waste splitting - differentiating energy for profitability - riaan
DESCRIPTION
Blasting Masterclass 30 September 2014TRANSCRIPT
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Waste Splitting - Differentiating ENERGY for profitability30 September 2014
WealthUnearthed
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Roadmap
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Geographical Location
Bambanani
Kopaneng
Simunye
K6
Kwezi
7mt/annum
475k oz
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Background
PGM Prices
Production costs
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Objective
• To optimise the blast design through effective ENERGY
distribution which will result in reef and waste separation during
blasting operations.
• To derive specific blast designs for specific reef conditions across
the 5 operating shafts and their sections.
• To maintain the ounce production of 475k oz for BP 15.
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0g/t
Main Top 12.39g/t
Main Seam 4.56g/t
Main Bot 7.62g/t
Footwall 0 g//t
Leader 2.42g/t
Internal Waste
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Methodology and Process
• Reef/Waste splitting was successfully trialled - March to May 2014.
• Safely blasted and loaded waste and reef separately during the trial
and waste packed in swept back areas.
• Logging of panels blasted (both reef & waste) completed – drilling
pattern, cast blasting, start & end time of loading, number of
buckets loaded etc. were recorded.
• A sampling & assay programme was conducted from the inception
of the trial to measure efficacy and results.
• On 30 April the K1 plant milled 8000 tons of only Kopaneng ore.
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Blast Design
NOT TO SCALE
Drill Rig 10m x 2.1 & 2.5 (61 holes)
15 cm
50 cm
40 cm
1,3m
80 cm
75 cm
NOT TO SCALE
Drill Rig 10m x 2.1 & 2.5 (56 holes)
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ENERGY Distribution
PF by 25% to 1.54kg/m³
PF by 100% to 1.10kg/m³
PF by 57% to 0.77kg/m³
Less is More !!!!
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Proposed Typical Cycle
Rig 1
Rig 1
M/S
Drill panel & blast waste
Drill panel & blast waste
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Cycle – 1st Shift - Drill Face & Blast Waste
Cast Blasting
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Proposed Typical Cycle
Clean waste & blast reef
Clean waste & blast reef
A/S
Rig 1
Rig 1
M/S
Drill panel & blast waste
Drill panel & blast waste
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Cycle – 2nd shift – Clean Waste & Blast Reef
“Drop & Pop”
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Proposed Typical Cycle
Clean waste & blast reef
Clean waste & blast reef
A/S
Clean reef & Support panel
Clean reef & Support panel
N/S
Rig 1
Rig 1
M/S
Drill panel & blast waste
Drill panel & blast waste
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Cycle – 3rd shift - Clean Reef & Support Face
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Proposed Typical Cycle
Clean waste & blast reef
Clean waste & blast reef
A/S
Clean reef & Support panel
Clean reef & Support panel
N/S
Rig 1
Rig 1
M/S
Drill panel & blast waste
Drill panel & blast waste
Rig 2
Rig 2
Rig 3
Rig 3
Drill panel & blast waste
waste
Drill panel & blast waste
Clean waste & blast reef
Clean waste & blast reef
Clean reef & Support panel
Clean reef & Support panel
Drill panel & blast waste
Drill panel & blast waste
Clean waste & blast reef
Clean waste & blast reef
Clean reef & Support panel
Clean reef & Support panel
24 Hours
waste
Drill panel & blast waste
Drill panel & blast waste
Clean waste
blast reef
Clean waste & blast reef
Drill panel & blast waste
Drill panel & blast waste
Clean reef & Support panel
Clean reef & Support panel
Clean waste & blast reef
Clean waste & blast reef
Drill panel & blast waste
waste
Drill panel & blast waste
N/SA/SM/S
24 Hours
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A Marked Blastface
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Hangingwall Parting
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Bottom Reef/Waste Parting Exposed
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Benefits
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Improved excavation integrity due to less ENERGY tr ansmitted into H/W
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Improved excavation integrity due to less ENERGY tr ansmitted into H/W
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Reef Fragmentation
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Waste to be discarded in swept areas
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Waste Packing Discipline
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Base grade Proposed Head
Grade
Kopaneng
project gradesamples
Silo grade
samples
Strike belt
samples
Plant Recovery Tail grade
2.23
2.9
3.413.57
3.88
>80% 0.77
0.47
Grade Improvement
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Reduced drilling costs and time per panelAllows for 2 additional panels to be drilled
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Reduced explosives costs – R1.5m
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Reduced hoisting costsLess pressure on maintenance
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Reduced tramming costs
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Reduced Plant costs – R45mImproved Grade
Reduced Tail grade Improved maintenance Scheduling
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Benefits
• Original BP15 ore flow per shaft was used as base.• U/G waste packing was recalculated according to blast design
and ore flow was recalculated using BP15 parameters.
BP 20157,137,795 Tonnes Blasted
475,244 ounces
BP 2015 revised6,353,438 Tonnes Blasted
485,696 ounces
10% Less Waste Tonnes sent to the plant………..
10 450 More Ounces……….
R150m
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Acknowledgement
Wessel PumoGM Kroondal Operations
Jan StrydomManager Projects Kopaneng
Brent ParkerManager Projects
Dave StarleyGM Projects
Team
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Thank You
Wealth flows from ENERGY and ideas.William Feather