the push of a button. Each cement dispenser 12 is able to accurately dispense loads in units of 1kg, increasing the measurement increment from the previous 20kg increments to 1kg increments.

Once each cement dispenser is full to its capacity (e.g., 2.4 tonnes), the operator moves to an external control panel and uses the start batch function to dispense the predetermined volume of cement into the mixing container of the batching

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18000426_1 (GHMatters) P105058.AU stations 14. The hopper 26 is arranged to recognise the deduction of the predetermined quantity from the tare weight and upon doing so automatically stops the augers from conveying cementitious material to the batching station 14. One or more sensors are associated with the hopper 26 to measure the tare weight of the cementitious material. The automatic deduction system reduces wastage through implementing an automated batching system. This process is repeated until there is enough space (via tare weight) in the hopper 26 to hold a further bulk bag of the cementitious material.

The one or more batching stations 14 are configured to receive the cementitious material from the cement dispenser, mix it with fluids, such as water, which is then transferred to the one or more delivery stations 16 for delivery to various applications in the underground environment. Each batching station 14 includes a batching tank 32 and a holding tank 34.

As illustrated in Figure 2, two batching stations 14 are disposed proximate the respective cement dispensers 12 such that the augers of the cement dispenser 12 can convey the predetermined amount of cementitious material into the batching tank 32. The batching tank 32 comprises a predetermined quantity of fluid, such as water, for mixing with the predetermined quantity of cementitious material, doing away with wastage and inaccurate cement to water ratios during in-situ calibration at the batching station 14.

Further, each batching station 14 comprises the holding tank 34 for holding the predetermined mixed cementitious material for dispensing to the underground environment application once it has been sufficiently blended in the batching tank 32. The holding tank 34 is disposed proximal to and is in fluid communication with the batching tank 32 via a transfer pump and steel transfer pipes.

Turning to Fig. 4, the illustrated underground pumping system 10 has the second cement dispenser 12 and the second batching station 14 disposed next to the first cement dispenser 12 and first batching station 14 in the same arrangement as described above.

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18000426_1 (GHMatters) P105058.AU

Depicted in Fig 2, the underground pumping system 10 further comprises the delivery pump station 16 for delivering the mixed cementitious material to the underground environment application. The delivery pump station 16 further comprises separate delivery lines including first and second lines 36, 38. The first line 36 is arranged in fluid communication with the holding tank 34 via clear suction hoses (not shown) to draw the mixed cementitious material from one of the batching stations 14.

The second line 38 is arranged in fluid communication with the other holding tank 34 via clear suction hoses (not shown) to draw the mixed catalysing material from the one of the batching stations 14. The catalyst activates the mixed cementitious material travelling via the first line 36 to the underground application, i.e., underground destination.

The mixed cementitious material is delivered via the first line 36 and the catalyst is delivered via a second line 38 in a delivery ratio of 1:1. The two delivery lines 36, 38 transport the catalyst and the mixed cementitious material in separate lines from the delivery pump station 16 to the destination. For example, the delivery lines 36, 38 can transport the catalyst and the mixed cementitious material up to 5km from the pumping system 10.

Illustrated in Fig. 2 the underground pumping system further comprises a starter box 18. The starter box 18 comprises a transformer which transforms 1000v power to different voltages depending on the application.

The underground mine applications which utilise cementitious material can include:

cribbing: pumping the cementitious material into collapsible columnar containment bags for providing underground support in underground mines, for example at the openings;

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18000426_1 (GHMatters) P105058.AU

* "seals": retainment walls separating areas of the mine to isolate the underground environment from areas that cannot be ventilated or contain hazards such as gases, water, fires, etc.;

• backfilling roadways for support, that are then re-mined;

• backfilling old mines or roadways no longer in use; and

* filling false roofs and or cavity filling in areas of a mine where strata has fallen leaving an unsupported cavity.

The underground pumping system 100 can be deployed according to the outlined embodiments, wherein the cement dispenser 12 is utilised in conjunction with the batching station 14, the delivery pump station 16 and the starter box 18. In alternate embodiments the cement dispenser 12 can be travelled underground for use with pre-existing batching/delivery pump stations. The cement dispenser 12 is able to convey cementitious material to pre-existing batching stations since the incline auger 20 may be positioned such that the outlet 24 is disposed over the catchment area of the requisite batching tank. Further, the hopper 26 of the cement dispenser 12 is arranged to recognise the deduction of the predetermined quantity from the tare weight and upon doing so automatically stops the augers from conveying cementitious material to the batching station. The cement dispenser does not need to be in communication with the batching station and can be used with pre-existing batching stations in the underground environment. The one or more cement dispensers may be retrofit with other batching station systems.

A Quick Detach System 60 (QDS) is integrated into the underground pumping system 10 allowing the components to be adapted to all underground loaders.

Furthermore, the illustrated embodiment of the underground pumping system 10 includes a dust extraction system (not shown) which greatly reduces the amount of airborne dust in the underground environment. Thus, the underground pumping system 10 offers improved performance while reducing airborne dust.

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The dust extraction system is arranged to extract airborne dust from the cement dispenser 12 to reduce the number of airborne particles (such as silica) in the underground environment. The dust extraction system is activated when the bulk bag of cementitious material is released into the hopper 26 of the cement dispenser 12. Once the hopper 16 is filled to its capacity, the dust extraction system is deactivated.

The dust extraction system operates by creating negative pressure inside the cement dispenser 12 to extract the dust as the cementitious material is released from the bulk bag into the cement dispenser 12. In the illustrated embodiment the dust extraction system is integrated with the cement dispensers 12, for example, the dust extraction system may be positioned proximate the cement dispensers 12 and include an extractor respectfully connecting the extraction system and each cement dispenser 12. The dust extractor system may also be directly connected to the cement dispenser itself and form part of the cement dispenser.

The underground pumping system 10 can be deployed in an underground environment where the application of mixed cementitious material is required, and the topography poses restrictions such that the mixing of the cementitious material must be carried out underground. Utilisation of the underground pumping system 10 reduces the idle time of manually loading cementitious material and reduces the wastage and inaccurate mixing ratios that result from loading the batching station in bulk 20kg increments. Further the 2.4 tonne holding volume of each cement dispenser 12 allows for continuous dispensing of the cementitious material to the respective batching station 14. This allows mixed cementitious material to be readily available to be used in a range of underground applications.

In the disclosed embodiments, an external control panel (not shown) allows an operator to set a predetermined amount of cementitious material to be dispensed by the cement dispenser 12 to the batching station 14 in increments of1kg. Once the hopper 26 of the cement dispenser 12 is full, an automated activation operation (for example, a push button) will allow the operator to start dispensing

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18000426_1 (GHMatters) P105058.AU the predetermined amount of cementitious material to the mixing tank 32 of the watching station 14. The auger will automatically stop conveying the cementitious material once the hopper 26 recognises the deduction of the predetermined quantity from the tare weight. This process is repeated until there is enough capacity in the hopper to receive another bulk bag of cementitious material. Once the predetermined quantity of cementitious material reaches the mixing tank 32 of the batching station 14 it is mixed with a predetermined quantity of fluid and once sufficiently mixed is transported to the holding tank 34 of the batching station 14. The mixed cementitious material is then drawn from the holding tank 34 via the first line 36 of the delivery station 16 for delivery to the application site in the underground environment. The catalyst of the other holding tank of the other watching station 34 is delivered in the second line 38 to the mixed cementitious material, and both are delivered up to 5km from the delivery station 16 in a 1:1 ratio. In some embodiments, a first container is included in the delivery station to receive the mixed cementitious material from the holding container prior to delivery in the first line to the underground site.

In general, the flow of the cementitious material through the pumping system goes from the one or more cement dispensers to the one or more batching stations to the one delivery pump station with one or more delivery lines and then finally to the underground mine application (left to right in Figs 1, 2 and 4). A method of dispensing cementitious material in the underground environment includes the following steps:

• positioning one or more cement dispensers in the underground environment, the one or more cement dispensers being configured to hold at least one tonne of the cementitious material;

• positioning one or more batching stations in the underground mine, the one or more batching stations being arranged to receive a predetermined quantity of the cementitious material from the one or more cement dispensers; and

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18000426_1 (GHMatters)P105058.AU

• dispersing the predetermined quantity of cementitious material to an underground mine application.

In the illustrated embodiment, the method further comprises the following steps:

• conveying the predetermined quantity of cementitious material from the one or more cement dispensers to the one or more batching stations via a conveying system, the conveying system comprises one or more augers;

• conveying the cementitious material via the one or more augers to the one or more batching stations;

• automatically stopping conveying of the cementitious material to the one or more batching stations when the predetermine quantity of cementitious material is contained in the one or more batching stations;

• determining the predetermined quantity of cementitious material from the tare weight;

• activating a dust extractor system integrated with the one or more cement dispensers when the cementitious material is being dispensed into the one or more cement dispensers; and

• deactivating the dust extractor system when the one or more cement dispensers are filled to capacity, for example, each dispenser having a 2.4T capacity.

The user can operate the underground pumping system 10 by selecting from predetermined outputs on the cement dispenser, starting and ending a batching cycle, transferring from the batching tank to the holding tank, adjusting the flow rate of the delivery pump system and starting and stopping the delivery pump station. The system and method disclosed herein are highly customisable, increased productivity through increasing volume capacities, reducing manual labour and reducing inefficiencies. The underground pumping system is low

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18000426_1 (GHMatters) P105058.AU profile to suit the available space in the underground environment. Further, the reduction of airborne dust when loading and dispensing cement in the working underground environment.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

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Claims

1. An underground pumping system for dispensing cementitious material in an underground environment, the pumping system comprising:

one or more cement dispensers positioned in the underground environment configured to hold at least one tonne of the cementitious material;

one or more batching stations configured to receive a predetermined quantity of the cementitious material respectively from the one or more dispensers; and

wherein the one or more batching stations are configured to dispense the predetermined quantity cementitious material to an underground mine application via a delivery pump station.

2. An underground pumping system according to claim 1, further comprising a conveying system arranged to convey the predetermined quantity of cementitious material from the one or more dispensers respectively to the one or more batching stations.

3. An underground pumping system according to claim 2, wherein the conveying system automatically stops conveying the cementitious material to the one or more batching stations when the quantity of the cementitious material reaches the predetermined quantity of cementitious material.

4. An underground environment cement dispensing container comprising:

one or more cement dispensers positioned in the underground mine configured to hold a quantity of cementitious material; and

a dust extraction system integrated with the one or more cement dispensers, the dust extraction system arranged to extract airborne dust from the one or more cement dispensers to reduce amount of the airborne dust in the underground mine.

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5. A method of dispensing cementitious material in an underground mine, the method comprising:

positioning one or more cement dispensers in the underground mine, the one or more cement dispensers being configured to hold at least one tonne of the cementitious material;

positioning one or more batching stations in the underground mine,

receiving a predetermined quantity of the cementitious material in the one or more batching stations from the one or more dispensers; and

dispensing the predetermined quantity of cementitious material to an underground mine application via a delivery pump station.

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32

20 30 28

28 1/4

Fig. 1

24 20 32 44 22 30 34 28

26 2/4

12 14 16 18

Fig. 2

28

20 3/4

44

Fig. 3

32 34 14 40

12

12 4/4

18 32 34 36 38 14 16 Fig. 4