Rock Preconditioning application in virgin caving condition in a panel caving mine, CODELCO Chile El Teniente Division

O.A. Araneda CODELCO El Teniente Division, Chile R.F. Morales CODELCO El Teniente Division, Chile E.G. Rojas CODELCO El Teniente Division, Chile J.O. Henrquez CODELCO Head Office, Chile R.E. Molina CODELCO Head Office, Chile

Abstract
The deepening of the mine operations at El Teniente involves exploiting more competent rocks which are under higher stresses. In the particular conditions of El Teniente Mine, this has meant an increase in the seismic activity induced by the mining. Among several techniques that El Teniente has utilized to face this problem, it recently decided to use a pre conditioning technique for the in situ rock mass, through hydraulic fracturing, in one of the exploitation sectors of the deposit. This application was carried out in at the start of a virgin caving condition; a situation that constitutes an exceptional case in the history of the mining industry. At this present time, the obtained results confirm the expectations of reaching improvements in cavability, seismicity and productivity, in the management of the caving process. In practice, the observed outstanding effects were in the seismic activity and cavability. With regard to seismic activity, a notable decreasing of the seismicity level was observed during the process of connection to the upper crater. With cavability, an increment in the propagation rate of the caving (reduction in the ramp up period) was observed, which will allow the steady state production to be reached sooner. In this way, preconditioning, particularly the hydraulic fracturing, will transform into a very important technical option to incorporate at the beginning of the exploitation of a new sector, with different expectations regarding the condition of caving in state, offering exploitation scenarios with smaller risk, greater control and greater profit value. The previous issues will facilitate the exploitation of the great quantity of geological resources that exists within the Division. Future applications of rock pre conditioning in full production sectors will allow its validation, in order to be introduced industrially to the exploitation by Block and Panel Caving systems in the El Teniente Mine.

Introduction

In 1999, the first studies on preconditioning of the rock mass were initiated in CODELCO Chile. From then, preconditioning applications have been carried out in the Andina and Salvador divisions, using the techniques of hydraulic fracturing and dynamic weakening with explosives. However, the geomechanics conditions presents in the rock mass in the El Teniente Division (which has a stress environment greater than other divisions and prominent seismic activity), it was only in 2004 that the project "Validation of the of Preconditioning Technology in Competent Rock with Hydraulic Fracturing El Teniente Division" was started, with the main objective to validate the hydraulic fracturing technique application.

The application in El Teniente was carried out in Diablo Regimiento sector, in the condition of the start of virgin caving. This condition is not frequent in the Corporation and it is probable that it will not be repeated until 2016 with the entry in production from new mines in Andina, Chuquicamata and El Teniente. Therefore, these two aspects motivated the need to evaluate the technical viability, with an emphasis on clearing doubts related to the generation of induced seismic activity that would be able to cause rock burst events, by means of an industrial test with the hydraulic fracturing technology.

Preconditioning concept

The concept of the pre conditioning is basically to treat the rock mass, by means of some process, prior to its conventional extraction, in order to create new fractures and/or to weaken some of them, to cause the mobilization of its existing structural pattern that is sealed, helping the propagation of its smaller characteristics or micro cavities, or to create in an explicit way an assembly of fractures with favorable characteristics for subsequent caving. Finally, the idea is to induce a massive weakening of all the competent material of interest. In this case, the application of preconditioning is the hydraulic fracturing technique. This process does not intend to fragment the rock mass, such as happens in an operation of forced caving by means of blasting with free a face, but through the fractures generated, leaves the rock mass in the appropriate condition so that the subsequent process of caving causes the propagation, and the intersection of the defects, resulting in a material with the most favorable characteristics for exploitation through caving. Problems are known to exist in caving competent rock. This is the case at El Teniente. In addition, due to the conditions of the current stresses, there is also the important consideration of seismic activity, which from time to time has resulted in rock burst events. In this way, the main objective of the preconditioning technology development has been to have a technically efficient process that permits the in situ pre-treatment of the massive bodies of competent rock prior to mining, to transform into a material with: Better cavability Smaller fragmentation Increase the propagation rate of caving Appropriate seismic response, such that it diminishes the occurrences of rock bursts

The outcome of preconditioning is to obtain an economical or operational benefit by means of Block or Panel caving, with high standards in safety and productivity in mines with competent rock, high stresses and hardness, and with a competitive operational cost.

Hydraulic fracturing application in El Teniente Mine

This validation exercise was carried out in Diablo Regimiento sector, the one that is located in the Southern part of the deposit (as shown in Figure 1), to the elevation 2,200 m, with a competent ore column height of 150 m.

RESERVAS NORTE

DACI TA PI LAR NORTE

ESM ERALDA

+200 N

FR.L LEG. CH IM.#7

FR. # 8

XC 20 AS
FR.L LEG. FR. # 10 CHIM.# 8 FR. # 5

XC 22 S
FR. # 6 FR. # 2

FR.LL EG. CH IM.# 9

XC 24 S

XC-25 S

DR 15 AR

00
DR 14 AR D R 12AR
Fr ont.Caer os Fr ont .Rises y T aller es

XC-26 S
FR.LL EG. CHIM.# 10

XC-27 S DR 16 AR DR 21 R D R 19 R

FR.LL EG. CH IM.# 11

RAMPA AL H UND IM IENTO

Fro nt .Ref. N3 Fr ont.Ref. N 2 Front.Ref. N1

Front.Ref. N4 Front.Ref. N5

Fr ont.Ref. Front.Ref. N 6 N7

Fr ont.Ref. N 8

Front.Ref. N9 Front.Ref. N10

Front. Oficinas

E 200

E 600

-200 S

E 400

E 800

-200 S

-400 S

-400 S

-600 S

-600 S

DI ABLO REGI M I ENTO

1200 E 1000 E 1400 E 800 E 1600 E 200 E 600 E 0 1800 E 400 E

-800 S

Figure 1 Production sectors El Teniente Mine The preconditioning application was done on an area of 10,200 m2 of virgin caving (as shown in Figure 2), located under Teniente 4 Regimiento sector. The tonnage involved in the volume of preconditioned ground is 3.87 Mt.

Teniente 4

Preconditioned area UCL DR

Production level DR

Undercuttiing progress

Figure 2 Preconditioned sector in Diablo Regimiento The hydraulics fractures were generated with 1.5 m spacing. The fracture form has been estimated as semicircular with a 40 m radius. The pressures of breaking fluctuated between 25 and 30 MPa, with the propagation pressures at approximately 18 MPa. A typical arrangement of fracturing application is shown in Figure 3.

Ten-4 Reg Level

Hydraulic Fracture

Ten-5 Level

Drill hole

Under Cut Level - Diablo Reg

Production Level - Diablo Reg

Figure 3 Typical arrangement of hydraulic fracturing application The predominant lithology unit recognized in the study area corresponds to Complejo Mfico El Teniente (CMET), with some demonstrations of Diorite, as shown in Figure 4.
86

60

69 79

82

73 70

82 81

70

83 70

80

200S
69

77 80 72 88 83 80 52 74 87 50 61 70 84 77 80 80 70 80 88

81

71 75 43

80 80

52

82

81 65 88 88 73 83

88 72

Preconditioned Area
75 67 60 70 27 12 10 66 30 65 25

64

46

75 77

63 23 67 54

82

63 77 64 72

71

40

64

53 63

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88 69

70 61 82 67 17 87 30 67 59 42 23 25 89 62 62 53 65 26 45 55 69 58 61 30 75 65 53 63 57 66 66 56 14 81 11 37 52 24 60 43 58 81 62 87 31 70 29 77 61 87 35 77 51 83 78 72 71 49 74 63 72 36 46 50 25 54 63 67 55 61 70 73 63 60 65 79

76 57

75

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400S

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81 38

54 70 70 29 72 72 74 83 62 57 30 85 57 24 74 61 72 71 82 68 74 43 70 74 74 64 75 76 73 59 83 67 65

79

57 54 80 49 84 25 66 62 41 85 69

66 31 67 70 12 49 43 82 19

73

63

62

65 51

83 86 81 86 88 85 51 45

600S

80

32

LITHOLOGY DIORITE PORPHYRY CMET TOURMALINE BRECCIA

800S

Figure 4 Diablo Regimiento lithology The CMET is a competent rock, like Andesite, with veins frequency from 5 to 7 per meter. The unconfined compressive strength is about 120 MPa. The predominant structural pattern is represented by the main structural set shown in Table 1. The main stress pattern is represented in Table 2.

Table 1 Main structural pattern

Table 2 Main stress in Diablo Regimiento

Set 1 2 3

Bearing N 66 W +/- 30 N 22 E +/- 12 N 74 W +/- 13

Dip 66 N +/- 20 90 +/- 8 28 N +/- 9

Stress (MPa) S1 : 51 S2 : 33 S3 : 23

Azimut () 343.5 88.9 242.5

Dip () -13.42 -47.99 -38.88

The application decision for this technology in El Teniente (due to the environment of stresses and seismicity) motivated the execution of this validation exercise. An acceptance protocol was defined, establishing parameters and measurement and evaluation methodologies. The concepts that control this protocol refer to key aspects that preconditioning faces: the seismicity and cavability of the rock mass. In relation to cavability, the crater connection time, is a variable that impacts directly in the production ramp up. On the other hand, the seismicity is the parameter that reflects directly the dynamic response of the rock mass to the mining activity. Therefore, the aspects that were evaluated in the protocol were: Seismicity induced level: seismicity induced during the hydraulic fracturing process and subsequent process of evolution of caving during the ore extraction Cavability: connection time to broken material or old crater Fragmentation: fragmentation of preconditioned ore in draw points

Acceptance protocol evaluation

Diablo Regimiento sector initiated the undercutting process in August 2004. Simultaneously, the main features and reaches of the preconditioning test were consolidated, being defined the stop of the undercutting process to allow the hydraulic fracturing execution. The operation of hydraulic fracturing was carried out during the months of February and March 2005. The new beginning of the undercutting process went from June 2005 and the production began in September 2005. In the framework of the preconditioning test validation, this work delivers the measured results, which reflect the key changes that the preconditioning technology introduces in the mine process. The results obtained for each one of the respected aspects in the acceptance protocol are now discussed.

4.1 Seismicity Induced level

The induced seismicity can be understood as a micro fracturing process of a rock mass, conformed by a micro breaks assembly that have associate liberation energy, the one that is transmitted for the rock through elastic waves. The mining excavations induce considerable gradients of deformation and stresses. Such temporary and spatial gradients generate of microseismic activity when the stress surpasses the load capacities of the rock mass. The results with the measurements up to February 2007, 18 months since the start of the extraction in the sector in September 2005, were complemented with an understanding of the background of the mining activity of the sector, plus the information of the different geomechanics parameters, visual inspections of upper works and the readings and interpretation of the geomechanics instrumentation. In relation to the seismic response of the preconditioning sector, the observed results allow establishing the following aspects: In the period from August 2004 to January 2005, where the mining activity was only undercutting, 10,000 m2, the seismic activity is notable with events until a magnitude of 1.6. This is appreciated in Figures 5 and 6.

 During the period of generation of the hydraulic fractures, from February to March 2005, the seismic response remains stable. In fact, only three events of small magnitude, below 1, were detected in this period. This it is appreciated in Figure 5 It is important to observe the seismic behavior of the sector before and after hydro fracturing the rock mass. Figure 5 shows as the seismic activity after applying the technique, with diminishing high magnitude events demonstration and increments in the activity of smaller magnitudes The situation after 18 months of initiating the production shows a seismic behavior under the protocol reference curve, see Figure 7
40.000

Conection

2.800

Rate of Undercutting, Active Area, Production m, t

Seismic event > 1

Accumulated seismic events

30.000

Accumulated undercutting area

2.100

N Events

20.000

1.400
Accumulated active area PC

10.000

700
Mean mobile production

0
29-08-04 28-09-04 28-10-04 27-11-04 27-12-04 26-01-05 25-02-05 27-03-05 26-04-05 26-05-05 25-06-05 25-07-05 24-08-05 23-09-05 23-10-05 22-11-05 22-12-05 21-01-06 20-02-06 22-03-06 21-04-06 21-05-06 20-06-06 20-07-06 19-08-06 18-09-06 18-10-06 17-11-06 17-12-06 16-01-07 15-02-07

Date

Figure 5 Seismic and mining activity evolution

5 After Preconditioning 4 Before Preconditioning

LOG10(N)

0
-2 -1.7 -1.4 -1.1 -0.8 -0.5 -0.2 0.1 0.4 0.7 1 1.3 1.6 1.9 2.2 2.5

MAGNITUDE

Figure 6 Seismic behaviors before and after the application of hydraulic fracturing

In order to evaluate the induced seismicity by the preconditioning application, a protocol of acceptance based on a Gutenberg Richter curve was established, summarizing the seismic experience of similar sectors as the Esmeralda and Teniente 4 S. The comparison with this curve will motivate the acceptance of this aspect of the protocol. This protocol considered the induced seismicity during the hydraulic fracturing process and during the subsequent process of caving evolution during the extraction of the ore. Table 3 indicates different credibility levels of the preconditioning effects. If there are not events with magnitude over 2.1, then the process will be considered as a success. Table 3 Acceptance indicators for induced seismicity Failure Low credibility Average credibility Success Maximum magnitudes > 3,1 3,1-2,6 2,6-2,1 < 2,1

Cumulative events up to Feb2007 Protocol

LOG10(N)

0
-2 -1.7 -1.4 -1.1 -0.8 -0.5 -0.2 0.1 0.4 0.7 1 1.3 1.6 1.9 2.2 2.5

MAGNITUDE

Figure 7 Cumulative seismic activity behavior referred to test protocol In this way, the result of induced seismicity aspect due to the application has been successful. Furthermore, the doubt about the occurrence of a major seismic disruption due to the technique application was not observed. Therefore, the technique contributes to the seismicity decrease without the demonstration of disastrous events such as a rock burst.

4.2 Cavability
This aspect of the acceptance protocol was focused in the evaluation of the connection time to upper old crater. Although this process could be seen as simple, it was not in the Diablo Regimiento sector due to the preconditioned volume of rock initially causing instability, which then accelerated the subsidence process of the upper levels. Because of the impossibility to verify physical evidence in the upper levels, it was

necessary to define an alternative methodology to define when the connection occurs, given the supposed behavior of the preconditioned volume. So, the analysis methodology that supports this definition considered the evaluation of the production background, seismic activity analysis, geo-structural analysis and subsidence monitoring. The information generated in the analysis is summarized in Figure 8. This figure shows the projected envelopes of subsidence, extraction and seismic activity. Seismic activity is shown as a distribution of events and cumulative variation of the deformations expected into the rock mass. Then, these concepts permit to evaluate and to determine the rupture surface position generated by the extraction.
Site Site Site

Site

Undercut Level Production Level

Undercut Level Production Level

Active Volume Active Seismicity Limit Break Limit (June 2006)

Extraction Zone Broken Zone Site TDR Monitor (June 2006)

Figure 8 Estimated envelope limits on June 2006 In June 2006, the rupture surface generated by the extraction of Diablo Regimiento sector was declared. The connection area was approximately 8,000 m2. Therefore, it was determined that the connection between Diablo Regimiento sector and Teniente 4 sector, was effectively achieved during this period of time. Until the connection date, 709 kt of ore had been extracted, equivalent to approximately 18% of the total average extraction. These results indicate that the connection was produced ten months after the extraction had begun, in September 2005. In the acceptance protocol, the degree of success qualifies as the connection time obtained in the preconditioned ore, according to Table 4. Table 4 Acceptance indicators for connection time Connection time > 23 months 23- 20 months 20-15 months < 15 months

Failure Low credibility Average credibility Success

Where the values of connection time are based on the divisions experience, mainly on the Esmeralda sector experience, where was the last sector being connected in a virgin condition. Therefore, this variable is declared successful with high credibility according to the protocol.

4.3 Fragmentation
The evaluation criterion of this parameter was the fragmentation curve. An expected result by the application of preconditioning technology is to obtain a material with the fragmentation characteristics required in the points of extraction. That is to say, to get a decrease of the fragmentation, regarding a block not preconditioned, in all those points under the preconditioned block. This aspect is important, because it affects directly the productivity and costs of the extraction system. This was the less achieved aspect in the process of validation of the hydraulic fracturing technique. Some hypothesis arises in the first analysis of this aspect. Basically, they are: The generation of hydraulic fractures implies an introduction of a new structural system This new system is the weakest one, because it does not have infill, and in practice it will have the greater probability to fail The condition of virgin caving would only cause the weakest structures to act (initially). Perhaps, in the condition of caving in state, the outcome should be better, due to that also act many failures by stresses The greater seismic activity measured (but with smaller magnitudes) would affect fragmentation in a negative way

In general, the results obtained show a similar condition to the situation without hydraulic fracturing. Nevertheless, it is necessary to indicate that the non-existence of an adequate base line complicates the analysis. With the collected information to date, based on the geological expert criterion, Figure 9 does not categorically show that the results established favorable behavior in the primary fragmentation.

100 90 80 70

No preconditioning With preconditioning

Oversize %

60 50 40 30 20 10 0 0 50 100 150 Major axis cm cm Major axis 200 250 300

Figure 9 Oversize distribution curve, Diablo Regimiento sector

Conclusions

The preconditioning test carried out in the Diablo Regimiento test block, has permitted to show that it is feasible to carry out hydraulic fracturing in the conditions of the current stresses in the El Teniente deposit, without adverse effects to the existing conditions. The results obtained to date confirm that the test has been successful in terms of seismicity and caving propagation rate. The results of these variables are notable, one by the time decrease of connection to crater, and another by the behavior of observed prominent seismic activity. These aspects allow visualizing an important potential impact in the business and in the reliability compliance of the production plans. With regard to fragmentation, the results are less promising. No doubt, the next step of the preconditioning application should motivate an improvement in this aspect.

Finally, it should be mentioned that the paper has demonstrated the empirical and practical experience in the El Teniente Mine. These are very promising results to assist in addressing some important problems in the mine operation, like the high level of stress and induced seismicity. Based on these results and the results in Andina and Salvador divisions, El Teniente has established as a normal practice, the application of hydraulic fracturing technique to all those sectors with competent rock. As such, to date more than 80,000 m2 have been preconditioned, with a further total of 300,000 m2 foreseen in the next two years. Also, nowadays the Division is working in quantifying the benefits of the preconditioning, expressed in design criteria, planning parameters and operational guides.