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Maptek Forge Sept 10
Maptek Forge Sept 10
SEPT 2010
Intensive processing takes place at the site to produce magnetite concentrate and pellets. This highly technical process includes crushing, milling, separating, thickening and filtering the magnetite ore after mining. The benefit of magnetite mining is that less energy is required to process the final product into steel than with haematite. Maptek became involved in the Sino Iron project in 2008 when CITIC Pacific Mining selected Vulcan as its mine planning and geology tool. Grade control was implemented as the initial prestrip of the mine commenced, to define the quality of magnetite ore within the reserve. This information has become the basis for mining to ensure that the most economically viable areas of the resource are delivered to the crushers. The nature of magnetite mining requires extensive on-site infrastructure. Mine planning must take into account that crushers are located within the pit. Vulcan is used by CITIC Pacific Mining to not only help identify the optimal position for the pit but also to position the infrastructure required for the project.
Following the success of Vulcan from the start of the project, CITIC Pacific Mining asked Maptek to enhance the current implementation to allow visualisation of grade control and reconciliation data within the site work flow. The new functionality provides automated techniques for calculating reconciliation data from a resource block model, onscreen display of multiple blasts and export of blast data to Excel for analysis. Grade block triangulations, constructed during the block out process, are used in conjunction with a block model to calculate the expected values which can then be compared with the actual values calculated from the drillholes. CITIC Pacific Mining has invested heavily in the 25-year Sino Iron project, and Maptek looks forward to providing the tools to support the companys mine planning goals.
Thanks to Richard Inglis Manager, Mine Geology Sino Iron Project, CITIC Pacific Mining
DESIGNING STOPES
Chris Alford from Alford Mining Systems talks about a key area of product commercialisation.
How did the stope optimiser project come about?
In 1995 I wrote some floating stope software to roughly create stope volumes to guide engineers with manual design of stope shapes. Typically if 5 engineers do a set of stopes you get 5 different results. A software tool was needed to produce those stope shapes automatically in a repeatable and optimal way. The PRIMO project took a new research prototype developed in 2005 to a commercial product. Maptek was one of three software supplier sponsors to join the project. Each supplier has now got to the point of a commercial product either delivered or about to be delivered.
that you could move data between the different software packages.
What are some key features that people will be interested to see?
The key objective was to be able to design the individual stopes to automatically generate stope shapes, taking into account stope geometry as well as geological and geotechnical constraints. The software might do 5,000 - 20,000 iterations to work out the optimal shape that maximises value, for example. The other key issue in underground selective mining is to identify not just the stope shapes to extract, but also the ones to leave behind. PRIMO case studies exposed us to a range of stoping methods. Stope optimisation for a narrow veined gold project is hugely different to tackling optimisation of a vast complex like BHP Billitons Olympic Dam.
PRIMO (Planning and Rapid Integrated Mine Optimisation) is an AMIRA research project looking at mine design and schedule optimisation tools. AMIRA International Ltd is an independent association of minerals companies facilitating collaborative research on industry issues. Alford Mining Systems (AMS), based in Melbourne, Australia, specialises in stope and underground mine optimisation applications. wall to mimic overbreak. There are many other enhancements, different ways of applying cutoffs and various ways of reporting stopes. Rapid automated generation of stope shapes at different cutoffs is the starting point for underground strategy optimisation. Enhancements initially restricted to the PRIMO sponsors deal with stope layout optimisation and case management.
What are the specific Vulcan benefits from the stope optimiser?
The stope shape is the key. Weve been impressed with how rapidly Maptek has been able to develop the Vulcan interface and integrate the tool. This flexibility will make migration to version 2 a quick process. AMS looks forward to working with Maptek over the next three years on further applied research.
SEPTEMBER 2010
Multiple scenarios can be set up and visually compared using section or plan polygons or triangulations. Minimum pillar dimensions or exclusion zones can be considered by the optimiser for a more accurate design. Flexible configuration means the tool can be applied to very steep orebodies or even horizontal benches, making it workable for open pit scenarios or horizontal underground designs. Detailed output reports allow analysis and comparison of results, with stope triangulations ready for design, reserve and/or scheduling. Considerable time savings and better targeting of mineable zones can be achieved with the stope optimiser. Fully integrated within the Vulcan 3D environment, it is the ideal platform for quick stope design for underground engineers. Results are optimised, meaning time can be spent in evaluating several alternatives rather than in time-consuming manual design.
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MAPTEK FORGE
The time in Edinburgh gave David and MMD the chance to thoroughly evaluate the value of the Vulcan platform for MMD. It was also an opportunity for David to work through an entire life-of-mine scheduling study for a large, open pit coal deposit under the direction of Maptek. I had already seen that Vulcan was an extremely strong package during the coursework at Camborne. Working with Maptek greatly increased my knowledge and understanding of Vulcan. We were able to show the great value of advanced mine planning solutions for planning our engineering applications, commented David. The project focused on Vulcan open pit mine design tools and Chronos products to evaluate several scenarios. The aim was to optimise the application of MMDs innovative in-pit products. Vulcan and Chronos provided the engineers with the power and flexibility to optimise allocation of this equipment to the mine plan. The engineers were able to choose which phases of the mining development best suited MMD technology, and which MMD products were ideal for each task. By the end of the mine planning study, MMD was able to demonstrate the lifeof-mine cost saving and value adding
MMD was founded in 1978 to design and manufacture mineral processing equipment for the UK underground coal mining industry. The company developed the Twin-Shaft Mineral Sizer, an innovative product providing a technological breakthrough in mineral reduction. Over the years MMD has provided mining solutions for many types of mineral deposits. Installations ranging from fixed and semi-mobile to fully-mobile have been designed and implemented by MMD. To date MMD has installed the worlds largest fully-mobile sizer station, proven to cope with rates of up to 12,000 tph during peak load testing. MMD has optimised its fully-mobile designs to provide a simpler, more effective crushing and conveying system to improve a mining operations efficiency and production. benefits of its technology over other solutions. This will help customers to see the potential of MMD solutions to their individual applications.
Thanks to David Johnson Mining Engineer MMD Group
I ALREADY KNEW THAT VULCAN WAS AN EXTREMELY STRONG PACKAGE... WE WERE ABLE TO SHOW THE GREAT VALUE OF ADVANCED MINE PLANNING SOLUTIONS FOR OUR ENGINEERING APPLICATIONS.
David Johnson, MMD
MAPTEK FORGE
SEPTEMBER 2010
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landfills, infrastructure development, topsoil and overburden removal, as well as contaminated material removal from previous mining operations. With 13 to 15 different areas under construction over the 700 hectare site, traditional survey methods simply arent fast enough. The survey team needs to provide up-to-date progress maps and material volumes for accurate decisionmaking and contractor payments. Speed, accuracy and safety are crucial Mapteks vehicle mount allows the scanner head to be attached on site vehicles. Besides speeding up the actual survey tasks, conducting surveys from the safety of the vehicle cab significantly minimises risk. The project area is typical of inland tropical regions, with forested hills and small mountains separated by river valleys and dense jungle. Maximum relief is 500 m above sea level. Annual precipitation can exceed 1500 mm, with a hurricane season from September to October. During the rainy season, lightning detection systems alert personnel to seek refuge in designated protection areas or a vehicle. Normally the crew would have to stop surveying even though conditions may be perfect for capturing
data. Scanning from the safety of the vehicle means that surveyors can continue to work even during storm warnings. The laser scanner is used every day, mounted either on the survey vehicle or on a tripod for more precise work and in areas inaccessible by vehicle. Scan data is used for generating surfaces for volumetric measurements, updating designs, slope stability monitoring and as-builts. It takes about two days to scan all the active areas. The mobile system allows quick movement between scanning locations for stop-go data collection. I estimate the amount of time saved in tripod setup is about 50%, and we dont have to put out targets, which all adds to time saved in the field, said Jefferys. The scanner is mounted on the roof of the truck cab with one GPS receiver mounted directly on the scanner and another on the hood of the truck for scan alignment. The mounting frame for the scanner is made from stainless steel and aluminium, and includes anti-vibration pads. The surveyors only need to lift the scanner head on to the frame, clamp the quick release bracket and connect the cables for transport and scanning. One scan and two GPS points are recorded for each location. The GPS
MAPTEK FORGE
SEPTEMBER 2010
WITH I-SITE WE ARE ABLE TO TRACK VOLUMES MORE OFTEN THAN EVER POSSIBLE. WITH TRADITIONAL METHODS WE WOULD BE STRUGGLING TO TRACK VOLUMES 4 TIMES A YEAR. WE ARE NOW DOING IT 24 TIMES A YEAR WITH EASE.
Sean Jeffrerys, Barrick Pueblo Viejo
system coordinates the position and orientation of the scanner, eliminating the need for scan control via other means. Scans can be previewed on the field tablet to ensure all areas are covered. Each scan takes about five minutes, and the stop-go scanning continues for two solid days during month end measurements, as the crew drives the vehicle to all active areas of the site. The route changes daily as different areas are affected by construction activity; with the scanner mounted on the vehicle it is easy to move to new locations on the fly. Maptek I-Site Studio software is used for processing, modelling and analysing the data. Scans are imported into I-Site Studio in a pre-registered format straight
from the cab-mounted controller. Data is accurately registered in a coordinate system in as little as 10 minutes using a one-step global registration tool. Being a survey traditionalist, I was sceptical of the global registration process, but it has been tested and proven. It works, and is a huge time saver. Human error is virtually excluded, commented Jefferys. Editing out vehicles, vegetation and other unwanted objects from the data takes only a few minutes. The topography filter removes overlapping data and redundant points. The data set is reduced to a manageable size, and volumes are quickly calculated for each of the active areas surveyed earlier in the day.
The final step is to export the data for use by the engineers in CAD and mine planning packages. Accurate and timely information helps the engineers make decisions with realistic data. Other applications for the I-Site system are now being investigated, such as geotechnical mapping and slope stability monitoring. Laser scanning makes it possible to record and monitor areas which cant be surveyed traditionally. Edited extract of article published in POB, June 2010
Thanks to Sean Jefferys Chief Surveyor Pueblo Viejo, Barrick
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01 Mobile scanning improves speed and safety during the busy construction phase at Pueblo Viejo mine (facing page) 02 Surveyors scan active areas in the limestone quarry and update models with the latest data - areas that have changed are shown in a different colour 03 Modelled surfaces can be analysed to monitor the slope stability of construction areas
Maptek founder and chairman Dr Bob Johnson has been named an Innovation Hero by Sydney University Warren Centre for Advanced Engineering.
Bob has pioneered technology that has significantly benefited the mining, engineering and surveying industries. Vision - the art of seeing what does not exist - only comes to a reality by hard work and team effort, said Bob on receiving the award at the Innovation Lecture in Adelaide, South Australia in June.
Professor Mike Dureau, Executive Director of the Warren Centre commented, The recipients of the Award possess a unique vision and drive to see their products commercialised to the benefit of local and international industries.
MAPTEK TECHNOLOGY FOCUSES ON ANALYSING AND MODELLING DATA FROM DISPARATE SOURCES TO SOLVE THE PROBLEMS THAT ENGINEERS, GEOLOGISTS AND MINERS FACE EVERY DAY.
Dr Bob Johnson flanked by Innovation Lecture presenter, Professor Hugh Durrant-Whyte and Executive Director of the Warren Centre Professor Mike Dureau
MAPTEK FORGE
SEPTEMBER 2010
At Maptek we see our role as creating innovations for our mining customers, allowing them to develop their resources in a safe and efficient manner.
SOUTH AMERICA
Maptek invites delegates and presenters to attend the 2010 users conference in Chile.
The central theme of the conference, to be held from 2-3 November, 2010 in Via del Mar is Applying Maptek technology to increase productivity.
AUSTRALIA
Join Maptek in Perth, Western Australia from 4-6 April, 2011.
Partnering for innovation & success is the conference theme, to be explored at the Vines Resort & Country Club. Industry professionals are invited to share success stories and celebrate our 30-year anniversary. Applications of Vulcan, I-Site and MineSuite will address issues critical to mine planning and productivity and stimulate discussion. Case studies on best practice are eagerly sought; presenters pay no registration fees. Early bird discounts apply till February 1. www.maptek.com/australia_2011
UNIVERSITY ADDRESS
Earth science students at the University of Venda in Limpopo province, South Africa were recently introduced to Vulcan.
Maptek geologist Brilliance Mabhena spoke about Vulcan techniques including image registration, CAD design and digitising, projections to elevation, data validation, triangulations and block modelling. It is vital to ensure earth science undergraduates are kept abreast of innovation and technology so they are better equipped for their entry into the mining industry, commented Brilliance.
AFRICA-EUROPE
Save the date: September 2011
Scotland is the location for the conference to be held in September 2011. Mark your calendars and budget now for this great opportunity for presentations, discussion forums and networking.
Guest speaker Brilliance Mabhena talks to Venda University students about Maptek technology
The twin peaks, evident in some histograms, are anecdotally attributed to the different loading styles of individual operators on each crew. Over the course of the study, convergence of these peaks presumably shows loader operators adjusting techniques for more consistent loads.
The earliest of this data was collected when the system had been in operation for a limited time. Average and standard deviation were the two most relevant measures of optimised payloads. This data was then split to compare operators (or at least crews made up consistently of the same two or three loader operators), as well as examined on a whole of mine level to highlight sitewide trending over the 9-month period. A target payload of 49 tonnes was established, with any decrease in variation (as represented by standard deviation) being recognised as an improvement in operator performance.
Results Significant quarter on quarter gains on the two measures of optimisation were revealed over the site as a whole and when broken down by individual crew. The data depicts a consistent and sustained shift in the mean payloads and a less well defined, but significant decrease in the variance of payload tonnages. The graph below highlights an increase in the mean payload from 46.1 tonnes in Quarter 1 to 48.6 tonnes in Quarter 3. Conclusion The MineSuite system provided the data and information that enabled optimisation of payload tonnages of the underground fleet. A 2.5 tonne increase in payload per trip represents a 5.4% lift in productivity. While further tonnage gains are limited by inherent design constraints, greater efficiency might be achieved via continued reduction in variability of load levels.
Thanks to Ben Hawkins Mine Engineer Cracow Gold Mine
MAPTEK FORGE
SEPTEMBER 2010
VULCAN
BARRICK GOLD CORPORATION has purchased additional Vulcan licences for the Cortez Mine in Elko, Nevada. The open pit gold operation will use Vulcan for mine planning and design, geological modelling, and drill and blast work. CASTLEMAINE GOLDFIELDS will use Vulcan GeoModeller for exploration activities in the Ballarat goldfields, Victoria, Australia. CQ MINING ENGINEERS, based in Mackay, Queensland will use Vulcan for consulting. CROSSLANDS RESOURCES, headquartered in Perth, will use Vulcan for modelling of the Jack Hills expansion project. The open cut mine in mid-west Western Australia will expand to 175 mpta. CSA GLOBAL, a Perth-based geological, mining and management consulting company will use Vulcan to provide quality solutions to the international minerals industry. CUBE CONSULTING provides services and software systems to the mining, energy, industrial and government sectors. Based in Perth, Cube will apply Vulcan to resource estimation projects. KINGSTON SURVEYS, based in Kalgoorlie, Western Australia, has added mine survey capability and Vulcan software to their consultancy business. NEWMONT MINERA YANACOCHA in Per has purchased Vulcan for modelling and resource estimation for the sulphide project. PRECISION MINING, based in Brisbane, Queensland will use Vulcan for consulting. SASA MINE, a lead-zinc operation in eastern Macedonia has purchased Vulcan for geological modelling, underground mine design and survey.
I-SITE
ANGLO CHILE MANTOS BLANCOS has purchased an I-Site 8800 system plus vehicle mount for stockpile, geotechnical and topography survey at the copper operation north of Antofagasta, Chile. BARRICK CORTEZ HILLS MINE in Crescent Valley, Nevada, has purchased an I-Site 8800 laser scanning system. Cortez Hills is an open pit and underground gold mine, one of the largest and highest grade operations in North America. The open pit group will use the I-Site system for end-ofmonth surveying and highwall monitoring. BHP NICKEL WEST MT KEITH, 460 km north of Kalgoorlie in Western Australia is a large open pit mine with nickel concentrator. An I-Site 8800 system with vehicle mount has been purchased for daily survey measurements and tracking pre- and postblast material to the stockpile. BODDINGTON BAUXITE MINE has taken delivery of the first I-Site 8800 long range laser scanner, which emerged from the Maptek production facility in Adelaide in August. Boddington will use the system for end-of-month surveying and stockpile volumes, mostly picking up multiple open pits for monthly reconciliation. WESFARMERS CURRAGH PTY LTD, in Queenslands coal-rich Bowen Basin, has purchased an I-Site 8800 long range scanner for general survey pickups, geological mapping and project work.
MINESUITE
ANGLO PLATINUM BATHOPELE MINE MineSuite Fleet Management System proof of concept for extra low profile equipment in a room and pillar operation in South Africa, providing synchronisation and management of face activity and state, supplemented by an Operational Planning Module. ARM FERROUS ASSMANG implemented MineSuite at operations in South Africa: CATO RIDGE FERROMANGANESE WORKS Production Management Information System (PMIS) configured for in & outbound logistics and smelter activity. The system will track product and grade at intermediate locations, as well as plant performance, monitoring processes across the beneficiation and processing value chain. KHUMANI IRON ORE MINE, KING PLANT PMIS configured for crushing and screening processes feeding into Khumani Iron Ore beneficiation plant. NCHWANING MANGANESE MINE PMIS configured for new beneficiation plant, delivering production quality and engineering management information from underground mechanised workings through the plant.
SEPTEMBER 2010
TASEKO MINES has purchased Vulcan for mine planning and design at their open pit gold mine operations in Vancouver, Canada. VALE LIMITADA has purchased Vulcan for coal modelling and washability, geotechnical evaluation, groundwater modelling and mine planning at the Moatize coking and thermal coal project in Mozambique. XSTRACT GROUP mining consultants will use Vulcan for coal projects in the Bowen Basin of Queensland, Australia.
CURRAGH IS EXCITED TO IMPLEMENT THE I-SITE SCANNING TECHNOLOGY ACROSS DRAGLINE, TRUCK-SHOVEL, DOZER-PUSH, GEOTECHNICAL MONITORING AND CAST BLASTING APPLICATIONS. THE I-SITE 8800 WILL HELP ACHIEVE A SOLID RETURN FOR OUR SHAREHOLDERS.
Tom Cobcroft, Manager Technical Services
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MAPTEK FORGE
www.maptek.com
November 15-19 New Caledonian Nickel Conference Noumea, New Caledonia November 30 - December 1 Mines and Money - London, UK
Maptek Forge newsletter is published quarterly. You can receive it by mail, emailed pdf or emailed link to the Maptek website. Email forge@maptek.com to subscribe or advise changes to contact details. Articles may be reproduced with acknowledgement. 2010 Maptek
Maptek, Vulcan, I-Site, and MineSuite are registered and unregistered trademarks of Maptek Pty Ltd; Maptek Computacin Chile Ltda; Maptek Computacin Chile Ltda, Sucursal Per; Maptek S de RL de CV; Maptek Informtica do Brasil Ltda; and KRJA Systems, Inc. Marks are registered in one or more of the following countries: Australia, Brazil, Canada, China, Chile, Greece, India, Indonesia, Mexico, Per, Republic of South Africa, Russia, Spain, UK and USA.