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Modern Practices for the Design and
Planning of Underground Mines
Rob McGill
Head of Mining
WorleyParsonsTWP
Contents
• Underground Mining Trends
• Mine Life-cycle
• Key Success Factors for Mine Planning and Design
• Mine Planning Process and Tools
• Examples of Outputs
• Expected developments in Underground Mining
• Conclusion
Underground Mining Trends
• Low commodity prices/tight margins
• Fewer projects meeting hurdle rates
• Access to funding/risk aversion
• Deeper underground deposits
• Higher opex costs
• Safety and regulation
• But demand for commodities will be lasting
• Increased underground focus
– Mature pits
– Environmental pressures
Mine Life-cycle
Resource
Definition
Target
Identification
Exploration
Resource
Estimate
Project
Evaluation
Phase
Concept/Scoping Pre-feasibility Feasibility
Mine
Construction
Phase
Detailed design Project Execution
Mine
Production
Phase
Build-up Steady state
Mine
Closure
Production
decline
Rehab and
closure
Value Curve
Project
Evaluation
Phase
Concept/Scoping Pre-feasibility Feasibility
Phase Objective Key Focus Areas Costs
CONCEPT/PEA
 To identify major options for opportunity
realisation
 Confirm alignment with the business case
 Assess the potential value of the
opportunity
 Define the work required to assess the
opportunity
 Establish a plan for the Pre-Feasibility
phase
 Is this the right opportunity for the client?
 Is the opportunity consistent with the client’s
overall business strategy?
 Does the potential value from the opportunity
justify further investigation?
 The thoroughness of evaluation of alternative
technology, costing and implementation
approaches.
 Integrity of Pre-feasibility planning.
 Have areas of opportunity and risk been
investigated in later stages to enhance
value?
CapitalCost
+/-25%
Project
Evaluation
Phase
Concept/Scoping Pre-feasibility Feasibility
Phase Objective Key Focus Areas Costs
PRE-FEASIBILITY
 The best project size, scope, technical and
production solution has been selected and
is a viable business concept aligned to
business strategy.
 Demonstration that all the discarded
project options have been studied and are
clearly inferior and have no probability of
re-emerging as viable options.
 A workable plan for taking the concept
through the Feasibility development stage.
 Have all of the options been adequately
considered and reviewed on an equal basis?
 What criteria were used to select the
preferred option?
 Have all opportunities for optimisation been
reasonable pursued?
 Are the risks and possible mitigators well
understood?
 Does the potential value from the opportunity
still justify further investigation?
 Integrity of Feasibility planning.
CapitalCost
+25%to–15%
Project
Evaluation
Phase
Concept/Scoping Pre-feasibility Feasibility
Phase Objective Key Focus Areas Costs
FEASIBILITY
 Develop a Proven Business proposition at
the appropriate level of detail and
accuracy for implementation funding.
 Is there a thorough understanding of the
value and risks associated with the
opportunity prior to moving into
Implementation?
 Is there an acceptable risk profile?
 Is there a workable plan for taking the
Project through the implementation &
Operational readiness stages?
 Is the opportunity recommended for
approval?
CapitalCost
+15%to–5%
Typical Project Organogram
Project Manager
Mining
Geologist
Geotechnical
Engineer
Mining
Engineer
Ventilation
Engineer Mine Planner
Engineering
Discipline
Engineers
Drawing
Office
Capital
Estimator
Project
Services
Project
Secretary
Project
Planner
Key Success Factors for Mine Planning
and Design
• Quality/quantity of inputs
• Understanding of value chain and link between
inputs and outputs
• Experience and skill
– Mining operations and projects
– Planning tools
• Team integration
• Consistency and applicability of design criteria
• Benchmarking/callibration
Mine Planning and Design Inputs
Mine
Design
and
Planning
Geology
-Block Model
-Geometric and structure
model
-Stratigraphic model
Geotech
-Rock Mass ratings
-Empirical design “rules-of-
thumb”
Ventilation
- Empirical design “rules-of-
thumb”
-Regulatory design criteria
-Mining equipment
specifications
Mining Engineering
-Mining method
-Development and stoping rates
-Preferred equipment specs
-Targeted production schedule
and volumes
Infrastructure
- Preferred access methodology
-Requirements for
services/transport
-Capacities and constrants
Strategic Goals
-Life-of-mine
-Payback Period
-Financial goals
Mining Method Selection
Common Methods
• Block Cave
• Sub-level cave
• Open-stoping
• Sub-level open-stoping
• Cut and fill
• Drift and fill
• Shrinkage
• Bord-and-pillar
• Step bord-and-pillar
• Narrow flat tabular
Design Considerations
• Ore body geometry
• Rock Mass properties
• Required production
volumes
• Opex/Capex cost
• Safety/Productivity
• Skills available
• Equipment available
• Grade control
Access Methodologies
• Declines
– Drill and blast
– TBM
• Ramps
• Shafts
– Blind-sink
– Raise-bored
– Bored
• Combinations
• Criteria:
– Depth/Geometry
– Timing
– Bottom Access
– Production Volume
– Cost and capital
availablity
Project Construction Time
12
24
36
48
60
72
84
600 800 1000 1200 1400 1600 1800 2000
Developmenttimeinmonths
Depth in metres
Drill and Blast TBM Conventional Shaft Bored Shaft
Advantages of TBM Access
Development
Seems obvious
Quicker
One pass
Safer
Continuous and reliable
But slow to catch on in mining
Hard rock applications and non-isotropic/non-homogenous material
High rock stress and fracturing
Geometry and size of equipment
Lack of hands-on experience
Seen as expensive and elegant
Mine Planning Software Tools
• Gemcom –Surpac/Mineshed/Minex
• CAE – 5D Planner / Enhanced Production
Scheduler(EPS)
• MINERP – CADSmine / No scheduler
(Reporting done in spreadsheets)
• MINERP – MINE2-4D / Enhanced Production
Scheduler(EPS)
• 29.486 Moz
• LoM – 43 years (2052)
• Building up to 330 Kt/m
• To produce up to 800,000
ounces/ year (25 tonnes)
DESIGN CRITERIA OVERVIEW
MINERAL RESERVES AND LOM
Main and Vent shaft
Current Mine
MINERAL RESERVES AND LOM
Main and Vent shaft
Current Mine
MINERAL RESERVES AND LOM
Current Mine
Main and Vent shaft
MINERAL RESERVES AND LOM
Main and Vent shaft
MINERAL RESERVES AND LOM
Main and Vent shaft
MINERAL RESERVES AND LOM
Main and Vent shaft
Project Footprint
2
4
-
100,000
200,000
300,000
400,000
500,000
600,000
GoldOunces
BP12 Level 1 Phase 2 Phase 3
Production Profile
25
Mine design
Criteria Remarks
Stoping Design
Sequential Grid Mining
Method
Mining Levels 113,116,120
ORD development rate 45m/month
Reef development rate 30 m/month
Mining Crews per raise line(
between levels)
5 maximum
Ledging Face Advance 10 m/month (average)
Stope Face Advance 7.2 m/month (average)
Ledging crews(between levels)
Dependant on available raise
lines – with not more than3
crews per raise line
Stope Width 120 cm
Panel Length 25 m to 35 m
MCF(as per BP2013) 60%
Plant recovery factor 97,4%
0
5000
10000
15000
20000
25000
30000
2013 2014 2015 2016 2017 2018 2019 2020 2021 2022
Project Carbon Leader reef monthly tonnes milled
Average – 4500 m2/month Average – 120kg/month
Average – 23000 tonnes month Average – 253m/ month
28
Thickness and Grade Distribution
> 8
6 - 8
4 - 6
2 - 4
< 2
COLOURTHICKNESS
> 8
6 - 8
4 - 6
2 - 4
< 2
COLOURTHICKNESS
20 - 100
15 - 20
10 - 15
8 - 10
6 - 8
4 - 6
2.2 - 4
0 - 2.2
COLOURGRADE
20 - 100
15 - 20
10 - 15
8 - 10
6 - 8
4 - 6
2.2 - 4
0 - 2.2
COLOURGRADE
29
Isometric View of Design Options
Longitudinal
Sub Level Open Stoping
Longitudinal
Retreat
Existing mining
Existing infrastructure
Different colours
represent different
months schedule
Animation output
Production Report
Production Report fed from outputs of Enhanced Production Scheduler
Vertical shaft access
Planta en caverna
Chancadoras
Longitudinal Sub Level Stoping / Bench and Fill Stoping
Expected Developments in Underground
Mining
• Increased mechanization and automation
• Tunnel and shaft boring
• Environmental/safety pressures
• Margin pressures
• Better quality design and planning
• More standardization in design and planning
Conclusion
• Mine design and planning has become more critical in
projects and operations in recent years
• Quality of tools have improved with better computer graphics
and processing speeds
• Projects now require full designs and plans using software
tools for auditability
• These designs and plans are only as good as the inputs
provided and the skills of the engineers and planners. Actual
hands-on mining experience is critical in applying the tools
correctly
Av. La Encalada N° 1257
Centro Empresarial La Encalada
Oficina N° 801
Santiago de Surco
Lima 33, Perú
Hector Paredes Tarazona
Managing Director - Peru
Hector.Paredes@Worleyparsons.com
Modern practices for the design and

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Modern practices for the design and

  • 1. Modern Practices for the Design and Planning of Underground Mines Rob McGill Head of Mining WorleyParsonsTWP
  • 2. Contents • Underground Mining Trends • Mine Life-cycle • Key Success Factors for Mine Planning and Design • Mine Planning Process and Tools • Examples of Outputs • Expected developments in Underground Mining • Conclusion
  • 3. Underground Mining Trends • Low commodity prices/tight margins • Fewer projects meeting hurdle rates • Access to funding/risk aversion • Deeper underground deposits • Higher opex costs • Safety and regulation • But demand for commodities will be lasting • Increased underground focus – Mature pits – Environmental pressures
  • 4. Mine Life-cycle Resource Definition Target Identification Exploration Resource Estimate Project Evaluation Phase Concept/Scoping Pre-feasibility Feasibility Mine Construction Phase Detailed design Project Execution Mine Production Phase Build-up Steady state Mine Closure Production decline Rehab and closure
  • 6. Project Evaluation Phase Concept/Scoping Pre-feasibility Feasibility Phase Objective Key Focus Areas Costs CONCEPT/PEA  To identify major options for opportunity realisation  Confirm alignment with the business case  Assess the potential value of the opportunity  Define the work required to assess the opportunity  Establish a plan for the Pre-Feasibility phase  Is this the right opportunity for the client?  Is the opportunity consistent with the client’s overall business strategy?  Does the potential value from the opportunity justify further investigation?  The thoroughness of evaluation of alternative technology, costing and implementation approaches.  Integrity of Pre-feasibility planning.  Have areas of opportunity and risk been investigated in later stages to enhance value? CapitalCost +/-25%
  • 7. Project Evaluation Phase Concept/Scoping Pre-feasibility Feasibility Phase Objective Key Focus Areas Costs PRE-FEASIBILITY  The best project size, scope, technical and production solution has been selected and is a viable business concept aligned to business strategy.  Demonstration that all the discarded project options have been studied and are clearly inferior and have no probability of re-emerging as viable options.  A workable plan for taking the concept through the Feasibility development stage.  Have all of the options been adequately considered and reviewed on an equal basis?  What criteria were used to select the preferred option?  Have all opportunities for optimisation been reasonable pursued?  Are the risks and possible mitigators well understood?  Does the potential value from the opportunity still justify further investigation?  Integrity of Feasibility planning. CapitalCost +25%to–15%
  • 8. Project Evaluation Phase Concept/Scoping Pre-feasibility Feasibility Phase Objective Key Focus Areas Costs FEASIBILITY  Develop a Proven Business proposition at the appropriate level of detail and accuracy for implementation funding.  Is there a thorough understanding of the value and risks associated with the opportunity prior to moving into Implementation?  Is there an acceptable risk profile?  Is there a workable plan for taking the Project through the implementation & Operational readiness stages?  Is the opportunity recommended for approval? CapitalCost +15%to–5%
  • 9. Typical Project Organogram Project Manager Mining Geologist Geotechnical Engineer Mining Engineer Ventilation Engineer Mine Planner Engineering Discipline Engineers Drawing Office Capital Estimator Project Services Project Secretary Project Planner
  • 10. Key Success Factors for Mine Planning and Design • Quality/quantity of inputs • Understanding of value chain and link between inputs and outputs • Experience and skill – Mining operations and projects – Planning tools • Team integration • Consistency and applicability of design criteria • Benchmarking/callibration
  • 11. Mine Planning and Design Inputs Mine Design and Planning Geology -Block Model -Geometric and structure model -Stratigraphic model Geotech -Rock Mass ratings -Empirical design “rules-of- thumb” Ventilation - Empirical design “rules-of- thumb” -Regulatory design criteria -Mining equipment specifications Mining Engineering -Mining method -Development and stoping rates -Preferred equipment specs -Targeted production schedule and volumes Infrastructure - Preferred access methodology -Requirements for services/transport -Capacities and constrants Strategic Goals -Life-of-mine -Payback Period -Financial goals
  • 12. Mining Method Selection Common Methods • Block Cave • Sub-level cave • Open-stoping • Sub-level open-stoping • Cut and fill • Drift and fill • Shrinkage • Bord-and-pillar • Step bord-and-pillar • Narrow flat tabular Design Considerations • Ore body geometry • Rock Mass properties • Required production volumes • Opex/Capex cost • Safety/Productivity • Skills available • Equipment available • Grade control
  • 13. Access Methodologies • Declines – Drill and blast – TBM • Ramps • Shafts – Blind-sink – Raise-bored – Bored • Combinations • Criteria: – Depth/Geometry – Timing – Bottom Access – Production Volume – Cost and capital availablity
  • 14. Project Construction Time 12 24 36 48 60 72 84 600 800 1000 1200 1400 1600 1800 2000 Developmenttimeinmonths Depth in metres Drill and Blast TBM Conventional Shaft Bored Shaft
  • 15. Advantages of TBM Access Development Seems obvious Quicker One pass Safer Continuous and reliable But slow to catch on in mining Hard rock applications and non-isotropic/non-homogenous material High rock stress and fracturing Geometry and size of equipment Lack of hands-on experience Seen as expensive and elegant
  • 16. Mine Planning Software Tools • Gemcom –Surpac/Mineshed/Minex • CAE – 5D Planner / Enhanced Production Scheduler(EPS) • MINERP – CADSmine / No scheduler (Reporting done in spreadsheets) • MINERP – MINE2-4D / Enhanced Production Scheduler(EPS)
  • 17. • 29.486 Moz • LoM – 43 years (2052) • Building up to 330 Kt/m • To produce up to 800,000 ounces/ year (25 tonnes) DESIGN CRITERIA OVERVIEW
  • 18. MINERAL RESERVES AND LOM Main and Vent shaft Current Mine
  • 19. MINERAL RESERVES AND LOM Main and Vent shaft Current Mine
  • 20. MINERAL RESERVES AND LOM Current Mine Main and Vent shaft
  • 21. MINERAL RESERVES AND LOM Main and Vent shaft
  • 22. MINERAL RESERVES AND LOM Main and Vent shaft
  • 23. MINERAL RESERVES AND LOM Main and Vent shaft
  • 26. Mine design Criteria Remarks Stoping Design Sequential Grid Mining Method Mining Levels 113,116,120 ORD development rate 45m/month Reef development rate 30 m/month Mining Crews per raise line( between levels) 5 maximum Ledging Face Advance 10 m/month (average) Stope Face Advance 7.2 m/month (average) Ledging crews(between levels) Dependant on available raise lines – with not more than3 crews per raise line Stope Width 120 cm Panel Length 25 m to 35 m MCF(as per BP2013) 60% Plant recovery factor 97,4%
  • 27. 0 5000 10000 15000 20000 25000 30000 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 Project Carbon Leader reef monthly tonnes milled Average – 4500 m2/month Average – 120kg/month Average – 23000 tonnes month Average – 253m/ month
  • 28. 28 Thickness and Grade Distribution > 8 6 - 8 4 - 6 2 - 4 < 2 COLOURTHICKNESS > 8 6 - 8 4 - 6 2 - 4 < 2 COLOURTHICKNESS 20 - 100 15 - 20 10 - 15 8 - 10 6 - 8 4 - 6 2.2 - 4 0 - 2.2 COLOURGRADE 20 - 100 15 - 20 10 - 15 8 - 10 6 - 8 4 - 6 2.2 - 4 0 - 2.2 COLOURGRADE
  • 29. 29 Isometric View of Design Options Longitudinal Sub Level Open Stoping Longitudinal Retreat
  • 30. Existing mining Existing infrastructure Different colours represent different months schedule Animation output
  • 31. Production Report Production Report fed from outputs of Enhanced Production Scheduler
  • 33.
  • 34.
  • 35. Planta en caverna Chancadoras Longitudinal Sub Level Stoping / Bench and Fill Stoping
  • 36. Expected Developments in Underground Mining • Increased mechanization and automation • Tunnel and shaft boring • Environmental/safety pressures • Margin pressures • Better quality design and planning • More standardization in design and planning
  • 37. Conclusion • Mine design and planning has become more critical in projects and operations in recent years • Quality of tools have improved with better computer graphics and processing speeds • Projects now require full designs and plans using software tools for auditability • These designs and plans are only as good as the inputs provided and the skills of the engineers and planners. Actual hands-on mining experience is critical in applying the tools correctly
  • 38. Av. La Encalada N° 1257 Centro Empresarial La Encalada Oficina N° 801 Santiago de Surco Lima 33, Perú Hector Paredes Tarazona Managing Director - Peru Hector.Paredes@Worleyparsons.com