DRAW CONTROL AT KOFFIEFONTEIN MINE 97

Introduction
The Koffiefontein Diamond Mine is located in the south-
west portion of the Free State, 137 km south-west of
Bloemfontein and 107 km south-east of Kimberley. Mining
of the kimberlite pipe commenced in 1878, but ceased
several times from 1892 to 1913 and from 1919 to 1931 due
to World War I. It reopened in 1970 as an opencast
operation and converted to an underground operation in
1981 with the development of levels 27 to 60. Due to the
downturn in the diamond market, the mine closed in 1982.
In 1987 the mine re-opened with a sub-level open-stope
mining method, but the mining method was immediately
converted to the blast hole open stoping, compound-ring
method
1
.
Koffiefontein mine is a low grade, marginal mine and the
forecasted ore dilution due to pit sidewall failures when
extracting the kimberlite pipe to lower levels resulted in an
investigation into an alternative mining method. Reducing
the waste influx to the underground drawpoints is vital to
ensure a viable future when deepening the mining
operations. It was appreciated at the start of the blast hole
open stoping that early waste dilution would be a problem,
but the method enabled the mine to get production, and
hence revenue, quickly. If a block cave or front cave was
started instead, the build up period would have delayed the
production start-up and the required initial capital
investment was considered too high. Blast hole open
stoping on the 37 Level was later replaced by sub-level
caving in an attempt to cut off the increasing quantities of
waste rock reporting to the drawpoints from the open pit.
The susceptibility to slope failures demanded a revision
of the mining method at depths below 37 Level. Several
mining methods were evaluated and front caving provided a
technically sound, financially viable option.
Figure 1 shows a diagrammatic section through the mine.
Front caving was selected above other methods for
technical and financial merits. The front cave layout
constitutes two levels with 4 m wide by 4.2 m high tunnels
spaced at 15 m centres. The upper level, 48 Level, acts as
the main undercut level. The lower level, 49 Level, is the
main extraction level and lags the upper level by 12 to 24 m.
HANNWEG, L.A. and VAN HOUT, G.J. Draw control at Koffiefontein Mine. 6th International Symposium on Mine Mechanization and Automation, South
African Institute of Mining and Metallurgy, 2001.
Draw control at Koffiefontein Mine
L.A. HANNWEG* and G.J. VAN HOUT

*De Beers Consolidated Mines Limited, Koffiefontein, Free State, South Africa

De Beers Corporate Headquarters, Southdale, Gauteng, South Africa

In a first for the diamond industry, Koffiefontein Mine in the Free State, South Africa, opted for
the front cave mining method to extract a 90 metre high block of kimberlite ore. Block caving,
because of its high initial capital requirements, resulting in a negative internal rate of return (IRR),
was ruled out as a feasible mining method for Koffiefontein Mine.
Front caving is essentially a combination of the traditional block cave and sub-level cave
mining methods, but uses two or more levels of retreating drawpoints. Two extraction levels, in
the case of Koffiefontein Mine, are spaced 12 m apart vertically, with the upper 478 m level (48
Level) acting as the undercut/extraction level, and the lower 490 m level (49 Level) as the
extraction level. Caving is achieved by undercutting a small column of ore, which is then drawn,
on both the 48 and 49 Levels, until the planned extraction percentage is achieved. The next
column of ore is then mined by advancing the undercut (48 Level), and the process is repeated
until the entire ore block is depleted to the contact.
Caving-by-gravity techniques of mining rely on closely controlled draw of the caved ore to
ensure proper caving action and to minimize the dilution of ore with waste material from the open
pit. This paper discusses the need for, and implementation of, a draw control system at
Koffiefontein Mine a computerized production management system, and a draw control system
based on linear programming, to allow control over the draw rate and mining sequence a major
factor in all production planning to optimize production efficiency, ore recovery and cave
management.
Keywords: Draw control, Koffiefontein Mine, Front cave, Caving
Figure 1. Diagrammatic section through Koffiefontein Mine
The vertical inter-level spacing is 12 m. The extraction
tunnels run north-south and are staggered between the two
levels to enhance rock mass stability.
Load-Haul-Dump (LHD) machines are used to transport
the ore from loading points at the end of the extraction
drifts to ore passes located outside the orebody.
As the draw zone associated with the loading points has a
limited reach and the depletion of an ore column happens
over a considerable time period, the loading points must
remain static both in space and time. However, due to the
large volume of ore fragments gravitating down through the
small tunnel openings and the relatively weak kimberlite
rock mass, the brow at the loading points tend to wear away
rapidly. This brow erosion must be kept to a minimum to
maintain the rock mass integrity and to ensure safe loading
from loading points which are fixed until the column has
been depleted. It is not within the scope of this paper to
MINE MECHANIZATION AND AUTOMATION 98
Figure 2. Basic plan showing layout of 48 Level
C
E
D
A B
Figure 3. Front cave mining sequence A - Slot cutting B - Undercutting C Caving progress
D Holing into the pit floor E Retreating the undercut (Koffiefontein is currently at this stage)
NORTH
SOUTH
LEGEND
KIMBERLITE CONTACT
MUDSTONE CONTACT
UNDERCUT
DRAW CONTROL AT KOFFIEFONTEIN MINE 99
describe in detail the support for these loading points, also
called Semi Permanent Drawpoints (SPD), but its design is
very similar to the support type employed at Henderson
Mine. The support installed at the SPDs has successfully
managed to protect the brow of the loading points and
recent inspections of the brows at loading points that have
ceased production showed very little deterioration.
Once a column is depleted the associated SPD will be
destroyed and a sequence of drill/blast/load 2 m wide blast
hole rings around the extraction drift is repeated until the
undercut face has been retreated to the next SPD position in
that drift.
The following front caving layout
2
resulted from a
number of planning sessions held at the mine involving all
affected disciplines, as well as input from Dr D.H.
Laubscher.
The front cave mining method would be ideal if three
production levels were to be developedthe bottom
level being a scavenger level to recover any ore not
extracted on the upper two levels. Koffiefontein could
not financially justify the third level, and a compromise
was made to develop only two production levels: 48
and 49 Levels were planned with 4 m wide drawpoint
drifts (see Figure 2).
The undercutting should start against the north contact
of the mudstone and retreat northwards. By starting at
the mudstone, the mining sequence will be from poor to
better rock mass and caving is expected to progress
more rapidly. There will be no development in the
mudstone which would present major development and
maintenance problems due to its poor Rock Mass
Rating (RMR).
The drawpoint drifts will be oriented in a north-south
direction, that is perpendicular to the long axis of the
pipe. This will ensure maximal tunnel stability in the
kimberlite zone close to the contact. Figure 3 illustrates
the front cave mining sequence.
Why the need for a draw control system?
It was recognised that there is a need to control the
extraction process, to gain maximum ore recovery with
minimum waste dilution, particularly at the time of near
exhaustion. Careful control of the production will ensure
that the secondary fragmentation process
3
within the cave
takes place, resulting in acceptable fragmentation size
blocks reporting at the drawpoints, reducing secondary
blasting and occurrence of hang-ups.
The need for a very strict draw control system at the mine
became more crucial due to the reduction in extraction
levels from three to two. This reduced the flexibility of
draw, as the production section would not be able to
return if ground was left behind. Other benefits for a draw
control system can be highlighted by listing the following:
To identify priority drawpoints
To minimize production delays
Ensure the draw horizon is strictly maintained and that
the ore is drawn from the correct drawpoints in a
controlled manner
Estimate the cave profile and the ore-waste interface
Make as accurate as possible a forecast of the carats
mined.
The following operating parameters affecting draw
control were established for the front cave before it came
into full production.
Side dilution entry will commence at 20 per cent draw
and will amount to approximately 10 per cent of the ore
column volume. Side dilution is sourced from the
previously mined area and occurs as a result of the
ground left behind from the previous block. Its
appearance is rapid due to its close proximity to the
drawpoints
Top dilution entry will commence at 52 per cent draw
and the waste content will gradually increase as the
column is drawn down. The dilution entry and rate of
influx are determined from the ore recovery chart based
on the following parameters (after Laubscher
3
); ore
column height, height of interaction, swell factor and
draw control factor.
From the ore recovery chart the draw cut off percentage
can also be determined. The maximum tolerable
instantaneous waste in the head feed is 20 per cent,
resulting in a draw cut off percentage equal to 81 per
cent of the column reserves.
Draw control must be strictly controlled on the upper
level, as waste drawn into the drawpoints on the 48
Level will cut off the 49 Level resources. Currently it is
planned to extract 40 per cent of the mineable resource
from the upper level and 60 per cent from the lower
level. Limiting the extraction on the upper level is due
to the fact that the associated draw ellipsoid does not
fully develop as a result of the adjacent unmined block.
Also 48 Level draws ore from columns that are less
matured than the ones that 49 Level produces from.
The undercut is mined in a breast fashionwhen
drawpoints on the eastern side are reaching maturity,
drawpoints at the west side will only be commencing
extraction. This allows for a blending of diluted ore
from the east side with undiluted ore from the west
side. As the west side starts to mature, so the east side
will be reaching draw cut off and the undercutting of
the next block commences. This sequence will also
ensure that, at all times, there are enough drawpoints
available to achieve call while other drawpoints are
being prepared to come into production when the most
mature ones become depleted.
The ore columns should be drawn down uniformly across
the cave to ensure the ore-waste interface is maintained.
Poor draw control practices lead to premature waste
dilution with the possibility of waste either cutting off
payable ore or diluting payable ore to such an extent that it
becomes unpayable.
If draw control is mismanaged and premature dilution
occurs on the 48 and 49 Levels, higher dilution will
continually be drawn as the undercutting blast hole rings
are retreated toward the next series of semi-permanent
drawpoints. In that case, the following contingency plan
should be applied:
Progress with the flat undercut, drawing only a limited
tonnage to ensure a successful undercut between the
contaminated area and the next semi-permanent
drawpoints. This would ensure that the undercut is
maintained, preventing cave inhibition.
Drawing should then commence on the 49 Level only.
If dilution reoccurs, it is drawn onto the lower level and
not carried on the undercut face contaminating the
remaining ore blocks.
The interface between waste, from the expected pit
sidewall failures, and the top of broken ore within the cave
is designed to be maintained at an east-west angle of 25
degrees for the following reasons:
A horizontal interface would imply that all semi-
permanent drawpoints (SPDs) would have to be
MINE MECHANIZATION AND AUTOMATION 100
retreated simultaneously once the first strip is depleted.
This would result in a loss of production for a long
period as undercutting and SPD construction takes
approximately 6 weeks.
An angle less than 25 degrees would have the same, but
less severe effect, on production loss.
A steeper angle would result in less beneficial
geotechnically conditions as it would increase the
probability of the overlying waste mixing with the ore
material through toppling and sliding.
A compromise between geotechnical issues and
availability concerns was achieved by selecting a 25
degree angle. This was calculated by making a careful
estimate of the draw-down versus availability of the
new line of SPDs.
Maintaining a constant angle in the cave is essential and
can sometimes overrule other constraints. As a drawpoint
matures to the end of its life, it will begin to draw more and
more waste until it becomes uneconomic to continue
mining. If adjacent drawpoints are still mining at low waste
contents, there may be a necessity to continue to extract ore
from the high waste drawpoints to maintain the correct
shape to maximize extraction from the more economic
drawpoint.
Investigations are currently being carried out to replace
the concept of a constant angle with a constraint that
controls the depletion difference between columns. It is
easier to derive a depletion percentage as the angle
calculation requires a greater understanding of the swell
factor and density of the material within each column.
The draw cut-off percentage is a crucial parameter for the
Front Cave at Koffiefontein Mine as extra recovery of a
few per cent has a huge financial benefit. The development
of the draw control programme was necessary to ensure
maximum extraction of the ore resource. Two main factors
determine the allowable draw cut-off percentage:
Negative financial impact by waste dilution
Treatment plants inability to treat diluted ore. The
plant can only manage a maximum of 20 per cent
instantaneous waste in the head feed after which
diamond production losses occur.
If good draw control practices are adhered to, at least 81
per cent of the resource can be expected to be extracted,
and if waste blending is achieved maybe even a figure
approaching 100 per cent. An extra recovery (above 81%)
of only a few per cent easily pays back the cost of installing
a state-of-the-art draw control system.
Draw control system requirements
A draw control programme capable of the following was
thus required to control the draw of ore from the Front
Cave:
Allocate dynamic calls on a shift-by-shift basis
ensuring that the long-term draw control strategy was
being adhered to.
Model the pipe into different ore resource blocks.
Ore resource blocks must be allocated to draw points.
Different quantities (tonnages) of vertical virgin,
vertical wedge and other sources must be ascribed to
the different programme ore resource blocks.
Drawpoints to be denoted by a sequence of numbers
and letters.
Base ore resource tonnages can be adjusted throughout
the life of the mine. This would facilitate resource
adjustment should it be necessary to carry out remnant
extraction mining during the later life of the mine.
Automatic optimal call distribution facility throughout
the block so that high and low extraction areas are
pulled to maintain uniform draw down.
Facility to divide the ore resources into horizons.
Be able to produce three-dimensional longitudinal and
cross-sections of statistical extraction data.
Be able to produce a block plan as per strategic draw
control exercise
Be able to produce a three-dimensional digital ground
model of extraction data.
Be able to accept daily data from a standard vehicle
management system. This will reduce the necessity for
manually booked tally sheets.
As there was no package available on the market to
satisfy the above-mentioned criteria, Koffiefontein Mine, in
collaboration with head office, developed a Mixed Integer
Linear Programme (LP) based application. This draw
control package meets the criteria set out above and has
many other benefits over other existing applications
considered to be draw control programs. The system has
been described by Guest et al
4
. As the system proved to be
highly successful, Premier Diamond Mine also decided to
implement it for the block caves.
Vehicle monitoring system
As good draw control practice requires correct and real
time production data, a vehicle management system
(VMS) was developed for Koffiefontein to become an
integral component of the draw control system. The VMS, a
productivity monitoring and vehicle dispatching system,
was set up to provide continuous real-time data to the
control room computers. The draw control linear
programme needs to communicate the shift production calls
for each drawpoint to the VMS, and also capture from VMS
the previous shift production tonnages produced from each
drawpoint.
Both systems independently maintain their shift
calendars. The VMS has an internal real-time shift calendar
for all mini-shifts (night, morning and afternoon shifts).
The draw control system will be based on whole day shifts
and also be able to report using the mines production
calendar. Exceptional shifts (extended weekend shifts) will
be manually added by system operators for both systems.
Interfacing between the VMS and the draw control system
is simplest if done on a daily basis.
Planned production and actual production tonnage are
stored in specifically named files. The planned and actual
files contain an entire shift days tonnages. The files reside
in one location on a central fileserver. The draw control
system manages the import of actual data files. The two
programmes interface with each other and update the draw
control tally information on a continuous basis. The vehicle
monitoring system is the most crucial component of an
integrated draw control system as it feeds the real/actual
underground data into the other components.
Results of implementation of the draw control
system
Implementing the combined LP draw control system and
vehicle monitoring system at Koffiefontein, has enabled
better control and management of the ore resource resulting
in a more efficient draw and recording process.
The flow charts in Figure 4 illustrate the improvement in
the reporting/recording system. Figure 5 shows a graph
drawn during the implementation of the vehicle monitoring
DRAW CONTROL AT KOFFIEFONTEIN MINE 101
system. Manual reports were compared to VMS results and
plotted per shift. Major variances were seen during the
implementation phase, however vast improvements can be
seen since the systems have been fully up-and-running. A
graph (as in Figure 5) drawn for March 2001, would show a
single line no difference between what the miners report
and what the VMS records.
The theoretical cave profile is checked every two weeks
by plotting a graph of the tonnages drawn from the cave.
This is done in an attempt to ensure that the 25 degree angle
of broken ore in the cave is maintained. Figure 6 shows an
example of this graph.
Conclusions
The need for a strict draw control system at Koffiefontein
Mine resulted from the need to maximize ore recovery and
limit the waste dilution from pit sidewall failures but
became crucial after the decision to develop only two
extraction levels. The flexibility of draw was reduced and
the production section would not be able to return to the
level and extract what was left behind.
Draw control at Koffiefontein centres around optimizing
tonnage rather than carats, as this is a massive mining
method where geotechnical constraints cannot be overruled
by financially more attractive scenarios unless a full risk
assessment exercise has been conducted. In the planning
stage, decisions should not be made based on NPV
attractive scenarios that overlook the risks and associated
costs by violating the geotechnical well-defined constraints.
The implementation of the integrated draw control system
and vehicle management system has improved the
recording of tons loaded from underground drawpoints.
Production efficiency, ore recovery and cave management
have been optimized, and are improving with new ideas and
concepts every day.
Acknowledgements
The permission of the Director, Operations, De Beers
Consolidated Mines Limited, to present this paper is
gratefully acknowledged.
The authors acknowledge the assistance of the General
Manager: Geotechnical Engineering, Alan Guest;
Koffiefontein Mine Management; colleague Mr H. Grobler
and all other persons who made valuable contributions and
expressed constructive criticism.
References
1. GUEST, A.R. The Compound Ring- Post
Implementation, in Proceedings Massive Mining
Methods, Randburg, The South African Institute of
Mining and Metallurgy, 1996.
2. PREECE, M. Front Caving A solution to waste
dilution at Koffiefontein mine for the extraction of the
370 m to 490 m ore reserve. Massive Mining
Methods, Randburg. The South African Institute of
Mining and Metallurgy, 1996.
3. LAUBSCHER, D.H. Cave mining, the state of the art,
Inl. S.A. Inst. Min. Metall., October, pp 279293.
4. GUEST et al. An application of Linear Programming
for Block Cave Draw Control, in Proceedings
MASSMIN 2000, Brisbane, 2000. pp. 461468.
Figure 4. Flow charts showing the original (left) and improved (right) draw control systems
real time
every hour
as required
once a day
once a week
PRODUCTION
GEOTECH
PLANNING
DEVELOPMENT
DRAW CONTROL
SYSTEM
XLS LP
S/BOSS
CAL SHEET
ORIGIN
once a week
once a day
once a week
real time
once a week
PRODUCTION
GEOTECH
PLANNING
DRAW CONTROL
SYSTEM
XLS LP
ORIGIN
once a day
MINE MECHANIZATION AND AUTOMATION 102
Figure 5. Graph showing comparison between PRODMAN and miners reports during August 2000. The same graph drawn for March
2001 is one line
Figure 6. Graph showing broken ground profile, as well as profile of waste rock in the pit
DRAW RESULT-FACE POSITION 19 MARCH 2001
DRAW RESULT-FACE POSITION 02 APRIL 2001
DOLERITE AS ON 05 MARCH
DOLERITE AS ON 19 MARCH
KOFFIEFONTEIN
MINE FRONT CAVE
SECTION No. N
DATE APRIL 2001
48 LEVEL
49 LEVEL