AEL value added blasting (vab) - Ivan

|6 October 2014 1

AEL Value Added Blasting (VAB)MineScope™ Presentation

Ivan Wayland

|6 October 2014 2

Discussion points


Introduction to BHI & i-Mining Solutions

Value Added Blasting and MineScope™

Blasting Efficiency

MineScope™ Framework

Planning

|MasterClass | 6 October 2014

BHI & i-Mining Solutions joint venture

3

A long history with AEL

Local and international

experience

Strategic links with other

world-class service providers

Solutions with a

quantifiable impact


BHI & i-Mining Solutions joint venture

4

Identifying

constraints in an

initial analysis

Improve client

performance

by Developing

solutions with

an optimum

payback

Supporting

implementation

with change

management

Ensuring

sustainability

with

organisational

capacity at all

levels


Value Added Blasting & MineScope™

5

The beginning

Began in AEL

18 years ago in

Underground

Operations

To optimise

drilling and

blasting

Measure the

financial

impact of

quality and

performance

improvement

17 projects

successfully

completed

Wayne Du Chenne of AEL led the initiative and intends to extend

the concept of a Value Added Blasting Service to customers in

Opencast Operations – hence the development of the

MineScope™ Framework

1996



6

Impact flow

Process flow


Blasting Efficiency – Integrated approach

7

�� Capacity development and performance improvement ��

Service delivery and client profitability

Development• Coaching• Mentoring

Resource planning• Flexibility• Hours• Skills

MCS• Blast-i Tablet• Short interval controls

Discipline• Behaviour• KPIs• R&R

Organisational

development

Organisational

development

��

High

performance

teams

Management

Control System

(MCS)

Blast-i Tablet


Blasting Efficiency – Development of the MCS

8

Brown Paper – “as is”

(constraints and what needs to

change)

White paper – “to be” AEL and

Mine standard, systems and

procedures

Technology – AEL Blast-i

Tablet process & control

automation on the bench

(accuracy, paperless &

real time)

Management

and Client

reporting

(compliance,

root cause

analysis and

action

tracking)


VAB MineScope™ Framework – Impact of blast design

9

Blast design and planning Fragmentation Muckpile Profile Muckpile Throw

Blasted

Muckpile

In-situ

Rock

Blasted

Muckpile

In-situ

Rock

Blasted

Muckpile

In-situ

Rock

A: Long Row DelaysSuitable For Dragline Excavators

B: Moderate Row DelaysSuitable for Front End Loaders

C: Short Row DelaysSuitable for a Back Scoop



10


Drilling Blasting Load & haul Crushing Milling Plant

Value chain Waste Ore

“Blasting is the Client of Drilling”

… the “Beneficiaries of Drilling and Blasting”

ORGANISATION DEVELOPMENT

CHANGE MANAGEMENT



11



Value chain Waste Ore Blast design Relationships Processes Profit

Impact of blast design1

Relationships to be established2

Processes to be followed3

Value calculator – financial models4



12








• Cost

• Cycle time

• Cost

• On-time

• Match to equipment

• Cost

• Cycle time

• Cost

• Throughput

• Cost

• Throughput

• Cost

• Recovery

• Throughput

• Dilution


1


13






• Drill pattern to cycle time

• Blast design to cycle time

• Dig time to fragmentation & muckpileshape

• Void ratio of equipment to fragmentation

Input fragmentation to

• Output size

• Throughput

• Energy level

• Size to throughput (if energy level is constant)

• Crushed size to energy consumption (if throughput is constant)

• Blast design to dilution

• Feed grade to recovery rate





14





• Baseline & impact of changes to capacity and throughput

• Identify and adjust fixed & variable costs

• Apply financial model

Baseline & impact of changes on

• Effectiveness

• Operational capacity

• Throughput

• Identify and adjust fixed & variable


Baseline & impact of changes on

• Cycle time

• Throughput

• Equipment factors



• Establish costs for processing over-sized ROM (primary crusher)

Baseline & impact of changes to crusher & mill in

• Throughput

• Energy consumption



Impact of changes on

• Dilution

• Throughput

• Recovery rate

• Identify and adjust fixed and variable cost






0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

0

1 000

2 000

3 000

4 000

5 000

6 000

AEL Blast 1 AEL Blast 2 AEL Blast 3 Case Blast 1 Case Blast 2 Case Blast 3 Case Blast 4

Kg/m³Tonnes/hour

Avg loading rate AEL Avg loading rate Sishen Avg tons/hour AEL

Avg tons/hour Sishen PF (Kg/m³)

Loading rate improvement project | Case study 3


Planning for Optimal Blast Design

16

Process to be followed

“As Is”

factors

Design Control and

Measure

Re-design

(improvement

planning)

Rock Type

Rock Properties

Rock Response

Geological

Structures

Bench Height

Loading Method

Cast or choke

Fragmentation, Muckpile profile & throw based on

• OEM loading parameters

• Hauling size parameters

• Material destination

• Disposal method

• Crush/ mill feed parameters

Short interval control over

• Preparation & staking

• Drilling• Charging• Timing

Measure effects

• Fragmentation

• Muckpile profile• Muckpile throw

Cause & effect

Root cause analysis

Corrective action

• Next planning cycle

• MCS to implement



17

Impact flow

Process flow

• Cost

• Cycle time

• Cost

• On-time

• Match to equipment

• Cost

• Cycle time

• Cost

• Throughput

• Cost

• Throughput

• Cost

• Recovery

• Throughput

• Dilution

Value proposition

|6 October 2014 18


Questions and answers

Ivan Wayland

AEL value added blasting (vab) - Ivan

Engineering

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