THERMAL FRAGMENTATION: REDUCING MINING WIDTH WHEN EXTRACTING NARROW PRECIOUS METAL VEINS

Donald Brisebois and Jean-Philippe Brisebois Rocmec Mining, Canada

ABSTRACT
The mining of high-grade, narrow vein deposits is an important field of activity in the precious metal mining sector. The principle factor that has undermined the profitability and effectiveness of mining such ore zones is the substantial dilution that occurs when blasting with explosives during extraction. In order to minimise dilution, the Thermal Fragmentation Mining Method enables the operator to extract a narrow mineralised corridor, 50 cm to 1 metre wide (according to the width of the vein), between two sub-level drifts. By inserting a strong burner powered by diesel fuel and compressed air into a pilot hole previously drilled directly into the vein, a thermal reaction is created, spalling the rock and enlarging the hole to 80 cm in diameter. The remaining ore between the thermal holes is broken loose using low powered explosives, leaving the waste walls intact. This patented method produces highly concentrated ore, resulting in 400% - 500% less dilution when compared to conventional mining methods. The mining method reduces the environmental affects of mining operations since much smaller quantities of rock are displaced, stockpiled, and treated using chemical agents. The fully mechanised equipment operated by a 2-person team (1 thermal fragmentation operator, 1 drilling operator) maximises the effectiveness of skilled personnel, and increases productivity and safety. The Thermal Fragmentation is currently employed in 3 mining operations in North America.

INTRODUCTION
The mining of high-grade, narrow vein deposits is a predominant field of activity in the precious metal sector. These types of deposits are located throughout the globe and have a significant presence in mining operations. The principle factor that has undermined the profitability and effectiveness of mining such ore zones is the substantial dilution that occurs when blasting with explosives during extraction and the low productivity associated with todays common extraction methods. The Thermal Fragmentation Mining Method has been conceived to mine a narrow mineralised corridor in a productive and cost efficient manner in order to solve these particular challenges. The following describes this mining method in depth and outlines its successes in improving the extraction process of such ore bodies.

DESCRIPTION OF TECHNOLOGY
A strong burner powered by diesel fuel is inserted into a 152 mm pilot hole drilled into the vein (Figure 1) using a conventional longhole drill. The burner spalls the rock quickly, increasing the diameter of the hole to 30 - 80 cm (Figure 2) producing rock fragments 0 - 13 mm in size. The leftover rock between fragmented holes is broken loose using soft explosives and a narrow mining corridor with widths of 30 cm to 1 metre is thus extracted (Figure 3). Since the waste walls are left intact, the dilution factor and the inefficiencies associated with traditional mining methods are greatly reduced.

Figure 1: The Method (Creating the Opening)

Figure 2: Fragmented Hole (60 cm Wide)

Figure 3: Stope (80 cm Wide)

THE BURNER
The burner (Figure 4), powered by diesel fuel and compressed air, creates a thermal cushion of hot air in the pilot hole, which produces a thermal stress when coming in contact with the rock. The temperature difference between the heat cushion and the mass of rock causes the rock to shatter in a similar manner as putting a cold glass in hot water. A spalling effect occurs (Calman and Rolseth, 1968), and the rock is scaled off the hole walls and broken loose by the compressed air.

Figure 4: The Burner

THE FRAGMENTED ROCK

The process of fragmenting the rock is optimal in hard, dense rock. The spalling process produces rock fragments 0 - 13 mm in size. Figure 5 illustrates the size of the fragmented ore. The finely fragmented ore requires no crushing before entering the milling circuit and can be more efficiently transported since it consumes less space than ore in larger pieces.

Figure 5: The Fragmented Rock

TONNAGE COMPARISON WITH ALTERNATIVE METHOD

The method produces highly concentrated ore, resulting in 400% - 500% less dilution when compared to conventional mining methods. Table 1 below compares the quantity of rock extracted when mining a 50 cm-wide vein using the thermal fragmentation mining method as opposed to a shrinkage mining method.

Table 1: Tonnage calculation; comparing thermal fragmentation and shrinkage methods Tonnage Calculation (40 m by 20 m Ore Block) Width in situ (m) Mining Width Final Result Planned Dilution Height (m) Length (m) Density Total Volume (t) Thermal Fragmentation 0.5 0.5 0% 20 40 2.8 1120 0.5 1.8 260 % 20 40 2.8 4032 Shrinkage

The table above shows approximately 4 times less rock needs to be mined for the equivalent mineralised content. This method of extraction allows mine operators to solely extract mineralised zones, thus significantly reducing dilution factors and optimising mine operations as a result. The technology enables the operator to mine ounces and not tonnes.

DRIFT DEVELOPMENT AND STOPE LAYOUT

Drift development is performed directly into the ore at intervals of 15 to 20 metres (Figure 6) in accordance with the geology of the ore body. Using a re-suing method, the ore is blasted and recovered in the first cut, then the waste is blasted and hauled away in the second cut. Following the creation of two sub-level drifts, a pilot hole is drilled between the two levels and enlarged by way of thermal fragmentation. The unit is designed to operate in a compact underground environment, in a drift as small as 1.8 m wide by 2.8 m high (Figure 7). The company also produces a unit measuring 0.8 m wide by 2.1 m high, which is capable of working in smaller sublevels.

Mining Width: 50cm Total: 1062 Tonnes

Figure 6: Stope Layout

Figure 7: Equipment Dimensions

OTHER APPLICATIONS - DROP RAISING

The thermal fragmentation equipment is also used to create the centre cut in traditional drop raising. The burner can enlarge a 152 mm pre-drilled pilot hole into an 80 cm cut on a 20 meter distance in approximately 4 hours total. By creating this large centre cut quickly and efficiently, larger sections can be blasted with minimal vibrations (Figure 8), thus avoiding damage to the surrounding rock (Figure 9). The number of blast holes needed and explosives are reduced and the risk of freezing the raise is minimised.

Figure 8: Thermal Cut (80cm) with blast hole

Figure 9: Drop Raise (20 m x 0.9m x 1.2m)

ENVIRONMENTAL IMPACT ANALYSIS

There is a growing need to develop sustainable mining methods that minimise the environmental footprint left behind by mining operations. While developing the Thermal Fragmentation Mining Method, important efforts were made to address and reduce the environmental effects that mine operations have on the surrounding areas. Using the method, mine development is performed directly into ore, resulting in less waste rock being extracted and displaced to the surface. By solely extracting the mineralised zone, only the necessary excavations are made. As shown in Table 1 above, 4 times less rock needs to be mined for the equivalent mineral content.

As a result of less rock being mined, fewer tonnes need to be processed at the mill to extract the precious metals. The quantity of chemical agents needed in the process is greatly reduced and the quantity of energy needed to process the ore is also greatly diminished. The reduced quantity of energy for hauling and processing the ore results in fewer greenhouse gases being emitted. The mining residue that remains once the precious metal contents are removed is 4 times less abundant, using the example above, meaning much smaller tailing areas need to be constructed, maintained, and rehabilitated once mining operations have ceased. The space needed to host the mine site is greatly reduced, the alterations to the landscape are significantly diminished, and the result is a cleaner and more responsible approach to mine operations.

PRODUCTIVITY AND SAFETY

The shortage of skilled personnel in the mining community has made it essential to find ways to increase productivity per worker while improving working conditions in order to attract and retain skilled miners.

PRODUCTIVITY
The work group required to operate 1 thermal fragmentation unit consists of a 2 person team (1 thermal fragmentation operator, 1 drilling operator). Table 2 shows the time needed to extract an ore block using the thermal fragmentation mining method in comparison to using a shrinkage mining method.
Table 2: Tonnage calculation; comparing thermal fragmentation and shrinkage methods Tonnage Calculation (40 m by 20 m Ore Block) Width in situ (m) Mining Width Final Result Planned Dilution Height (m) Length (m) Density Total Volume (t) Number of Personel Productivity per 12 hrs Shift (t) Tonnes Extracted per 24 hrs Days Required to Extract Ore Block Thermal Fragmentation 0.5 0.5 0% 20 40 2.8 1120 2 30 60 18.7 0.5 1.8 260 % 20 40 2.8 4032 2 30 120 33.6 Shrinkage

The table above demonstrates that for the equivalent amount of mineral content, it takes approximately half the time to mine the ore zone using the thermal fragmentation mining method than when using a shrinkage mining method. Furthermore, since less rock needs to be mucked and hauled from the stope, fewer personnel are needed for handling the ore.

MECHANISATION AND EMPLOYEE SAFETY

Each unit is completely mechanised, reducing the risk of injuries and strain caused by manual manipulation of heavy equipment. The operator stands at a safe distance from the stope, virtually eliminating the risk of flying debris and falling loose rock from the waste walls. Furthermore, unlike shrinkage mining methods, smaller excavations are made (0.5 m compared to 2 m) so the occurrence of falling loose rock is greatly diminished.

ECONOMIC ANALYSIS
By rendering a greater number of narrow, mineralised zones that are economical to extract, the mining method has the potential to convert a substantial portion of the mineral resources of an operating company into mineral reserves. A large number of mines currently in operation today contain narrow, precious metal veins throughout the ore body, but unless these veins are of significant width (usually 1 m or greater) or very high grade they are often overlooked. As the mine operator develops the zones to be extracted, high grade, narrow ore bodies are often uncovered, but not extracted since it is uneconomical to mine such ore bodies using conventional mining methods (shrinkage, long hole, room and pillar, etc.) Table 3 below demonstrates the cost savings per ounce of using the thermal fragmentation mining method in comparison to the long-hole method. The study was done by Canadian Institute of Mining using 2001 exchange rate figures.

Table 3: Estimate cost comparison between underground thermal fragmentation and long hole Tonnage calculated on the basis of a 60 m by 60 m reserve block Grade in situ (g/t) Width in situ (cm) Minimum width (cm) Planned dilution Geological reserves Reserve grade (g/t) Mining Wall dilution Stope recovery Ore development Planned mining reserve Grade (g/t) Mill recovery Produced ounces Thermal Drilling Unit Cost $/M Development Drifts Subdrifts Raises Drawpoint Mining cost ($/t) Mucking Transportation Milling Environment Backfilling Total $ per tonne $ per ounce US$ per ounce 0.65 657 127.00 335.06 326.49 212.22 1000.00 1000.00 1000.00 1000.00 113.50 8.00 12.00 16.00 2.00 222 600.00 15 690.00 23 535.00 31 380.00 3922.00 180 000.00 120 000.00 60 000.00 1000.00 1000.00 1000.00 1000.00 19.00 4.00 6.00 20.00 2.00 5.00 180 000.00 120 000.00 120 000.00 60 000.00 277 516.00 58 424.00 87 636.00 292 122.00 29 212.00 73 030.00 1 297 940.00 88.86 590.59 383.88 Total Cost $/M 5% 79% 544 1961 33.25 96% 2013 Long-hole Drilling Unit Cost $/M Total Cost $/M 35% 90% 2540 14 606 4.88 96% 2198 Thermal drilling 3024 t 35.00 30 30 0% 3024 35.00 Long-hole drilling 3024 t 35.00 30 140 367% 14 112 7.50

As the analysis above shows, it is approximately 45% less costly to mine a narrow vein ore body using the thermal fragmentation mining method than using a conventional mining method. Overall profitability of mine operations is increased since more precious metals can be economically mined for the same level of development expenditures.

CONCLUSION
Many variations and adjustments have been made to conventional methods of mining narrow precious metal veins, but the serious shortfalls brought upon by dilution remain. The Thermal Fragmentation Mining Method is a new and innovative way of mining narrow vein ore bodies and a foremost solution to solving the problem of ore dilution by reducing it by a factor of 4 to 1. It uses a unique tool, a powerful burner, to mine with precision, a narrow mineralised corridor in an effective and productive manner. The technology is positioned to meet the growing challenges of skilled labour shortages, tougher environmental guidelines, and the depletion of traditional large scale ore deposits mined using conventional methods. As the technology continues to develop and spread through the mining community, the objective remains to optimise the productivity and profitability of mining narrow, high-grade, precious metal ore bodies and to make a substantial, lasting contribution to this sector of activity.

REFERENCES
Canadian Institute of Mining. (2003). Thermal rock fragmentation Applications in narrowvein extraction. Vol 96, #1071. CIM Bulletin, Canada. pp. 66-71.[1] Calaman J.J, Rolseth H.C., (1968). Surface Mining First Edition. Chapter 6.4 Society for Mining Metallurgy and Exploration Inc., Colorado, USA p.325-337. [2]