mining r & d at xstrata nickel -...

1

MINING R & DAT XSTRATA NICKEL

Bergforsk Meeting, LuleåMay 23-24, 2007

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Our Vision and Values

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Who We Are

• World’s fourth-largest producer of refined nickel with fully integrated operations

• Head Office based in Canada• Producer of nickel

and ferronickel• Approximately 4,500 employees• One of the world's largest recyclers

and processors of nickel and cobalt bearing materials

• Excellent portfolio of brownfieldprojects:

Nickel Rim SouthFraser-MorganRaglan ExpansionOnaping/Craig Depth

• Strategic focus: Growth

Top 5 Nickel producers (refined)

-

90

145

177

243

109

0 100 200 300

Norilsk

CVRD / Inco

BHP Billiton

Xstrata

Jinchuan

Kt

4

Sudbury Technical Services/Mines: Existing Capacity R & D

• Ground Control/Geotechnical – 1 Principal Engineer

Ground Support/Mine-Stope-Slope Stability/Geotechnical Audits

• Mine Systems – 1 Principal EngineerVent/Fill Distribution/Air/Water

• Industrial Engineering – 1 Principal EngineerMining Process Capability/Simulation/Data Analysis

• Mine Engineering – 1 Senior Mine EngineerMine Design/Project Management/Applied Research and Development

• Drilling and Blasting – 1 Principal Engineer; 50% Mine Technologist/Specialist

Improved Drilling Quality, Reduced Rock Damage

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Focused Research Strategy

• Need Business Case Justification/Retention of Knowledge/Skills• In House OR Consortia Based ?

In HouseXstrata Nickel know-how & capacity existsPartner with supplier's where applicableEasier/quicker to implement resultsResources limited

ConsortiaIndustrial Champions Minimum 1+1Active participation In-kind contributionGreater resource leverage

• University SupportAcademic Excellence and Future Skill Development

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Funded Mining R & D Areas2007 Budget:C$2.64mil; C$1.60mil Cash

• 3M Deformable Liner (In-House/Partnership) • Deep Mining (Deep Mining Research Consortium-DMRC)

Yielding Ground Support SystemsQuality Backfill Systems (Gelfill)Alternative Underground Hoisting/Transportation SystemsRapid Development for Overstressed ConditionsHeat Stress Quantification/MitigationRockburst Risk Evaluation

• Mine Design Optimization (Centre Excellence Mining Innovation-CEMI/LU)Industrial Engineering/Simulation ModelsMine Design & Productivity EnhancementsOptimized Planning and Financial Risk Control

• Frozen Backfill (LU)Binder Replacement with Ice/Permafrost Conditions

• Paste Backfill (University of Toronto)• Development Cycle Improvements (RTC/FBD Project)• Waterscaling/Shotcreter Combi Machine (Meyco/Rio Tinto/Inco)• Miner-Operated Underground Imaging System (CSIRO/Consortium)

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DMRC COST MODELShallow vs D epth Premium

$0

$50

$100

$150

$200

$250

Shafts, Hoist

s, Headworks

Vent ilation & Refrig

eration

High Intensity M

ining

Fill System

Seismic Decay Allowance

U/G Ore & W

aste Handling

Direct M

ining- L

ateral Dev

Rapid Advance Rates

COST

/SAVI

NG,

C$

x106

Shallow D epth Premium

125100

8062

41 32 30 24

Deep Mining Business CaseCost/Savings Opportunities

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Deep Mining Projects

• Waterscaling+Yielding Bolts & Deformable Liner

Strategy: auto-scaling in over-stressed rock conditionsNecessary rock preparation prior to liner applicationCoupled Bolts and Liner deform as a Unit

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• Toughness– i.e. Can deform significantly with minimal loss

of loading-bearing capacity• Adequate Coupling to Rock

– i.e. Energy can be effectively and efficiently transferred from rock to the support system

• Ease and Quality of Installation– i.e. Dependable and safe to install in seismically

active/stressed/over-stressed ground conditions

EFFECTIVE GROUND SUPPORT FOR DEEP MINING CONDITIONS DEMANDS:

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THE CHALLENGE: In Practice is the Ideal Support System Achievable?

Rock Fails Under Stress & Dilates, Stretching Liner

and Loading Rockbolt Plate

Liner Overloads at Plate, Fails & Permits a Groundfall. Ground Support must be Replaced

Failed Connection between Liner and Rockbolt

Fully Grouted Rockbolt + Mesh

or ShotcreteRock Fails Under Stress & Dilates, Stretching Liner


Rock Fails Under Stress & Dilates, Stretching Liner







or Shotcrete


or Shotcrete

Liner Separates from Failing Rock Surface – in limit acts like a “BAG”; Connection between Liner and

Rockbolt is Maintained

Conebolt Plows Through Resin at a Constant Load Threshold

Rock Fails Under Stress & Dilates, Loading Rockbolt Through Plate to Yield Limit. The Liner accommodates stretch

System requires NO rehab for Life of Mine

NTC Conebolt+3M Liner













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Proposed Cycle Steps

1. Combi Semi-Auto HPWS/Liner Applicator sets up in heading

2. Operator inspects heading for any “obvious” loose and scales down prior to pattern scaling

3. Pattern scaling, Back and Walls4. Pattern and Selective scaling, Face5. Apply Liner6. Combi leaves heading

7. L2C Jumbo sets up8. Jumbo drills, Operator installs Bolts from Boom Basket9. Visual inspection of face10. Jumbo drills face11. Check scale face from Boom Basket prior to loading12. Operator loads the face

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HPWS Status

• Sudbury Operations considers semi-automated water-scaling/washing action acceptable and most desirable in a variety of ground conditions

Must define ”loose” – back, walls and face• Equipment will provide for:

1. Pressure – 14.5 MPa2. Flow – 270 l/min3. Stand off distance min 1.5 m to max 2.5

meters• Pump capable of reduced effect: 75%,

50% and 25%

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ALL LINERS HAVE THEIR LIMITATIONS…..Shotcrete Limitations

• Failure concentrated as over-stressed rock dilates

– Irrespective of loading rates

– Fibres increase tolerance somewhat

• Does not perform as well as Lab-Based test results suggest

• Difficult to Rehab• Can Toughness be

yet improved?

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ScreenScreen

• Easily damaged by fly-rock

• Difficult to Install in a Single Pass with crews staying Safe & Productive

• Bolt/Screen Coupling fails in 75-80% of large strain/burst events

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TSL/3M Liner

• Easily damaged by fly-rock

• Safety trade-off: isocynates vslimited early strength

• Specification must address the issue of DEFECT PROPAGATION

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UNDERSTANDING TSLsLab Tests

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…and more Lab Tests:Buckling Test/Stacked Rock Plates

• Test develops complex post-failure deformations

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…and more lab tests…and more lab testsRockRock--onon--Rock TestRock Test

•This test looks at liner defect propagation and has been modellednumerically using FLAC 2D & 3D

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TSL Development Status

• Xstrata Management & Engineers + External Technical Review Committee continue to believe that the need for a tough, deformable Liner is still valid

• Early (minutes-hours) strength of liner is important

• In areas of high stress (active ground) bolting may have to precede liner application

• 3M considering possibilities to re-formulating their liner to provide higher early tensile strength with some possible reduction in other properties

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Deep Mining Contd..

• Rockburst Risk Studies, Lower Craig MineRisk related to high anomalous shear stress on faults prior to development or production miningPotential for collaborative project with LuH

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ONAPING MINE

CRAIG MINE

ZONE 1

ZONE 10

ZONE 11

ZONE 2

ZONE 3

ZONE 12

ONAPING DEPTH

ZONE 1

ZONE 8

ZONE 6ZONE 9

INCO

INCO

ZONE 2

ZONE 4

CRAIG MINE

LONGITUDINAL PROJECTIONLOOKING NORTH - DEC. 31, 2003

SCALE

0 250 500 m

MINERAL RESERVES AND RESOURCES

EL 1500 EL 1500

LEGENDPROVENPROBABLE

MINED OUT

MINERAL RESOURCE

E 50

00

E 40

00

E 45

00

EL 2000

EL 2500 ONAPING MINE

CRAIG MINE

ZONE 1

ZONE 10

ZONE 11

ZONE 2

ZONE 3

ZONE 12

ONAPING DEPTH

ZONE 1

ZONE 8

ZONE 6ZONE 9

INCO

INCO

ZONE 2

ZONE 4

CRAIG MINE

LONGITUDINAL PROJECTIONLOOKING NORTH - DEC. 31, 2003

SCALE

0 250 500 m

MINERAL RESERVES AND RESOURCES

EL 1500 EL 1500

LEGENDPROVENPROBABLE

MINED OUT

MINERAL RESOURCE

E 50

00

E 40

00

E 45

00

EL 2000

EL 2500

CurrentOnapingMining~1600 to1700m belowsurface

deepestcurrentmining~1600m

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Seismicity around FaultsThe major player for Lower Craig Mine

• ore emplacement related to fault zone

• high percentage of recorded seismicity from these areas

• high percentage of “large” events• 53% Mn>1 from lower Craig fault zone (72/135 from 2003 to May 06 see next slide)

• usually assumed to be fault slip• could be solid rock between faults failing• or combination of the two

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30 days of seismicityAround the 10 and 11Zone faulting

Orebody model notShown but associatedWith the faultingIn this area

development

Major faults in green

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STRUCTURAL DIAMOND DRILLING ONLYLooking North

New development

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June 3, 2004Fault related activity around vent raise

Development ~ 5x5m

12:36 Mn 1.912:41 Mn 1.817:21 Mn 2.517:23 Mn 0.8

27Photo of bottom of drop raise (April 2006) still some more muck peeling…

Major fault

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Vent raise bracketed by faulting

Green = design excavation

White = cavity survey after Seismic episode

Short term predictability ofMajor seismic episodes ? ?

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First event in sequence = Nutli Magnitude 1.9, no precursory activity recorded

First event in second event rate spike = Mn 2.5

No short term seismic warning

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Deep Mining Contd..

• Heat Stress Index/Acclimatization

Project to research, establish and validate an index that is appropriate and relevant to assessing thermal stress in miners working in Canada’s deep mechanized minesDevelop specialized clothing that promotes cooling effect in dry, ventilated environment

Figure 1. Ambient air temperature as a function of mine depth.Source: Natural Resources Canada, Sept. 2005

Figure 1. Ambient air temperature as a function of mine depth.Source: Natural Resources Canada, Sept. 2005

Bergforsk Meeting, LuleåMay 23-24, 2007

Heat Stress in Canada’s Deep Mechanized MinesLe stress thermique dans les mines profondes, mécanisées du Canada.

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ventilation & refrigeration control measures

optimize productivity and profitability

impact viability of local economies

worker performance and safety

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The ‘Snellen’ calorimeter

Gold standard method for measuring biologic heat release in humans.

Powerful research tool to: • study fundamental nutritional and physiological life-processes, and;

•evaluate stresses imposed by abnormal or severe environments

• advancements in our understanding of human heat regulation.

• improved estimation of changes in body heat content

Key technological advancements

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Predicting Heat Stress

• Activity (level and duration)

• Acclimatization

• Clothing Insulation

• Age

• Body Morphology

• Aerobic Fitness

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Gender? (1=Male; 2=Female)

Age? (Years)

Weight? (kg)

Height? (cm)

Consecutive work day?

Clothing? (1=High; 2=Moderate; 3=Low)

Mining Depth? (m)

1

35

80

178

4

1

1,200

Predicting Heat Stress

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Deep Mining Contd..

• Alternative U/G TransportationHatch & MacIntosh Completed an Independent High-Level, Pre-Investigation Study

Opportunities identified for advanced study

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Mine Design/Optimization

• In-house studiesMine FeasibilityNew Mining ProcessMine Design Strategies/Options

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Mine Simulation Model – Feasibility Studies

Active Headings per Monthby Phase

0

10

20

30

40

50

60

70

80

90

100

Act

ive

Hea

ding

Jumbo Drills Solo Drills Anfo Loader 6 yd LHD 10 yd LHD BolterScissor Trucks Shotcrete Machine Scalers Sprayers Miners

2004 201820172016201520142013

20122011201020092008200720062005 20202019

Phase 1 Pha

se 3

Phase 5Phase 2 Pha

se 4

Year

Equipment Utilization

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Mine Simulation Model – New Processes

Impact of Number of HeadingsSpray On Liner8 Hour Dry Time

1 Heading 2 Headings 3 Heading 4 Headings 5 Heading 6 Headings 7 Headings

Hou

rs B

etw

een

Bla

sts

Best Drill & BlastWith LinerBest Drill & BlastWith Bolt & ScreenBolt & Screen

Cross Over Point where dry time has reduced impact

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Ore Waste Handling Model• Impact of Reducing Underground Bin Capacity

Impact of Bin SizeOn Blasthole Production

0

10

20

30

40

50

60

70

80

6 m Taller Original 6 m Shorter 12 m Shorter

Shi

ftt

Shifts_Delayed_1280_ContactShifts_Delayed_1280_FootwallShifts_Delayed_1320_ContactShifts_Delayed_1320_FootwallShifts_Delayed_1480_FootwallShifts_Delayed_1500_FootwallShifts_Delayed_1590_FootwallShifts_Delayed_1620_FootwallShifts_Delayed_1660_Footwall

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Rapid Development Model – Sample Results

Project Velocity Simulation - Potential Advance Rates for Single Heading

6.36 6.30

9.589.11

7.56 7.54

10.7110.33

8.108.56

11.6911.32

9.06 9.12

11.4110.94

0

1

2

3

4

5

6

7

8

9

10

11

12

13

5.0X5.0 6.5X5.0 6.5X5.0 7.5X5.5

Heading Size [width(m) X height(m)]

Adv

ance

Rat

e [m

/day

]

Rebar & Screen (Robolter)Rebar & Shotcrete (Robolter)Super Swellex & Shotcrete (Jumbo)Rebar & Screen (Concept Vehicle)

22/12/2003

Note: Advance rates are calculated from the average cycle time. The average cycle time is obtained by running the simulation for 401 rounds.

Muck BaysSingle Equipment

Muck BaysSingle Equipment

No Muck BaysParallel Equipment

No Muck BaysParallel Equipment

Typical Existing Advance Rate for 5.0m X 5.0m Dev. Heading

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FINAL REMARKS

• GOOD MINING RESEARCH REQUIRES:Industry Specialists with

Big-Picture IdeasInnovative Talent, “Can-Do” AttitudeResults Driven - High impact below the collarUnderstanding of Project’s Business Case

Management withLong-term goalsWillingness to take risks

Universities thatMaintain relevant body of knowledge/Provide state-of-art skills training/attract industrial support

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ACKNOWLEDGEMENTSACKNOWLEDGEMENTS

• Xstrata Nickel, 3M Canada and Sandvik Management• Mr. Dawson Proudfoot, Scott Carlisle, Brad Simser, Peter

Rutherford of Xstrata Nickel Technical/Engineering Services

• Xstrata Nickel’s Fraser & Craig Mine Operations • CANMET’s Bells Corners & Kelly Lake Rd Laboratories• Dr. Richard Brummer, Dr. Patrick Andrieux, Mr. Chris

O’Connor, Mr. Michel Beaudry and Mr. Richard Larocqueof Itasca Consulting Canada Inc

• Mr. Greg Doyle, Mr. Terry Rayner and Mr. David Livingstone of 3M Canada

• Mr. Dale Rokochy of Sandvik • Mr. Charlie Graham of CAMIRO and member companies of

the Deep Mining Research Consortium • Mr. Fred Langevin of Agnico Eagle’s Laronde Mine• Dr Vassilios Kazakidis, Laurentian University

mining r & d at xstrata nickel -...

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