Appendix E6 - OP Drilling, Blasting, and Orica
Appendix E6 - OP Drilling, Blasting, and Orica
Appendix E6 - OP Drilling, Blasting, and Orica
Memo
From: Date: Re:
Jesse Aarsen, Graham Milne, and Matthew Erickson June 27, 2012 KSM Drilling and Blasting Operations
1. Introduction
This Memo describes the drilling and blasting operations at KSM for the PFS. Drilling and blasting operations create suitable fragmentation of the rock for the loading and hauling cycles. The Mitchell pit in the KSM project will have an extremely high engineered pit wall and as such, controlled drilling and blasting must be needed to allow safe operation of the pit.
2. Drilling
Production drilling will be done with electric drills with a 15m bench height. Similar sites and a study done by Orica (refer to Appendix A KSM-SABREX Study) show that a drill hole diameter of 311mm (12 ) should be used for the main production drilling. Smaller diesel drills (165mm 6 hole diameter) will be used to drill the highwall and buffer rows.
Burden Spacing Hole size Hole size Bench height Sub-drill Rock/Ore tonnes per hole Penetration rate (instantaneous rate) Set-up time Drilling time Moving time Productivity (includes set-up and moving time)
The drilling productivity excludes moving time between patterns and benches and doesnt account for operator efficiency.
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Based on schedule 11b, the maximum estimated fleet size is: 3 electric 311mm, 3 diesel 311mm, and 4 diesel highwall Drills. The yearly drill requirement is shown in Figure 1 below:
Figure 1 Yearly Production Drill Fleet Size
While most production drilling will be done to a 17m depth (bench height plus sub-drill), a few of the drills in the fleet should have a 34m drilling depth minimum capability to allow for double bench drilling in special circumstances.
stand-off required at the toe of the upper bench if doing single bench passes). This concept is shown in Figure 2 below:
The pre-split row will be drilled all the way along the highwall at 1.8m spacing. The next row out from the highwall will be a stab row approximately 8m deep. The burden for the stab row will be 3.0m and the spacing will be 5.5m. Three rows of buffer holes will then be drilled at regular bench depth (15m) and sub-drill (2m) with a burden and spacing of 4.8m and 5.5m respectively. All other rows will be regular production holes. A sample cross-section of this is shown in Figure 3 below:
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3. Blasting
Blasting operations will be performed by mine personnel on a 7 day per week, day shift continuous basis. A contractor will be employed to supply the operations with explosives and blasting accessories as well as to deliver the product to the hole. Orica has provided a blasting summary with calculated powder factors, other blasting parameters and budgetary capital costs. This report can be found in Appendix C - Seabridge Gold Operation with capital costs October 2009
It is important to pick an appropriate powder factor that maximizes the diggability of the material. Muck blasted with too low of a powder factor results in particles that are blocky and large and cause problems for the shovels to dig and load. This issue can cause under loaded trucks, and over the long term cause high maintenance issues for the shovels and trucks. In extreme circumstances, secondary blasting may even be required. While a low powder factor will save on drilling and blasting costs, the increased loading costs (due to lower productivity and higher wear and tear on the equipment) will offset these savings. Alternatively, using a higher powder factor will result in smaller particle sizes and better loading productivities up to a certain point where the shovels cannot load the material any faster despite the smaller particle sizes. At some point the increased drilling and blasting costs are not offset by the savings from increased productivities. A good middle point for powder factor must be chosen that results in proper fragmentation of the material that allows for the best loading productivities, balanced with reasonable drilling and blasting costs. Orica was employed to run a SABREX (Scientific Approach to Breaking Rocks with Explosives) simulation on the rock types that were most typical and most frequently found in the Mitchell pit. SABREX simulations were run on various pattern sizes from 7.5m to 9m square equivalent and the resulting fragmentation analyzed. The results show that an 8.5m x 8.5m pattern should be used with a powder factor of 0.96kg/m3. At an average rock density of 2.77 tonnes/m3 this equates to a powder factor of 0.35 kg/tonne. This is similar to other large open pit projects in the KSM area. SABREX simulations show that this powder factor results in fragmentation with 80% passing 0.56m particle size. The maximum particle size expected with this powder factor is 2.01m (judged to be of no concern for shovel loading purposes).
3.2 Explosives
Explosives for the mine site will be provided by a contractor. Because of the remoteness of the operation, an explosives manufacturing facility will be built on site. Capital costs for this will total approximately $11M (a breakdown of capital costs is shown in Appendix C). The location of the manufacturing facility, magazines and ANP storage is shown in
Figure 4 below.
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The explosives manufacturing facility will produce the emulsion/ANFO blend for blasting operations. From here explosives will be delivered to the mining areas via Mobile Mixing Units (MMU). A 70/30 emulsion/ANFO blend will be used for wet holes and a 35/65 blend for dry holes. It is assumed that 50% of the material to be blasted will be wet. The nominal plant capacity will be 80 tonnes/day with a peak production rate of 150 tonnes/day. Based on the amount of explosives stored at the facility, it must be a minimum of 960m from the magazines. A detailed layout of the explosives manufacturing facility can be found in Appendix D - KSM_PFS_Explosives Manufacturing Facility Two explosives storage magazines are required for this project. One will be sized at 6 x 8 x 8 and the other at 8 x 12 x 8. The location of these magazines is shown in
Figure 4 above.
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The ANP storage area is an emergency reserve of Ammonium Nitrate Prill (ANP). Orica has recommended that the storage capacity of this area should be 400 tonnes. This amount of storage requires a minimum separation of 561m from the explosives manufacturing facility. The AN prill at the storage area, when combined with the AN in the silos (in the explosives manufacturing facility) and the AN in solution will provide 10 days of emergency service if external delivery of AN to the mine was suspended. The prill will be stored here in 1 tonne tote bags. The tote bags will be stored together in sea cans to protect the AN prill from exposure to the environment as well as any accidental release. Approximately 20-25 bags will be able to fit in a sea can. The AN prill stored here will need to be turned every 6 months to avoid decay.
accumulation gets too high to find the holes again or the time delay is too long and the product decays in the hole.
3.4.2 Highwall blasting Controlled blasting will need to be done on the final highwalls in the pit to maintain proper wall control. The precise blasting that is required for best wall control means that electronic detonation must be used. 165mm pre-split holes will be drilled at an angle to match the designed bench face angle (approximately 600 to 700). These holes should be drilled two benches deep to avoid a step-out on the intermediate bench. The pre-split holes will be loaded 8|Page
with a 50mm pre-split product. This matches the 165mm pre-split holes and the product will be internally traced with detonating cord. The stab and buffer rows will be loaded with regular emulsion/ANFO mix. Stab holes will not have any stemming and the first two rows of buffer holes will have an air gap between the explosive and the stemming. A sample cross-section with the loading parameters is shown in Figure 5 below:
Further details of the highwall blasting can be found in Appendix E - KSM project PFS wall control 3.4.3 Cast Blasting Cast blasting involves loading a blast pattern with a larger amount of explosives and using a type of explosive that has more of a heaving power than a breaking power. It may be appropriate in certain pioneering circumstances where there is a large open face, steep topography below the blast (to allow blasted material to move down slope) and there is a thin burden of material to be moved. Care must be maintained when doing a cast blast to make sure that there is no down slope risk to working areas. If the above criteria are satisfied, a cast 9|Page
blast can be designed to move as much material as far down slope as possible to reduce the material movement costs. Remaining material on the bench can be pushed over the edge with dozers. Detailed cast blasts have not been designed at this stage and would need to be evaluated on a case by case basis to see if the savings in material movement costs would outweigh the increased blasting costs.
BUILDING CAPITAL COSTS ($CDN) Buildings $955,000 Concrete for Buildings $720,000 Processing equipment $6,200,000 Total Building Capital $7,875,000
Other capital costs are needed for the equipment and are outlined below in Table 4
Table 4 Explosives Equipment Capital Costs
EQUIPMENT CAPITAL COSTS ($CDN) Type Cost Number Repump MMU $510,000 4 Goat MMU $265,000 1 Pipeline MMU $435,000 1 Front-end loader $244,000 1 Pickup $58,000 2 Skid-steer $55,000 1 Magazine - 8' x 12' x 8' $25,000 1 Magazine - 6' x 8' x 8' $15,000 1 Total Equipment Cost
Total Cost $2,040,000 $265,000 $410,000 $230,000 $116,000 $55,000 $25,000 $15,000 $3,156,000
Total capital costs explosives facilities and equipment is $11,031,000 3.5.2 Operating Costs 10 | P a g e
The cost of the explosives products required for a sample production hole is outlined in Table 5 below (the designed burden and spacing results in 3,002 tonnes of rock per hole):
Table 5 Explosives product cost
Electric Detonation Total Cost per hole Product Cost Booster Electric Detonator Detonating Cord TOTAL Product cost $638.90 $6.50 $15.55 $11.05 $672.00 $0.224 (1 per hole) (~17m/hole) $/hole $/tonne material
Estimated monthly operating costs for operators, equipment, plant and power (of the explosives contractor) are outlined in Table 6 below. More detail on these numbers is given in Appendix C. The average monthly production of material (rock and ore) is calculated to be 13,000 kT.
Table 6 Monthly operating costs of explosives contractor
Monthly costs MMU/Plant operator - 3 req Working Supervisor Mechanic MMU (blend truck) - 3 req Pickup - 2 req Development process vehicle Forklift/Loader Magazines - 2 req Plant costs LOM average plant operating costs Estimated MMU operating costs Power costs Total monthly costs Monthly blasting costs $30,600 $10,500 $10,500 $22,500 $3,000 $5,000 $3,800 $900 $40,000 $10,273 $3,000 $3,425 $143,498 $/month $0.011 $/tonne material
The mine is also responsible to provide the diesel for the explosives products. A summary of the estimated diesel costs is shown in Table 7 below.
Table 7 Fuel Costs for Explosives
44 L/tonne explosive
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Sep 2012 PFS fuel cost Explosives fuel cost Powder factor Explosives fuel cost
The total blasting costs (in $/tonne of material blasted) are shown in Table 8 below.
Table 8 Total blasting operating cost
Explosives cost Explosives fuel cost Monthly blasting costs TOTAL BLASTING COSTS with 10% contingency
$0.224 $/tonne $0.014 $/tonne $0.011 $/tonne $0.250 $/tonne $0.275 $/tonne
The contingency covers the increased costs that will result from specialty blasting along the final highwalls.
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APPENDIX A
SABREX Study to Assess the Fragmentation Distribution Generated by Various Powder Factors
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GC Zhao Senior Technical Service Engineer Lee Pratt Technical Services Manager
Executive Summary
Objective Assessment Method Findings and Discussion
Report
Introduction SABREX Input Results
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Executive Summary
Objective
Assess the effect of powder factor on fragmentation and provide data for doing a p re-feasib ili ty stud y o n bl astin g at Seab ridg e KSM p ro ject u sin g th e SABREX blast model.
Assessment Method
The blast-engineering tool, SABREX, is used in this study. SABREX stands for Scientific Approach to Breaking Rock with Explosives and it is a proprietary computer program of Orica. It is a modular computer code that incorporates technology with a number of tested programs that have been used worldwide. SABREX predicts the performance of blasts in terms of fragment size and distribution.
be conducted for each rock type as soon as possible to allow fine-tuning of the blasting program to meet the productivity requirements.
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Figure 1. Mitchell Pit The Main pit of KSM Project Table1. Summary Geotechnical units and Design Properties
Input Description Intact Rock Unit Weight Young's Modulus Poisson Ratio Uniaxial Compressive Strength Brazilian Tensile Strength Rock Mass RMR '76 Joint Frequency Joint Orientation Value I-173 0.028 36.4 0.25 61 3.9 75 1.41 56 - 350 Units
Input Description Intact Rock Unit Weight Young's Modulus Poisson Ratio Uniaxial Compressive Strength Brazilian Tensile Strength Rock Mass RMR '76 Joint Frequency Joint Orientation
Units
per m degrees
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All patterns are drilled off with 311mm (12 ) diameter holes on a 15m bench. It should be noted that none of these 5 cases presented an optimum design. These designs could however produce good fragmentation as a start. The drill pattern varies from 7.5m x 7.5m to 9.0m x 9.0m. Both the Base Case and Case 4 have the same drill pattern but the latter has a meter less sub-drill resulting in a lower powder factor. This case examined the sensitivity of reducing sub-drill on fragmentation outcomes. Modeling results indicate a similar fragmentation outcome as the Base Case however an actual test blast program is recommended to evaluate the impact of reduced sub-drill on toe diggability.
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Results
The SABREX results for rock I-173 are summarized in the following Table 3 Table 3 SABREX Fragmentation for I-173 Phyllic Argillic altered rock % passing (cm) Base case Case 1 Case 2 Case 3 Case 4 20% passing 5.4 6.0 6.6 4.7 5.4 30% passing 9.6 10.7 11.7 8.6 9.6 40% passing 14.6 16.0 17.5 13.1 14.6 50% passing 20.3 22.4 24.4 18.2 20.3 60% passing 27.4 30.3 33.3 24.6 27.4 70% passing 36.6 40.9 45.0 33.1 36.6 80% passing 50.2 56.1 62.1 45.4 50.2 90% passing 74.2 83.6 92.2 66.6 74.2 100%passing 190.0 200.0 210.0 180.0 190.0 Figure 2 is the fragmentation distribution curve with different powder factors for I-173 Phyllic Argillic altered rock
100 80 % Passing 60 40
Case 1 (pf=0.34 kg/t) Base Case (pf=0.38 kg/t) & Case 4 (pf=0.35 kg/t)
20
00
50
100
250
300
Figure 2 Computed fragmentation distribution for various powder factors (I -173 Phyllic Argillic altered rock)
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The SABREX results for rock II - 325 are summarized in the following Table 4 Table 4 SABREX Fragmentation for II -325 Intrusive rock and hornfelsed volcanics % passing (cm) Base case Case 1 Case 2 Case 3 20% passing 5.3 6.0 6.6 4.7 30% passing 9.5 10.6 11.6 8.5 40% passing 14.4 15.9 17.3 13.0 50% passing 20.1 22.2 24.2 18.1 60% passing 27.1 30.1 33.0 24.4 70% passing 36.3 40.5 44.6 32.8 80% passing 49.8 55.6 61.6 45.0 90% passing 73.4 82.9 91.5 66.1 100%passing 195.0 201.0 212.0 185.0
Case 4 5.3 9.5 14.4 20.1 27.1 36.3 49.8 73.4 195.0
Figure 3 is the fragmentation distribution curve with different powder factors for II -325 intrusive rock and hornfelsed volcanics.
100
80
60 %Passing
40 20
Case 3 (pf=0.47kg/t)
50
100
200
250
300
Figure 3 Computed fragmentation distributions for various powder factors (II 325 intrusive rock and hornfelsed volcanics) 21 | P a g e
An analysis of the results in Table 3 and Table 4 indicates that the fragmentation generated from the two types of rock is very similar. Table 5 is the fragmentation passing size comparison for rock I-175 and II-325. Table 5 Fragmentation % passing comparison between rock I -175 and II 325 % passing (cm) Base case Case 1 Case 2 Case 3 Case 4 20% passing 5.4 (5.3) 6.0(6.0) 6.6(6.6) 4.7(4.7) 5.4(5.3) 30% passing 9.6(9.5) 10.7(10.6) 11.7(11.6) 8.6(8.5) 9.6(9.5) 40% passing 14.6(14.4) 16.0(15.9) 17.5(17.3) 13.1(13.0) 14.6(14.4) 50% passing 20.3(20.1) 22.4(22.2) 24.4(24.2) 18.2(18.1) 20.3(20.1) 60% passing 27.4(27.1) 30.3(30.1) 33.3(33.0) 24.6(24.4) 27.4(27.1) 70% passing 36.6(36.3) 40.9(40.5) 45.0(44.6) 33.1(32.8) 36.6(36.3) 80% passing 50.2(49.8) 56.1(55.6) 62.1(61.6) 45.4(45.1) 50.2(49.8) 90% passing 74.2(73.3) 83.6(82.9) 92.2(91.5) 66.6(66.1) 74.2(73.4) 100%passing 190.0(195) 200.0(201) 210.0(212) 180.0(185) 190.0(195) Rock I-173(II-325) I-173(II-325) I-173(II-325) I-173(II-325) I-173(II-325)
This means if identical blast design parameters are used for both rock I - 175 and rock II 325, fragmentation results from SABREX modeling for both rocks are very close. This appears logical after examination of the geotechnical properties for rock I-175 and II-325. Rock II -325 has higher rock strength (Youngs Modulus 45 GPa) but the rock is more fractured (Joint frequency 7.69/m). Rock I -175 has less rock strength (Youngs Modulus 36 GPa) but the rock is less fractured (Joint frequency 7.69/m). From a blasting perspective, these two rocks can be categorized as one type of rock medium hard rock. Fragmentation is considered to be one of the most influential factors to productivity. Depending on the capability of the truck and shovel team, one may find a distribution from Figure 2 or Figure 3 most effective to handle. On the basis of these results, it appears that a powder factor of 0.96 kg/m 3 with 8.5m x 8.5m pattern is reasonable to use to design start-up test blast program. The results of this start-up program should be closely monitored to establish a baseline for further optimization.
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APPENDIX B
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APPENDIX C
Seabridge Gold Project: The objective of the operation is to produce a 70/30 emulsion/ANFO blend for the Seabridge Gold Project. Nominal plant capacity is 80te/day with a peak production rate of 150te/day. Budgetary costs provided at this time assume drilling and blasting will be conducted by the mine. Blasting services are excluded from the normal operation, but will be offered by Orica under separate terms. Delivery of the explosives to the borehole is part of the Orica SLA and will be accomplished using MMUs. Operational Details: Borehole delivery: Time to fill MMU with gasser 5min Time to fill MMU with emulsion 25min Time to empty MMU 60 min Drive time to pit 60min return Capacity of MMU = 14te Example: MMU 1 starts 7:00am leaves site at 8:00am after inspections and filling. Returns for filling at 10:00am leaves at 10:30 Returns for filling at 12:30pm leaves at 1:30pm Returns for filling at 3:30pm leaves at 4:00pm Returns at 6:00pm is cleaned, greased, fuelled, etc. Manning: The plant will operate 12 hours per day, 7 days per week, 365 days per year. This will be accomplished by rotating shifts. As the mine is remote, the normal shift will be 2 weeks in and 2 weeks out.
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Recommended Operations:
1Years 1-2 Staffing: (per rotation) 2 MMU operator 1 Working Supervisor 1 Mine mechanic/electrician part time requirement 15 hrs/wk Rolling Stock: 2 MMU repump type 1 MMU repump type (spare) 2 Pickup truck 1 Front end loader w/ fork attachment 1 MMU (Goat type) for development work Other Equipment: 1 Type 4 magazine 6 x 8 x 8 1 Type 4 magazine 8 x 12 x 8
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Years 3+ Staffing (per rotation) 3 MMU operator 1 Plant operator 1 Working Supervisor 1 Mine mechanic/electrician part time requirement 30 hrs/wk Rolling Stock: 3 MMU repump type 1 MMU repump type (spare) 2 Pickup truck 1 Front end loader w/ fork attachment 1 MMU (Goat type) for ongoing development work Other Equipment: 1 Type 4 magazine 6 x 8 x 8 1 Type 4 magazine 8 x 12 x 8
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The following information is to assist with the preparation of a feasibility study for the Seabridge Gold Project and does not constitute Oricas final bid. Orica believes that these numbers are fair and accurate; however, these numbers are not binding. There is intellectual property in some of the processing equipment and Orica reserves the right to repurchase this equipment from Seabridge Gold. $CAD Personnel Costs: (each) MMU / Plant Operator Working Supervisor Mechanic Equipment Costs: (each) MMU (blend truck) Pickup Development process vehicle Forklift/loader Magazines Plant costs (amortized over 10 years-monthly rate) Fees after amortization period for plant (maintenance fees) $10,200 per month $10,500per month $10,500 per month
$7,500 per month $ 1,500 per month $5,000 per month $3,800 per month $450 per month approx. $40,000 per month To be determined from average maintenance costs at/near end of amortization period
Explosives Costs (budgetary only) Fortan Extra 35 (dry hole product) Fortis Extra 70 (wet hole product) Senatel Powersplit 50 mm x 10 m (wall control product for single benching) Senatel Powersplit 50 mm x 40m (wall control product for double benching)
$58.00 per 100 kilograms $65.00 per 100 kilograms $210.50 per case $239.50 per case
Blasting Accessories costs (budgetary only) Pentex boosters-1 lb Ikon RX 20meter detonator (electronic) Harness wire (6 rolls x 400 m/case) Cordtex AP-detonating cord Exel MS 18 meter detonator (non electric in hole detonator) Exel MS Connectors (surface delays)
$6.50 each $42.00 each $375.00 per case $65.00 per 100 meters $940.00 per 100 units $615.00 per 100 units
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Estimated Operating Costs: Estimated Plant Operating costs for years 1-3 $8,000.00/month Estimated Plant Operating costs for years 4+ $10,500.00/month Estimated MMU Operating costs excluding fuel $3,000.00/month 1Hydro, Fuel and Water to be supplied by mine Estimated Fuel Consumption 44.0 litre/te of product Estimated Water Consumption 123.0 litre/te of product minimum 400 l/day 32,000 kwh/month summer 75,000 kwh/month winter
CAPITAL COSTS $CAD Rolling Stock: (each) Repump MMU Goat MMU Pipeline MMU Front End loader with Forks Pickup Skid Steer loader with forks Magazine Type 4 8 x 12 x 8 Magazine Type 4 6 x 8 x 8 Equipment: Buildings (excludes AN Prill storage building) Concrete for Buildings (320 m3 @2000 per m3) Processing equipment includes piping, electrical and installation $510,000 $265,000 $435,000 $244,000 $58,000 $55,000 $25,000 $15,000
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Mine to provide: Hydro 600V, 400A service to the site. Water clean process water & potable via well or delivery truck Diesel delivered as required to the site Mechanic if the option is chosen Electrician if that option is chosen Use of maintenance garage for decontaminated process vehicles to replace engines, transmissions, etc Place to put used oil, hydraulic fluids, etc During construction the use of a crane will be required estimate 6 weeks to set silos, buildings, elevators, screw conveyors, tanks, etc Mine to provide site preparation for installation of buildings and truck traffic Mine to erect gate and necessary fencing around site meet Explosives Regulatory Requirements 6 feet high 3 wire Mine will be responsible for magazine site preparation Environmental Assessment including the explosives plant and magazines Storage for 400te of Ammonium Nitrate Prill in 1te totes. This is to serve as an emergency reserve. When combined with the AN in the silos and the AN in solution, this will provide 10 days of service. This will need to be located a minimum of 120m from the explosives plant. Transportation from storage to the plant is the responsibility of the mine. Stock will need to be turned every 6 months. All permits other than those specified as Orica to provide Accommodations for employees regularly on site and occasional visitors. Visitors would typically number no more than 2 at any one time. Typical visitors are safety and operations personnel and management, technical personnel chemists, engineers, blasting consultants
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Orica to provide : Design, procurement, delivery and installation of all buildings and processing equipment including piping and electrical, except the AN storage building listed above. Procurement and delivery of the requested quantity of delivery vehicles and licensing as required by the Explosives Regulatory Division of NRCAN Procurement and delivery of requested explosives magazines meeting the requirements of the Explosives Regulatory Division of NRCAN Factory license as required by the Explosives Regulatory Division of NRCAN
Special Considerations for Environmental Assessment: Boiler emissions for a 60hp diesel fired boiler AN dust emissions Note: the yearly consumption of AN will be transferred 2x (i.e. fill a silo and then fill a tank or truck) Diesel fuel emissions from storage tank and transfer to process Evaporation system will boil off water Surfactant tank emissions
On Site Storage: 60 te of surfactant 140te of Ammonium Nitrate Prill 80te of emulsion 300te of Ammonium Nitrate Solution 10te of water 23000 litres of diesel 5000 litre fuel phase tank 600 litres of aqueous Sodium Nitrite 600 litres of aqueous Ethylene Glycol
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APPENDIX D
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APPENDIX E
Overview Orica Canada was contacted by Moose Mountain Technical Services (MMTS) to give advice and rational input into suitable wall control blasting practices that will be required for the Pre Feasibility Study (PFS) of the Mitchell pit in the proposed KSM project. The contained information herein is related directly to that request, and is only intended for budgeting use during this specific PreFeasibility Study. It is the purpose of this paper to give an initial indication of the practices that would be required for wall control blasting in this proposed Mitchell pit, so that necessary costs related to blasting activities can then be generated for use in the Pre-Feasibility Study. 33 | P a g e
All information has been supplied in good faith, and Orica Canada Inc cannot be held accountable for differences seen in the field during implementation, in actual numbers or blast performance during operations, to the budgeted numbers that are put forwards here for use in the PFS. The information herein is generally known to be best wall control practices for a given final pit shell design such as the one proposed. This information is for costing purposes in the pre-feasibility stage only, and should not be considered fit for transfer into implementation by operations. Further and ongoing consultation will be required from Orica blasting professionals as information comes available and at critical stages of the projects development. The KSM project Mitchell Pit
Key Quotes from Appendix D9 - BGC - 20090430 Design Criteria - DRAFT.pdf 4.1.1. Blasting The PEA level design criteria are based on the assumption that generally good blasting practices will be used, especially for the final pit walls. These controlled blasting techniques may include trim and buffer blasting or pre-split blasting. Specific drill setups may be required for these modified production blasts, resulting in an increased cost. 4.1.3. Slope Monitoring The proposed Mitchell pit represents the upper range of achieved open pit slope heights in the world.
The KSM projects Mitchell pit will undoubtedly be one of the worlds most productive and high value gold/copper mines, containing the worlds tallest engineered rock face of 1650m. Orica certainly recognises the importance of this, and the value that is involved in creating the planned geometries outlined in the mine design. It is the successful completion in full of the intended pit design which is the true key to unlocking the potential economic value of the Mitchell pit. Due to the unprecedented nature of this proposed task, Orica recommends that only the best possible blasting practices should be used. This aligns with the customers assertion that controlled blasting will be required. It is highly recommended that for the final pit shell blasting that proposed options A and C should not be considered as viable practises, and as such they have not been investigated in this report. However during the creation of interim pit shells, there may be opportunities for less stringent blasting practices (possibly options of A and C), variations to the best practice concepts given here, that may be possible to implement. Such second-rate concepts will produce outcomes of lower quality, and will not be discussed here. The intended blasting outcomes that will be investigated are:
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- 30 m BENCHES, 70 BENCH FACE ANGLE - 0 m BREAK-BACK ANTICIPATED ON BERMS - BENCH SCALE JOINTS WILL REMAIN NEAR PEAK SHEAR STRENGTH DUE TO REDUCED DISTURBANCE FROM CONTROLLED BLASTING.
The methodologies delivered in this paper are what we know to be best practice, put forwards with the intent of fulfilling these required blasting outcomes. Proposed wall control methodology for use in the PFS After reviewing the given data, and due to the fact that the project is only in the pre feasibility stage, the best approach to budget for wall control blasting techniques is to adopt a singular best practice, and use this everywhere in the pit. The blanket approach suggested is the best practical wall control practice available, and generally gives more preferable results however it must be noted that it is also the most expensive way of blasting per BCM and m2. The basic concepts of this methodology are the same for both the upper and lower benches of the double stack: Drilling 165mm hole drilled from the from the crest to the toe of the desired face angle (70 or 60 deg) both benches 30m (2x15m) drilled at the same time in one pass 165mm stab hole 3 rows of 165mm buffer holes 251mm production holes after this Loading Initiate all holes with electronic detonators Load 165mm holes with 50mm presplit product (this is called presplitting these are called presplit holes) Load 165mm stab holes with bulk explosive, no stemming Load 165mm buffer holes with varying charge weights of bulk explosive, leave air gap between explosive and stemming Load 311mm production holes with bulk explosive Firing Face angle holes fired as double bench presplits All shots need to be totally free faced Each shot uniquely timed with electronic detonators dependant upon the various contributing factors that relate to blast outcome (geology, burden in front, fire direction, hole locations and blast geometry, etc) Each shot modelled for vibration effects using signature waveforms and a Monte-Carlo waveform analysis process A better look of the recommended blasting geometries for budgeting use in the pre feasibility study can be seen in the attached spreadsheet KSM - Mitchell Pit - Wall Control PFS.xls. For the pre 35 | P a g e
feasibility study to be conducted by MMTS, only the drilling and loading information needs to be considered for budgeting purposes at this stage - the organising of actual blast shapes and sizes and their firing order is an operational concern.
Further, more detailed studies based on domain and zone/rocktype information are possible at the feasibility study stage. It could is expected that the wall control blasting concepts and resultant budget numbers as given here will change somewhat based on the recommendations of more applicable blasting techniques in these different zones.
Notes of consideration with regards to the PFS budgeting process Double Bench face angle drilling issues Due to the said Bench face angle of 70 degrees, if the pre-splitting (presplitting is using packaged presplit products although this concept is valid for any type of double bench wall control done) is not done in one single 30m pass (2 x 15m - double bench presplitting), there will be a need to stand off the toe of the top bench to get the drill in to drill the second bench of the double bench split, most probably in the order of the magnitude of 2m of standoff. This stepout would decrease the effective double bench face angle from 70 to 66.7 degrees. This concept is illus trated in the Single or double pass drilling tab in the accompanying KSM - Mitchell Pit - Wall Control PFS.xls spreadsheet. To keep the overall interbench angle the same, this loss of 2m will have to be absorbed in the berms, therefore reducing each berm width by 2m. Another option would be to drill the second bench of the split at a steeper angle (near vertical). This will most probably not be allowed geotechnically, as the steeper angles would decrease the stability of the pit walls. Also, if the double bench is split in two passes, risks of rockfall incidents will rise having drills/drillers/blasters working right up against a highwall with only 2m of effective berm width, something which will certainly reduce levels of worker safety. This drilling constraint with regards to face angle drilling/presplit is important, as it will massively impact operational scheduling and safety. For this issue to be properly resolved, the drill selection process needs to have this complication included in its considerations. Explosive Selection Bulk Products A good starting point for finding the right bulk explosives that will be best suited for application in this pit would be to assume a 70%/30% emulsion/prill mix for wet holes and a 35%/65% emulsion/prill mix for dry holes. It should be assumed that at least half of the pit will be wet, and will need the 70% emulsion based product. These numbers are for budget purposes only, and may change depending on mining conditions and needs. Wall Control Products To match the 165mm holes recommended, a 50mm detonator sensitive packaged product internally traced with detonating cord a pre-split product will be required. 36 | P a g e
Drill Selection To complete the drill designs as mentioned in this brief, the correct drills would be required to do the job. A brief description of each type of drill and their needed capabilities is given below. Face Angle drilling ~6 1/2 Down Hole hammer drill. 36m drilling depth minimum capability needed to do 60 degree face angles. Used for presplit drilling. If equipment selection is optimised, the drill may also be used for buffers, and horizontal dewatering/slope/ground support/depressurisation holes. Buffers ~6 1/2 Down Hole Hammer combination of deck drill and front mount fleet. 32m drilling depth minimum capability for double benching. Need to be able to drill angles to be able to do pre shears on temp walls or to combat potentially undesirable faces. If equipment selection is optimised, front mount drills can also be used for horizontal dewatering/slope/ground support/depressurisation holes. Production rigs Rotary rigs need that need to have drilling capability for holes up to 311mm. Holes greater than 311mm may cause excessive levels of vibration due to charge weights, and increased spacing will decrease parity of blasthole ore control sampling. Production fleet needs to have combination of diesel (for mobility/flexibility) and electric (for efficiency) powered rigs. Some rigs need carousel to have 32m drilling depth minimum capability for double benching. Need to be able to drill angles to combat potentially undesirable faces.
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