How to improve the ramp-up of

block caving mines

Cmo mejorar la subida de produccin en
minas de block caving
Alfonso Ovalle, Dr. Peter Cepuritis
Amec Foster Wheeler, Chile

How to improve the ramp-up of block caving mines

MOTIVATION

Better production ramp-up will greatly affect NPV of the

project because of higher production in the early years,
usually of the better grades and at higher discount factors
90
80
70

kt / d

60
50
40
30
20
10
0
1

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Discount
rates

Years
10% 0.91 0.83 0.75 0.68 0.62 0.56 0.51 0.47 0.42 0.39 0.35 0.32 0.29 0.26 0.24 0.22 0.20 0.18 0.16 0.15 0.14 0.12 0.11 0.10 0.09 0.08 0.08 0.07 0.06 0.06 0.05 0.05
8% 0.93 0.86 0.79 0.74 0.68 0.63 0.58 0.54 0.50 0.46 0.43 0.40 0.37 0.34 0.32 0.29 0.27 0.25 0.23 0.21 0.20 0.18 0.17 0.16 0.15 0.14 0.13 0.12 0.11 0.10 0.09 0.09
6% 0.94 0.89 0.84 0.79 0.75 0.70 0.67 0.63 0.59 0.56 0.53 0.50 0.47 0.44 0.42 0.39 0.37 0.35 0.33 0.31 0.29 0.28 0.26 0.25 0.23 0.22 0.21 0.20 0.18 0.17 0.16 0.15

Discount factors

(Ref. 1)
Page 1 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS
Production Ramp-up of BC Mines ____
140

130
120
110

Production, t/d

100
90

80
70
60

Teniente 4 S Sector

50

Dec. 1981

40
30
20
10
0
0

10

11

Years

(Ref. 2)
Page 2 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS
Production Ramp-up of BC Mines ____
140

130
120
110

Production, t/d

100
90
80
70

Teniente 4 S Sector

60

Esmeralda, El Teniente

50
40

Sep. 1997

30
20
10
0
0

10

11

Years

(Ref. 2)
Page 3 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS
Production Ramp-up of BC Mines ____
140
130
120
110

Production, t/d

100
90

Palabora Lift 1

80

Jun. 2001

70
Teniente 4 S Sector

60
50

Esmeralda, El Teniente

40
30
20

10
0
0

10

11

Years

(Ref. 3)
Page 4 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS

Production, t/d

Production Ramp-up of BC Mines ____

140
130
120
110
100
90
80
70
60
50
40
30
20
10
0

Cadia East

Dec. 2012

Palabora Lift 1
Teniente 4 S Sector
Esmeralda, El Teniente

10

11

Years

(Ref. 4)
Page 5 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS

Production, t/d

Production Ramp-up of BC Projects -----140

130
120
110
100
90
80
70
60
50
40
30
20
10
0

NNM, El Teniente

10

2019

11

Years

(Ref. 5)
Page 6 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS

Production, t/d

Production Ramp-up of BC Projects -----140

130
120
110
100
90
80
70
60
50
40
30
20
10
0

PMCHS,
Chuquicamata

2018

NNM, El Teniente

10

11

Years

(Ref. 6)
Page 7 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS

Production, t/d

Production Ramp-up of BC Projects -----140

130
120
110
100
90
80
70
60
50
40
30
20
10
0

Palabora Lift 2

2018?

PMCHS, Chuquicamata
NNM, El Teniente

10

11

Years

(Ref. 3)
Page 8 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS

Production, t/d

Production Ramp-up of BC Projects -----140

130
120
110
100
90
80
70
60
50
40
30
20
10
0

Oyu Tolgoi

2018?

Palabora Lift 2
PMCHS, Chuquicamata
NNM, El Teniente

10

11

Years

(Ref. 7)
Page 9 of 28

How to improve the ramp-up of block caving mines

BC RAMP UPS

Production, t/d

Production Ramp-up of BC Mines ____

and Projects -----140
130
120
110
100
90
80
70
60
50
40
30
20
10
0

Cadia East
Oyu Tolgoi

Palabora Lift 2
PMCHS, Chuquicamata
Palabora Lift 1
NNM, El Teniente
Teniente 4 S Sector
Esmeralda, El Teniente
0

10

Years

Page 10 of 28

11

How to improve the ramp-up of block caving mines

ATTAINABLE BC RAMP UP

Production, t/d

Production Ramp-up of BC Mines ____

and Projects -----140
130
120
110
100
90
80
70
60
50
40
30
20
10
0

Possible
Cadia East
Oyu Tolgoi
Palabora Lift 2
PMCHS, Chuquicamata
Palabora Lift 1
NNM, El Teniente

Teniente 4 S Sector
0

10

Years

Page 11 of 28

11

Esmeralda, El Teniente

How?

How to improve the ramp-up of block caving mines

ASPECTS THAT GOVERN THE RAMP UP

Primary issue: the Cave Back Velocity (CBV)
must be greater than the extraction velocity
Undercutting rate

Air gaps are to be avoided or minimized

During cave propagation

Avoid big seismic events

Extraction rate
Fragmentation size at draw point
Design of caving system
Design of materials handling system design

Risk prevention
Operational hazards: rockburst, airblast
Design hazards, due to incorrect assessment of the
ground conditions

Page 12 of 28

How to improve the ramp-up of block caving mines

CAVE BACK VELOCITY

Rock mass properties

Intact strength & modulus

Major structures
Joint network geometry
Joint strength & stiffness

Preconditioning

Stresses
In situ stress
Induced stresses

Undercut size, shape and direction

Draw strategy
Adjacent mining

Improving cave propagation

Breakthrough to lowest elevation
High undercutting
Preconditioning the rock mass

Page 13 of 28

How to improve the ramp-up of block caving mines

PRECONDITIONING THE ROCK MASS

Teniente (widespread use of hydrofracturing)
Mitigation of rock bursts
Faster cave back velocity

1,200 m to surface
took less than 3 years

Cadia East (intensive pre-conditioning cave back velocity of 1.1 m/d)

Hydrofracturing
High undercutting

Confined Blasting

450 m

150 m

(Ref. 3)
Page 14 of 28

How to improve the ramp-up of block caving mines

GREEN LIGHT FOR FASTER RAMP UP

Cave propagation velocity in hard rock of 1.1 m/d
NOW A DESIGN PROBLEM

Increase
undercutting rate

Increase
extraction rate

Page 15 of 28

How to improve the ramp-up of block caving mines

FASTER RAMP UP
Increase undercutting rate:
Maximize undercutting velocity
Post undercutting, if possible
Establish more than one undercutting front
Undercutting front in spear shape
Split levels

Simple design
Enhance planning, equipment, services and logistics

Increase extraction rate:

Design for more area availability
If LHD, shorter tramming
RGO option (rock breaker, grizzly, ore pass)
Continuous mining option
Page 16 of 28

How to improve the ramp-up of block caving mines

DRAW RATE WITH LHDs

Draw rate with LHD system. Rim crushers arrangement.
Long tramming distances
- At 300 m from DP to crusher, a 12 t/bucket LHD produces 3,000 tpd
- If Production Drift is 240 m long and distance between drifts is 30 m, it uses 7,200 m2
- Maximum draw rate possible is 3,000 / 7,200 = 0,42 tpd/m2
- If density is 2.70 t/m3
- Maximum draw down rate is 0.50 / 2.7 = 0.15 m/d
- Using 75% utilization factor:
- Maximum Planning draw down rate is 0.12 m/d

240 m

30 m
To rim
crusher

Page 17 of 28

How to improve the ramp-up of block caving mines

MAKING DRAW RATE FASTER WITH LHDs

Draw rate with LHD system. Ore passes at 120 m & haulage level.
Ore pass and rock breaker in Production Drift arrangement
- A 12 t/bucket LHD produces 4,000 t/d (controlled by interference with rock breaker)
- With 120 m between OP and distance between drifts of 30 m, it uses 3,600 m2
- Independent ventilation for each 120 m segment to use an LHD
- Maximum draw rate possible is 4,000 / 3,600 = 1.11 tpd/m2
- If density is 2.70 t/m3
- Maximum draw down rate is 1.11 / 2.7 = 0.41 m/d
- Using 75% utilization factor
- Maximum Planning draw down rate is 0.31 m/d

120 m

120 m

30 m
Ore passes to Haulage Level
Page 18 of 28

How to improve the ramp-up of block caving mines

MAKING DRAW RATE FASTER WITH LHDs

Draw rate with LHD system. Ore passes at 80 m & haulage level.
Ore pass and rock breaker in Production Drift arrangement
- A 12 t/bucket LHD produces 4,200 t/d (controlled by interference with rock breaker)
- With 80 m between OP and distance between drifts of 30 m, it uses 2,400 m2
- Independent ventilation for each 80 m segment to use an LHD
- Maximum draw rate possible is 4,200 / 2,400 = 1.75 tpd/m2
- If density is 2.70 t/m3
- Maximum draw down rate is 1.11 / 2.7 = 0.65 m/d
- Using 75% utilization factor
- Maximum Planning draw down rate is 0.49 m/d

80 m

80 m

80 m

30 m
Ore passes to Haulage Level
Page 19 of 28

How to improve the ramp-up of block caving mines

MAKING DRAW RATE FASTER WITH RGO

RGO System (rock breaker, grizzly, ore pass)
Rock breaker directly on draw point to a grizzly
Grizzly connected to short ore pass
Lower collection level (with panzer feeder going to sizer or central OP)

Concepts of RGO System

Rock breakers are teleoperated
o
o

Less ventilation required

More operating hours possible

Production drifts belong to secondary blasting and hang up crews!

High area utilization possible
No diesel drives
(Ref. 8)
Page 20 of 28

How to improve the ramp-up of block caving mines

MAKING DRAW RATE FASTER WITH RGO

Rock Breaker Productivity (Ten 4 Fw test, primary ore)
5.000

Productivity, t/d

4.500
4.000

t/d, 20" x 36" grizzly

t/d, 20" x 20" grizzly

3.500
3.000
2.500
2.000
0

30

60

90

120

% Extraction
(Ref. 8)
Page21 of 28

How to improve the ramp-up of block caving mines

MAKING DRAW RATE FASTER WITH RGO

RGO System (rock breaker, grizzly, ore pass)
Draw rate calculation of RGO System
- One rock breaker produces 2,300 t/d (lowest rate at 30% extraction)
- One rock breaker for every 4 DP, or 40 m. Distance between drifts of 30 m, it uses 1,200 m2
- Independent ventilation for every three rock breakers
- Maximum draw rate possible is 2,500 / 1,200 = 1.92 tpd/m2
- If density is 2.70 t/m3
- Maximum draw down rate is 2.08 / 2.7 = 0.71 m/d
- Using 75% utilization factor
- Maximum Planning draw down rate is 0.53 m/d
40 m

40 m

40 m

40 m

40 m

40 m

30 m

|
Page 22 of 28

How to improve the ramp-up of block caving mines

MAKING DRAW RATE FASTER

Draw Rates,
LHD and RGO Systems
1,20
1,10
1,00
0,90

Draw Rate, m/d

0,80
0,70
0,60
0,50
0,40
0,30
0,20
0,10
0,00

LHD,
240m

LHD,
120m

LHD,
80m

RGO,
15%E

Block Caving Systems

Page 23 of 28

RGO,
45%E

RGO,
75%E

RGO,
105%E

How to improve the ramp-up of block caving mines

EVALUATION OF RAMP-UP INCREASE

The following block cave project was evaluated with normal and steeper
ramp-up production periods, caused by the following:
UNDERCUTTING RATE:
Increased from
34,000 m2/yr to
48,000 m2/yr for 2 years

DRAW RATE:
Increased from
0.20 m/d to 0.40 m/d
RESULT:
Ramp up was shortened
from 9 to 4 years

Page 24 of 28

How to improve the ramp-up of block caving mines

EVALUATION OF RAMP-UP INCREASE

MUS$

455

100

1,009

222

Total increase:

554

122

Due to Draw Rate increase:

400

88

Due to Undercutting Rate increase:

154

34

NPV (8%) SLOW RAMP UP:

NPV (8%) FAST RAMP UP:

Page 25 of 28

How to improve the ramp-up of block caving mines

CONCLUSIONS
Intensive preconditioning of the rock mass green light for higher
extraction rates
High Undercut:
HF preconditioning:
Forced Fragmentation Blasting:

helps early draw rates and prevents collapses

proven technology to improve the caving velocity
drill and blast to break base of columns

Vertical Shaft:

to connect UCL to surface that serving as path/guide

BC designs need to increase extraction rates

LHD systems: can go up to around 0.50 m/d, with difficulty
RGO system: can go beyond 0.50 m/d, with ease

Ramp up of BC projects can be shortened, with very important increase of

the NPV.

Page 26 of 28

How to improve the ramp-up of block caving mines

REFERENCES
1.

2.
3.
4.
5.
6.
7.
8.

Mass caving maximum production capacity, Alfonso W. Ovalle, Amec International; University of Chile,
MASSMIN 2012, June 11-14, 2012, Sudbury, Ontario, CANADA
Lecciones Aprendidas Explotacin El Teniente, A. Ovalle, Set. 2006
Block caving with Rio and NCM, Credit Suisse, 27 Set 2012, Visit Report
Newcrest Mining Company Quarterly Reports
Presentacin NNM, J. Revuelta, Nov. 2013
Presentacin PMCHS, S. Fuentes, Abr. 2013
Turquoise Hill Resources Ltd. Oyu Tolgoi 2014 Technical Report, October 2014, Job N 14003, OreWin,
Independent Mining Consultants, Figure 1.7, 2014 Reserve Case processing, pg. 28
Martillos picadors semi-mviles en Teniente 4 Norte Fw, 1990. Comunicaciones con A. Moyano.

Page 27 of 28

How to improve the ramp-up of block caving mines

END

Thank you for your attention

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