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
But demand for commodities will be lasting
Increased underground focus
Mature pits
Environmental pressures

Deeper underground deposits

Higher opex costs
Safety and regulation

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 Discounted Cash-flow Model

250
200
150

Steady-state

USD million

100
50

Project Construction

Build-up

0
2013
-50
-100
-150
-200
-250

2014

2015

2016

2017

2018

2019

2020

2021

2022

2023

2024

2025

2026

2027

Reporting Terminology

Phase

Concept/Scoping

Objective
To identify major options for opportunity

CONCEPT/PEA

Pre-feasibility

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

Feasibility

Key Focus Areas

Costs

Is this the right opportunity for the client?

Is the opportunity consistent with the clients

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?

Capital Cost
+ / -25%

Project
Evaluation
Phase

PRE-FEASIBILITY

Phase

Concept/Scoping

Pre-feasibility

Objective
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.

Feasibility

Key Focus Areas

Costs

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.

Capital Cost
+ 25% to 15%

Project
Evaluation
Phase

Phase

Concept/Scoping

Objective
Develop a Proven Business proposition at

FEASIBILITY

Pre-feasibility

Feasibility

Key Focus Areas

Costs

Is there a thorough understanding of the

the appropriate level of detail and

accuracy for implementation funding.

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?

Capital Cost
+ 15% to 5%

Project
Evaluation
Phase

Typical Project Organogram

Project Manager

Mining

Geologist

Geotechnical
Engineer

Ventilation
Engineer

Project
Services

Engineering

Mining
Engineer

Mine Planner

Discipline
Engineers

Drawing
Office

Capital
Estimator

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

Ventilation
- Empirical design rules-ofthumb
-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

Geotech

-Requirements for
services/transport

-Rock Mass ratings

-Empirical design rules-ofthumb

Geology
-Block Model
-Geometric and structure
model
-Stratigraphic model

-Capacities and constrants

Mine
Design
and
Planning

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

84

Development time in months

72

60

48

36

24

12
600

800

1000

1200

1400

1600

Depth in metres
Drill and Blast

TBM

Conventional Shaft

Bored Shaft

1800

2000

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 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)
DESWICK CAD/DESWICK SCHEDULER

DESIGN CRITERIA OVERVIEW

29.486 Moz

LoM 43 years (2052)

Building up to 330 Kt/m

To produce up to 800,000
ounces/ year (25 tonnes)

MINERAL RESERVES AND LOM

Main and Vent shaft

Current Mine

MINERAL RESERVES AND LOM

Main and Vent shaft

Current Mine

MINERAL RESERVES AND LOM

Main and Vent shaft

Current Mine

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
6

Production Profile
600,000

500,000

Gold Ounces

400,000

300,000

200,000

100,000

BP12 Level 1

Phase 2

Phase 3

27

Mine design

Criteria

Stoping Design

Remarks
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)

Dependant on available raise

Ledging crews(between levels)

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%

Average 4500 m2/month

Average 120kg/month

Project Carbon Leader reef monthly tonnes milled

30000
25000
Average 23000 tonnes month
20000
15000
10000

5000
0
2013 2014 2015 2016 2017 2018 2019 2020 2021 2022

Average 253m/ month

Resource Statement Longitudinal

Retreat Option
RESOURCE

=
=
=
+
+
=

30

In-Situ
In-Situ
In-Situ
In-Situ
In-Situ
In-Situ
In-Situ
Mined
Mined
Mined
Mined

GUMI
Inventory at (2.2 g/ton cut off)
Published
< 2m (MRO constraints)
Optimised
5M Pillars and Other Locked up
Scheduled
Extraction (94%)
Planned dilution (12%)
Reef Drive Dilution
Total

TONNES
t

GRADE
g/t

GOLD
` 000 Oz

GOLD
000 Kg

5,330,953
0
5,330,953
1,609,073
3,721,880
3,535,300
342,537
239,730
4,117,567

15.9

2,729
0
2,729
502
2,227
2,119
0
0
2,119

84.9
0.0
84.9
15.6
69.3
65.9
0.0
0.0
65.9

15.9
9.7
18.6
18.6
0.0
0.0
16.0

Thickness and Grade Distribution

THICKNESS

COLOUR

<2
2-4
4-6
6-8
>8

GRADE
0 - 2.2
2.2 - 4
4-6
6-8
8 - 10
10 - 15
15 - 20
20 - 100

31

COLOUR

Vertical Sections at 100 m Intervals

32

Design Assumptions
Dev Type Description
J
H
H
J
H
H
H
RB

33

LVL ACC FROM RAMP

MAIN HWD NORTH
ORE PASS
RAMP
RAMP RAR
RAMP RAR CONN
REEF DRIVE
RB INTAKE VENT HOLE

width
(m)
4.0
4.5
2.4
4.5
1.8
4.0
4.0

Height
(m)
4.0
4.5
2.4
4.5
1.8
4.0
4.0

Diameter
(m)

3.6

Unit
m
m
m
m
m
m
m
m

Rate
m/mth
60m/mo
40m/mo
20m/mo
60m/mo
15m/mo
60m/mo
40m/mo
55m/mo

Isometric View of Design Options

Longitudinal
Sub Level Open Stoping

Longitudinal
Retreat

34

KMS Air Requirements Longitudinal Sub Level Open Stoping kg/s

KMS Air Requirements Kg/s
As Per Tonnage Profile 07 Oct 08

375
350
325

Kilogram Per Second

300
275
250
225
200
175
150
125
100
75
50
25
0

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022

2023

2024

2025

2026

2027

2028

Ad For Open Stoping

0.0

0.0

0.0

47.6

92.8

75.3

70.0

104.4

96.9

78.6

75.3

55.2

39.5

67.6

28.0

19.4

25.9

7.2

9.8

Air Requirements

78

109

146

95.1

185.7

150.6

140.0

208.7

193.7

157.2

150.5

110.5

78.9

135.3

56.0

38.8

51.7

14.4

19.7

70% Air Utilisation

79

146

146

245

245

245

245

245

245

245

245

245

245

245

245

245

245

245

245

Air Available

88

162

162

350

350

350

350

350

350

350

350

350

350

350

350

350

350

350

350

Years
Air Requirements

35

Ad For Open Stoping

Air Available

70% Air Utilisation

Project Intake and Return Airways

KMVS

KMS

20 Level
Upcast Airflow
350kg/s

Downcast Airflow
39kg/s

50 To 20 Vent Hole Dimension

19.6m2
Intake Airflow From BSVS
311kg/s
BAC

50 Level

BAC

Zone 11
33.3kt/m (Max)

36

48 Level

Zone 8
29.6kt/m (Max)

Production Profile
STP Monthly Tonnes Milled Level 2 BP 2009 Longitudinal retreat
3,500,000

3,000,000

Tonnes per Annum Milled

2,500,000

2,000,000

1,500,000

1,000,000

500,000

0
KMS 50-60 (Z11)
KMS 50 - 60 (Z8)
Above 50 Lev Base

37

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022

2023

2024

2025

2026

2027

2028

23,334

65,551

50,272

132,183

159,312

145,446

191,749

239,383

159,936

143,224

145,033

99,654

146,247

45,448

44,963

57,303

45,430

62,244

26,041

79,980

67,876

105,994

147,574

135,914

199,743

227,176

216,149

223,899

204,123

150,015

281,710

131,708

77,678

106,374

714,722

2,326,036 2,763,804 2,761,284 2,767,111 2,764,522 2,636,393 2,627,333 2,627,333 2,624,628 2,624,628 2,624,628 2,616,987 2,616,987 2,613,634 2,221,589 1,666,191 1,249,645 1,033,615

Animation output

Existing infrastructure

Existing mining
Different colours
represent different
months schedule

Enhanced Production Scheduler

Production Report
Production Report fed from outputs of Enhanced Production Scheduler

Bord and Pillar layout with decline access to orebody

(High Level concept)

Conventional layout access via decline from surface

Vertical shaft access

Block Caving

Open Pit / Sub Level Caving

Tnel de Extraccin con Faja

Chancadora

Longitudinal Sub Level Stoping

Chancadora

Tnel Faja

Longitudinal Sub Level Stoping / Bench and Fill Stoping

Planta en caverna

Chancadoras

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

Rob McGill
robert.mcgill@worleyparsons.com
Phone +27827803587