Evaluation of Bench Height Selection for Limestone Resource Optimization A Case Study N K Sharma, R Mazumder, D K Panda, A K Dubey

Abstract The economic viability of the modern day limestone mine and its long term sustainability is highly dependent upon careful planning and management. Declining trends in availability of an average ore grades, increasing mining costs and environmental considerations will ensure that this situation will remain in the foreseeable future. The optimization and strategic planning for management of a large open pit limestone mine having a life of several years is an enormous and complex task. Strategic planning for mine optimization is carried out basically to enhance the quarry life with minimum generation of waste keeping in view the two main objectives (i) optimal grade of limestone and its production, a mine can produce up to the life of the deposit and (ii) optimization based on grade constraints keeping the consideration of raw mix based on cheaper fuel and additives avoiding the imported fuel and costlier additives. Though a number of techniques have been successfully applied to resolve some important optimization problems, the problem of determining an optimal ultimate pit which depends upon the selection of optimum bench height is still very much unresolved. In this paper, it has been attempted to provide a long term strategic plan for optimization of limestone mine by preparing ore body models at variable bench height systems of 9m, 10m and 12m to study the effect of dilution / segregation of various grade due to compositing at different bench heights. The effect of various ore body models is being compared for determination of optimum ultimate pit limit of a mine which depends upon blended (optimized) and final (un optimized) pit and resultant optimum production schedule over the total life of the mine. Multimine scheduler software which uses LG (Lerch-Grossman) method to determine an optimal ultimate pit is used to carry out pit optimization for maximization of resources for 9m, 10m and 12m bench model. The limestone deposit of the studied area belongs to Narji formation of Kurnool Group is stratiform, stratabound of regular habit associated with variable thickness of calcareous clay at the top and purple siliceous limestone as inter-burden and also at the bottom of various boreholes. The ultimate pit limit for all the three models is created with a specified ROM cut-off percentage of CaO and SiO2, which gives the shape of the mine at the end of its life. The results of ultimate pit reserve are reported as range of grade tonnage relationship for blended and final pit is compared for all the three bench models. This allowed to calibrate the model for mining bench height, realistic dilution / segregation, blending solution and production scheduling at specific cut off grade for optimized life of mine.

1.0 Introduction The production and management of desired ROM grade limestone for maximum life from a large open cast limestone mine is an enormous and complex task. Optimization techniques can be successfully applied to resolve a number of important problems that arise in the planning and management of a mine. These applications include: selection of optimum bench height for ore modeling and reserve estimation; the design of optimum ultimate pits; the determination of optimal blends; the determination of optimal production schedules; the determination of optimal operating layouts; and many more. The optimum ultimate pit of a limestone mine is defined as to be that pit which is the result of extracting the volume of material which is obtained by maintaining balance between elements or rock types according to user defined blending criteria whilst satisfying the operational requirement of safe wall slopes. The ultimate pit limit gives the shape of the mine at the end of its life. The production schedule of a mine can be defined as a year-by-year sequence in which blocks should be removed from the mine while targeting quality parameter such as CaO% and SiO2% etc. The bench height is the critical function for deciding ore grade composite for the height of the bench applied for mining. This paper deals with evaluating the impact of bench height selection on sustainability of quality and life of mine at feasibility stage to maximize the resource. 2.0 Geological and Mining Setup The Limestone in the study area geologically referred to as an equivalent of Narji Limestone belongs to Jammalamadugu formation of Kurnool Group of rocks of Palnad basin. The Litho units encountered in the subject area and the generalized succession of rock types is as follows. Surface Soil Dark Grey Limestone Light Grey Limestone Purple Siliceous Limestone The deposit has been classified broadly as per lithological units into three zones and are named as ZONE-1, ZONE-2 and ZONE-3 which represents the soil, calcareous clay and limestone (dark and light grey) respectively. Calcareous clay and limestone except soil are further classified into 7 classes based on the range of CaO% and taking SiO2% range between <15% and >15% as function of difference within the classes. Where the model grades falling CaO >42% and SiO2 <15% is for cement grade limestone (at CaO 2% interval) and while keeping SiO2 >15%, the blendable grade limestone is classified for limestone containing >42<48%CaO and low grade limestone containing >40<42% CaO and remaining material / rock units within

calcareous clay and limestone with CaO <40% as very low grade limestone. The grade categories are coded as 1, 2, 3, 4, 10, 11, 12 and 13. The details are given in Table. 1 for reference.
Table. 1: Zone and Grade Classification of various litho units
Litho-unit Categories ZONE-1(Soil) ZONE-2 (Calcareous Clay) and ZONE-3 (Dark & Light Grey Limestone) 4 10 11 12 13 1 2 3 Grade Code Block Cells Range of CaO% Range of SiO2% >42<44 >44<46 >46<48 >48 >42<48 >40<42 <40 >15.00% >15.00% >15.00% Blendable grade lst Low grade limestone V. Low grade limestone <15.00% Cement grade Limestone Soil and Limestone grades Soil (Waste)

3.0 Ore body regularization by different bench height To estimate mineable reserves it is necessary to consider economic, mining, environmental and other factors. A convenient way to discuss these factors is to consider the ore loss and dilution gain that is incurred during the various phases of the mining project. The concepts of ore loss and dilution gain are illustrated in Fig. 1.
ACTUAL ORE OUTLINE

GEOLOGIST S INTERPRETED ORE OUTLINE

ORE LOSS INTERNAL DILUTION EDGE DILUTION BENCH HEIGHT

Fig. 1: Dilution and ore concepts

During production, ore losses and dilution gains are caused by several interrelated factors, namely: irregularities in the outline of the ore zone; the sampling method and sampling density; the attitude of the ore body; the bench height;

 human error; and ore losses to the dump or heaps. Many of these factors can be best utilized by simulating mining through scheduler based on the various bench height systems. Not only does it solve mining, grade control and blending problems prior to mine development, but also many of the other geological and sampling uncertainties associated with estimating the in situ resources. There is a possibility of compositing of samples falling within the height of bench leading to segregation or dilution of internal or external waste into making material to be categorized blendable / low / very low grade material. Fig.2 shows the impact of compositing at different bench height.

Fig. 2: Borehole sample composites of 9m, 10m and 12m bench height system

This effect would impact the blending solution during production and determines the reserves in the blended pit (production) and final pit (not mined and left out due to no blending solution) during simulation of production scheduling. Bore hole composite sample length of 9m, 10m and 12m comprising of litho units of Calcareous Clay, Light Grey Limestone and Dark Grey Limestone have been tried for bench height selection for the Limestone Deposit as shown in Table 2.
Table. 2: Composite Sample Length and Percentage Recovery of Different Bench Height System (Total Sample Length= 1979.50m) Sample Category 9m Bench 10m Bench 12m Bench Height Height Height Composite Sample Length for SiO2 <15 1835.36 1828.33 1814.36 Percentage Recovery 90.31% 89.96% 89.27% Composite Sample Length for SiO2 >15 Percentage Recovery 197.02 9.69% 203.35 10.01% 218.31 10.74%

4.0 Deposit modeling To study the effect of dilution / segregation, different ore body models have been made at different height of mining block or cell dimension equal to bench heights of 9m, 10m and 12m. The top bench floor, block size details and number of benches for the three ore body models prepared are given in Table. 3.

Table. 3: Top bench floor, block size details and number of benches for each ore body model
Ore Body Models 9m Bench Model 10m Bench Model 12m Bench Model Top Bench Floor 86 90 86 X & Y Cell Dimension(m) 100m 100m 100m Z Cell Dimension / Bench Height (m) 9m 10m 12m No. of Benches 9 9 7

The 3D geological model has been created from the borehole data where Black cotton soil (overburden) and Calcareous clay is forming the top of the limestone for all the ore body models. For each ore body model bench height system is maintained till the depth of 14 mRL. The 3D geological model of a 12m bench model with black cotton soil, calcareous clay and dark and light grey limestone has been shown in Fig. 3.

Fig. 3: 3-D view of a 12m Geological Model of a limestone deposit with Black Cotton Soil, Calcareous Clay and Dark Grey and Light Grey Limestone Zones.

5.0 Optimization of Ultimate Pit and Scheduling The 3D geological model prepared for 9m, 10m and 12m bench height system is used for subsequent pit optimization with the help of Multimine Scheduler software. Multimine scheduler software which uses LG (Lerch-Grossman) method to determine an optimal ultimate pit is used to carryout pit optimization of all ore body models. The ultimate pit limits define what is mineable from a given deposit while satisfying the blending criteria according to which it identifies which blocks should be mined (blended pit) and which ones should be left in the ground (final pit). All the models prepared are being used for optimization of resource by finding the blending solution using all the grades present in the model except soil. Once the optimal solution is obtained for the specified cut off grade criteria, the ultimate pit shell is created around the blended pit. The blended limestone cut-off specification and quantity targets are given in Table.4.
Table. 4: Specification of blended Run of Mine Limestone
Annual Run of Mine Production Target Quality (%) Quantity(tonnes)

CaO% 45-47

SiO2% 11.5-12.5

2250000

Long term production strategy plan has been carried out for annual production target and production schedules has been prepared for 9m, 10m and 12m bench models with minimum quality variation and an effective optimal in pit blending scheme. 5.1 Impact of Bench Height Selection on Ultimate Pit Shell Limit The ultimate pit limit gives the shape of the mine at the end of its life. Optimum ultimate pit design plays a major role in all stages of the life of an open pit: at the feasibility stage when there is a need to produce a whole-of-life pit design; at the operating phase when pits need to be developed to respond to change in limestone grade requirement, mining cost, cement making costs, ore reserves and wall slope; and towards the end of a mines life where the final pit design may allow the economic termination of a project. Pit limit (excluding safety limits for road, railway track, rivulet, forest etc.), limiting bench parameter (desired bench upto which mining has to take place) and other required quality parameters constraints such as (e.g. CaO%, SiO2%) are applied to get the required optimal ultimate pit / blended pit. In this case the impact of variable bench height systems of 9m, 10m and 12m is studied to determine the most optimum ultimate pit for the limestone deposit in terms of its final shape at the end of the life of the mine and the total limestone reserve. Fig.4 shows the generalized layout of the limestone deposit and the shape of the ultimate pit shell simulated for the production scheduling based on the required blending criteria as per table.4 for 9m, 10m and 12m bench model at the end of the life of the mine. From the fig. 4 it is observed that the ultimate pit shell of the 12m bench model has the most favorable operating condition in comparison to ultimate pit shell of 9m and 10m bench model. The ultimate pit shells of 9m and 10m bench models have more number of working pits and some of the working pits are small in size which will be uneconomical for mining operation. However the ultimate pit shell of 12m bench model has less number of working pits and are wider in size and therefore the mining operation will be more economical and better manageable than the other models.

Generalized Layout of the Limestone Deposit

9m Ultimate Pit Shell

10m Ultimate Pit Shell 12m Ultimate Pit Shell Fig. 4: Generalized layout of the limestone deposit and the ultimate pit shell of the 9m, 10m and 12m bench model

5.2 Impact of Bench Height on resource optimization and blending The output of the pit optimization shows the reserves of the total rock, ore and chemical compositions of the blended pit and final pit for particular models. Here blended / ultimate pit is the pit obtained by maintaining balance between elements or rock types according to user defined blending criteria for production and development. Final pit material is the material which is left out in the mine and could not be utilized in blending as it does not satisfy the blending criteria. Table.5 shows quality and quantity of blended and final pit (with constraints such as excavation upto desired benches and ROM quality targets) obtained from blending all grades of limestone of 9m,10m and 12m bench model. The 12m bench model has the highest total blended limestone reserve of 221.64M.T which is 8.81and 7.12 M.T. higher than the 9m and 10m bench model, where as the blended ROM grade remains same. The quantity of limestone left in the final pit is 15% and rest 85% of the reserves have been utilized in blending for production in 12m bench model as compared to the 9m and 10m bench model where the final pit quantity is 18% and 17% and Blended pit quantity is 82% and 83% respectively (ref. Fig-5)
Table. 5: Quality and Quantity of Blended and Final pit for 9m, 10m and 12m Bench Model
Optimized Pit Blended Pit Final Pit Total 9m Model Rock (M.T) 219.81 47.38 267.19 Ore (M.T) 212.83 46.90 259.73 CaO (%) 47.00 48.31 47.24 SiO2 (%) 12.43 11.06 12.19 Rock (M.T) 220.62 45.68 266.30 10m Model Ore (M.T) 214.52 44.87 259.39 CaO (%) 47.00 48.69 47.29 SiO2 (%) 12.38 10.98 12.13 Rock (M.T) 228.65 39.01 267.66 12m Model Ore (M.T) 221.64 38.51 260.15 CaO (%) 47.00 48.49 47.22 SiO2 (%) 12.40 11.08 12.21

10m bench model

15% 51 , 38. 7% ,1 .87 44 % 18 .9, 46

9m bench model

12m bench model

% 82 3, 2.8 1 2 % 83 2, 4.5 21 % , 85 .6 4 221

Blended Pit

Final Pit

Fig. 5: Distribution of limestone (ore) in blended pit and final pit in 9m, 10m and 12m bench model

It can be inferred that from 9m to 12m bench model, there is an increase in the reserves of ore in blended pit and decrease in quantity of left out limestone in the final pit with change in bench height while the total reserves of ore remains same. It is also observed that there is a better segregation of grade and reserves in the 12m bench model for both cement grade and low grade limestone than other models which has resulted in optimum utilization of all the grades for blending on the ROM grade constraints imposed. Fig.6 and 7 shows the distribution of cement grade (SiO2% <15%) and low grade limestone having (SiO2% >15% including blendable and low grade limestone) in blended and final pit respectively.
200.00 180.00 160.00
Reserves (M.T)

140.00 120.00 100.00 80.00 60.00 40.00 20.00 0.00 Blended Pit 191.71 192.00 198.26 46.86 44.85 38.51

Final Pit

9m Bench Model

10m Bench Model

12m Bench Model

Fig. 6: Distribution of cement grade limestone in blended and final pit in 9m, 10m and 12m bench model

25.00

20.00
Reserves (M.T)

15.00 23.38 10.00 22.52 21.12

5.00

0.03 Blended Pit 9m Bench Model 10m Bench Model

0.01

0.00

0.00

Final Pit 12m Bench Model

Fig. 7: Distribution of low grade limestone in blended and final pit in 9m, 10m and 12m bench model

The distribution of blendable grade, low grade and cement grade limestone in 9m, 10m and 12m bench model in the blended pit is further evaluated for understanding the segregation of various grades of limestone both in the form of reserves and grade (Table. 6). It is observed that 90.66 M.T of cement grade limestone having CaO%>48 is obtained from 12m bench model which is 3.93 M.T and 10.23 M.T. higher from the 9m and 10m model having the limestone reserves of 86.73 M.T and 80.43 M.T respectively. Similarly 107.60 M.T of cement grade limestone having CaO% >42<48 is obtained from 12m bench model which is 2.60 M.T. higher from the 9m model and 3.97 M.T. less from the 10m model. It suggests that there is dilution in terms of tonnage within the cement grade in 10m model. Similarly low grade limestone having CaO% <40 and >40<42 and SiO2% >15 shows segregation both in the form of reserve and grade in 12m bench model. Low grade limestone of 8.02 M.T is obtained from 12m bench model having an average grade of 32.4% CaO and 28.03% SiO2 which is 1.72 M.T and 1.57 M.T. higher from the 9m and 10m model.
Table. 6: Quality and Quantity of Blendable grade, Low grade and Cement grade Limestone in Blended pit for 9m, 10m and 12m bench model
Blended Pit Limestone Blendable Grade Limestone Low Grade Limestone Limestone Model Grades CaO%>42<48; SiO2% >15 CaO% <40 and >40<42; SiO2%>15 CaO% >42<48 SiO2%<15 CaO%>48 SiO2%<15 T. Cem Gr Lst. Total Ore (Blended Pit) 9m Model Blended Pit (M.T) 14.82 6.30 104.98 86.73 191.71 212.83 CaO (%) 44.93 27.23 46.92 48.89 47.81 47.00 SiO2 (%) 16.58 30.52 12.39 10.47 11.52 12.43 10m Model Blended Pit (M.T) 16.07 6.45 111.57 80.43 192.00 214.52 CaO (%) 44.54 31.97 46.95 48.48 47.59 47.00 SiO2 (%) 16.47 28.87 12.28 10.37 11.48 12.38 12m Model Blended Pit (M.T) 15.35 8.02 107.60 90.66 198.26 221.64 CaO (%) 43.80 32.40 46.95 48.50 47.66 47.00 SiO2 (%) 16.43 28.03 12.23 10.53 11.46 12.40

Cement Grade Limestone

Distribution of different grades of limestone in blended pit in 9m, 10m and 12m bench model is shown in Fig.8. It is observed that, effective dilution gain in terms of grade & tonnage for low and blendable limestone, vis--vis segregation of CaO% >48 grade limestone in terms of tonnage is found in 12m bench height model. The overall factors responsible for better achievable blendability of various grades within the limestone ore body is due to its distribution, dilution & segregation of both low & high grade limestone for 12m bench height model.
10m bench model
15.35, 7%

,4 02 8. %

16.07, 7% 14.82, 7%

9m bench model

,3 45 6. %

,3 30 6.

90.66, 41%

80.43, 37%

86.73, 41%

104.98, 49%

12m bench model

111.57, 53% 107.60, 48%

BLEN. GR.

LOW GR.

CEM. GR.>42<48 CaO

CEM. GR.>48 CaO

Fig. 8: Percentage distribution of different grades of limestone in blended pit in 9m, 10m and 12m bench model

5.3

Production Scheduling

The blended pit limestone of each bench model is scheduled while targeting quantity and quality objectives like CaO% and SiO2% to find 5 yearly schedules for 9m, 10m and 12m bench model. Table.7 shows the 5-yearly excavation at the specified blended ROM quality for 9m, 10m and 12m bench model. It has been observed that 12m bench model sustains for the total life of 99 years which is 5 and 3 years higher in comparison to 9m and 10m bench model having life of 94 and 96 years respectively. The scheduler reports of blended ROM quality for 12m bench models are shown in Fig.6 indicating sustainable life of the deposit.
Table. 7: Scheduler result for 9m, 10m and 12m bench models (at specified ROM quality)
9m ore body model Year 0-5 6-10 11-15 16-20 21-25 26-30 31-35 36-40 Ore 11.29 11.22 11.31 11.30 11.32 11.10 11.26 11.35 CaO 46.24 46.45 45.97 45.84 46.99 46.96 45.19 46.47 SiO2 12.27 12.37 12.38 12.63 11.76 11.90 13.17 12.85 Year 0-5 6-10 11-15 16-20 21-25 26-30 31-35 36-40 10m ore body model Ore 11.38 11.28 11.19 11.29 11.19 11.25 11.18 11.27 CaO 45.73 45.60 46.73 46.11 45.82 46.53 46.22 47.29 SiO2 12.93 12.81 12.05 12.49 12.61 12.49 12.09 12.18 Year 0-5 6-10 11-15 16-20 21-25 26-30 31-35 36-40 12m ore body model Ore 11.37 11.19 11.42 11.04 11.30 11.42 11.06 11.43 CaO 46.55 46.54 46.92 46.03 46.36 45.64 45.99 46.48 SiO2 11.87 12.15 12.00 12.38 12.64 12.47 12.73 12.91

10

41-45 46-50 51-55 56-60 61-65 66-70 71-75 76-80 81-85 86-90 91-94

11.10 11.40 11.23 11.13 11.41 11.25 11.15 11.33 11.25 11.29 10.15

46.97 46.45 47.51 47.38 47.27 47.48 46.87 47.82 48.12 48.31 48.92

12.31 12.50 12.19 12.67 12.65 12.75 12.81 12.83 12.54 12.31 11.23

41-45 46-50 51-55 56-60 61-65 66-70 71-75 76-80 81-85 86-90 91-95 95-96

11.34 11.25 11.25 11.25 11.25 11.35 11.17 11.27 11.22 11.19 11.37 0.59

47.26 47.64 47.54 47.16 47.53 47.29 47.25 47.79 47.60 47.70 48.15 48.65

12.37 12.44 12.50 12.27 12.33 12.33 12.05 12.38 12.50 12.00 12.35 11.92

41-45 46-50 51-55 56-60 61-65 66-70 71-75 76-80 81-85 86-90 91-95 96-99

11.32 11.18 11.29 11.15 11.40 11.13 11.35 11.10 11.40 11.19 11.07 7.85

46.44 46.30 47.96 47.51 47.57 46.86 47.63 47.56 47.97 48.24 47.83 47.92

12.43 12.70 11.87 12.85 12.78 12.59 12.83 12.46 12.38 11.59 11.63 12.89

50.00 45.00 40.00 35.00

CaO% & SiO % 2

30.00 25.00 20.00 15.00 10.00 5.00 0.00 0-5 6-10 11-15 16-20 21-25 26-30 31-35 36-40 41-45 46-50 51-55 56-60 61-65 66-70 71-75 76-80 81-85 86-90 91-95 96-99 CaO% Year SiO2%

6.0 Conclusion

Fig. 6: Scheduler report (5-yearly) for 12m bench model

Strategic planning for mine optimization is carried out basically to enhance the quarry life with minimum generation of waste keeping in view the two main objectives (i) optimal grade of limestone and its production, a mine can produce up to the life of the deposit and (ii) optimization based on grade constraints keeping the consideration of raw mix based on cheaper fuel and additives avoiding the imported fuel and costlier additives. To study the effect of dilution / segregation of various grades of limestone due to compositing at different bench heights, bench models at variable bench height systems of 9m, 10m and 12m are prepared. The effect of various bench height models is being compared for determination of optimum ultimate pit limit of a mine which depends upon blended (optimized) and final (un optimized) pit and the resultant optimum production schedule over the total life of the mine. Pit optimization for maximization of resources is carried out with the help of Multimine scheduler software which uses LG (Lerch-Grossman) method to determine an optimal ultimate pit for 9m, 10m and 12m bench model. From the result of pit optimization of 9m, 10m and 12m bench model it is observed that the 12m bench model generates the ultimate pit shell with lesser number of working pits which are wider in size and hence will be more economical for mining operations. It is also observed that due to better dilution and segregation of both low and high grade limestone in 12m bench model in terms of grade and tonnage leads to more proper blending of different grades of

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limestone which results in the increase of the total limestone reserves in the blended pit with desired blended ROM limestone with optimum production schedule and enhanced quarry life. 7.0 Acknowledgement The authors have freely drawn upon completed R&D reports and some unpublished work of NCB. This paper is being published with permission of the Director General, NCB. 8.0 References 1. 2. 3. A J Simclair, G H Blackwell Applied Mineral Inventory Estimation Combridge University Press, 2002, PP-305-307. Cement and Concrete Science and Technology Vol-1, Part-II. Dagdelen, K., 2001, Open Pit Optimization Strategies for Improving Economics of Mining Projects Through Mine Planning, 17 International Mining Congress and Exhibition of Turkey. H Kose et.al., Economic Evaluation of Optimum Bench Height in Quarries The Journal of the South African Institute of Mining and Mettallurgy, Feb-2005, PP-127-135. I M Glacken et.al, Mining Bench Height Evaluation for Wallabay Resources A Conditional Simulation Case Study, 4th International Mining Geology Conference Coolum, dated 14-17 May 2000, PP-195. Integration Road to increased production by Stephen B Chessman, P Geo. Geocom Software International Inc. Pelly Peter, F.D., 1991, Guidelines to the evaluation of selectively mined, open pit gold deposits during the exploration stage of mine creation, MSc. Dissertation, Rhodes University, Grahamstown, Eastern Cape. South Africa. Raj K Singhal et.al (1988) Computer Application in Mineral Industry. A.A Balkema, Netherland. R Dey, A K Dubey, N K Sharma, D K Panda, M Imran, Multimine Scheduling for Optimization of Blended Limestone from Four Mine Blocks for Cement Manufacture 12th NCB International Seminar on Cement and Building Materials, 15-18 Nov. 2011, New Delhi. R M Jara, Block Size Selection and its Impact on Open Pit Design and Mine Planning The Journal of The South African Institute of Mining and Metallurgy, Vol. 106, March 2006, PP-205-211. R Mazumder, A K Dubey, N K Sharma, D K Panda, M Imran, Coordination of the Operation of Four Quarries to Optimize Limestone Blending Cement International, 1/2013, Vol II PP 38-45.

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