SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ
BLOCK CAVE PRODUCTION SCHEDULING USING PCBC
T. Diering, Gemcom Software International Inc., Vancouver, BC, Canada
O. Richter, Gemcom Australia, Perth, WA, Australia
D. Villa, Gemcom Software International Inc., Vancouver, BC, Canada
ABSTRACT
Gemcom PCBCTM is a software package which has been
developed over the last 22 years for the planning and scheduling of
block cave mines. This paper presents an update of the various
research and development activities done to PCBC recently. It also
provides an overview of the current capabilities of the software
including tools for both feasibility type studies as well as tools for
operating mines.
PCBC is used extensively by prospective and operating block
cave mines and some of the recent applications are described.
INTRODUCTION
History
PCBC was first developed in 1988 for the Premier Diamond Mine
in South Africa(Diering, 2000). In 1992, the first production scheduler
was added to the system and in 1994 a significant upgrade was done
for Northparkes Mine in preparation for their Lift 1. PCBC was
upgraded to Microsoft Windows operating system in 1996. In 2002,
the Cave Management System (CMS) was developed for Freeport
DOZ mine and this was upgraded to provide SQL Server database
support in 2003 for Finsch Diamond mine(Diering, 2004). A new
algorithm called Template Mixing (Diering, 2007) was added to provide
better and alternate flow modeling options to users.
More recently, various enhancements to the production scheduler
and other areas of the program have been completed some of which
are described here.
It is worth noting that the block cave market (in terms of software)
is very limited. As such, it is difficult to fund high quality research and
program development. We at Gemcom Software International Inc.
have been very fortunate to have companies sponsor custom
development activities within PCBC over the years. These companies
are listed in the acknowledgements section of this paper.
Typical project workflow
A significant number of block cave projects have been studied
using PCBC over its 20 year history. During that time, a well used
work flow has evolved which is usually used as a guideline for new
projects.
Conceptually, the steps are as follows:
Figure out what is in the ground (geological model)
Work out where you want to mine (X,Y,Z limits)
Work out the tons and grade that you will get from those limits
Work out how long it will take (time)
Optimize and iterate to add further value to the project.
Repeat the whole process every time a new geological model is
produced as the project evolves.
The overall steps in the process are described below:
Footprint Finder. This is an application which works off the
geological block model and whose primary objective is to help
assess the best elevation (or elevations) for the block caving
footprint (Z extent of the mine)
1 Copyright 2010 by SME
Preprint 10-097
Generate draw points. Setting up draw points requires
assessment of draw point spacing, tunnel orientation etc. (X,Y
extents)
Construct slice file. This is the process of conversion of a
geological model to be aligned with the draw points such that
each draw point has an in-situ (un-mixed) resource above it.
Compute best Height of Draw (HOD). Each draw column is
evaluated to assess the best or highest dollar value which can be
achieved for a given set of mining costs and product revenue and
recovery factors.
Production scheduling. This is the heart of the PCBC system. It
is important to distinguish between production (tons and grade
produced) and development scheduling (tunneling and
development). PCBC does production scheduling. This provides
the tons and grade forecasts for the project which has been
described as the mine planners promise to the shareholders as
to what the mine can produce.
Advanced schedules. No schedule is ever complete or final.
During the project evaluation stage, new pricing or geometrical
options will be considered and new geological models generated
as the exploration drilling progresses. During production, new
schedules are generated whenever the actual production varies
from the plan (which is always). So the need for a scheduler
which can run in typically less than 20 to 30 minutes per run is
important.
Operating mine set up. Once a mine is going into production,
then it is possible to set up a database to store production tons
and draw point assay and other observational data. The
importance of accurately recording and managing the tonnages
extracted from each draw point has long been recognized.
CMS can be used to help manage the daily (or shift based) draw
order. This is the daily tonnage target set for each draw point.
This is essential if a managed block cave is to be maintained.
Geological/geotechnical monitoring. Tools have been developed
within PCBC to help store, display and analyze observed data
Least Squares (LSQ) and grade reconciliation can be used to
base schedules on observed assay data instead of block model
data for more accurate schedules
During the above process, it is essential to have appropriate tools
to interrogate and query the results generated. Over the years, a
substantial toolbox has evolved based on project and user
requirements.
In this paper
This paper describes the various components in the PCBC
product. It is not intended to provide any explanation as to how these
components work or are used.
COMPONENTS OF PCBC
The various components of PCBC have evolved to support the
above project workflow. PCBC runs inside the Gemcom GEMSTM mine
planning package developed by Gemcom Software International Inc.
(Figure 1) The ability of PCBC to work inside of this framework has
proven invaluable over the years and has allowed our development
efforts to focus on the block cave part of the problem minimizing the
need to develop and maintain the underlying graphical and database
subsystems.
 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

Figure 1. Typical view of PCBC running inside the GEMS general

mine planning package.
Components of PCBC are described below including initial
assessment of footprint location, model set up and mineable reserve
assessment, then scheduling and production management.
Foundation
This is the framework within which PCBC operates. The various
components are summarized as follows:
Figure 2. Footprint Finder example on one level.
Graphical interface
Blocks
Tons Dollar value
Lines
Points 1,000 9,000
Triangulations 900 8,000
800 7,000
SQL database / workspaces

Dollar Value (M$)

700 6,000
Tonnage (Mt)

Profile editors / parameter management 600

5,000
500
Footprint Finder 4,000
400
Input for Footprint Finder utility comes from a geological block 300 3,000
model together with mining costs, revenue factors, etc. The program 200 2,000
will look at each level in the block model and then construct vertical 100 1,000
columns accumulating the dollar value. Vertical mixing is applied to - -
each column using an algorithm based on Laubschers mixing method
2560
2620
2680
2740
2800
2860
2920
2980
3040
3100
3160
3220
3280
3340
3400
3460
3520
3580
3640
(Laubscher, 1994).
Elevation
This is very useful to obtain an initial idea of where to locate a
footprint and what the initial footprint shape might be. Figure 2 shows
Figure 3. Footprint Finder : Tons and dollar value vs footprint
accumulated columns plotted according to value.
elevation.
Repetition of this process on each level allows the tons and value
generated to be plotted as shown in Figure 3.
An example from Freeports DOZ mine is shown in Figure 4.
The higher grade zones are shown in warmer colors. This type of
value plot assists considerably with the process of defining a
reasonable economically and geotechnically feasible outline.
PCBC
Overall steps of a typical project (from the program, not project
perspective) are as follows:
Set up the initial working environment inside a GEMS project.
Slice file construction (Figure 5). This is an integral part of the
process. Utilizing user-defined draw cone shapes, a column of
rock above each draw point is simulated and stored in what is
termed a slice file. The term slice as the total column is broken
into slices which match the vertical spacing of the geological block
model.
Figure 4. Footprint Finder example (DOZ mine).
Draw point locations are used to construct a vertical column which
is then intersected with the block model. The various overlaps of the Figure 6 shows a section of a block model and the resulting
draw cones are resolved so as to not double count material and this is NoMix slice file with one column per draw point.
accumulated into the slice file for each draw point. This is referred to
as a NoMix slice file, since no material mixing has yet been applied.
2 Copyright 2010 by SME

Figure 5. Schematic of block model to slice file conversion.
Figure 6. Block model to slice file conversion.
A variety of material mixing algorithms may then be applied to the
slice file to simulate the actual material mixing which takes place
as material is extracted from the draw points.
Best HOD. The Best HOD utility will accumulate tons, grade and
dollar value in each draw column (after application of vertical
mixing) to provide an estimate of mineable reserves for different
footprint shapes. As this process uses actual draw point locations
and assumed draw column shapes, it is generally considered
more geometrically accurate than the Footprint Finder.
Figure 7 shows that the results from Footprint Finder and Best
HOD tools are typically quite similar as one would hope.
Once the basic preparation work has been done, production
schedules can be generated.
A typical schedule requires input of the following key components
(Figure 8):
Sequence to develop the draw points (and undercut)
Constraints on the maximum draw rate which can be applied to
draw points
Tonnages required in each scheduling period
Information to control the cave shape. It is usual to look at
different strategies and compare
Numerous other inputs, constraints and reporting control options
3 Copyright 2010 by SME
SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ
Figure 7. Best HOD based footprint (bottom) vs Footprint finder result
(top) (Cadia East).
Figure 8. Production scheduling components in PCBC.
A basic schedule will open draw points according to the sequence
and deplete tons from each according the Production Rate Curve
(PRC), apply material mixing if required and report tons and grade
mined in a variety of formats.
An advanced schedule could look at changing parameters for
individual or groups of draw points, adjusting the schedule to past tons
mined, having the HOD profile follow a given cave shape and adding
information to report undercut tons separately from production tons.
Experience has shown that it is very useful to have a clean and
efficient interface between PCBC and Microsoft Excel. This allows
reports to be generated in a format which can quickly be further
analyzed by engineers.
In addition, when dozens or hundreds of schedules are being run,
it is useful to have what is called a playback tool. This allows various
aspects of the schedule to be studied visually to look for trends (or
data input errors!)
The production scheduler can just as easily be used for forward
looking schedules or for analysis of past performance. This is very
useful for grade calibration and reconciliation purposes.
Cave Management System
CMS was originally developed for Freeport DOZ mine and then
further refined for use at Finsch mine. Currently there are seven mines

using or planning to use CMS. CMS aims to generate a draw order for
each draw point every day or shift. It uses the recent historical (actual)
tonnages to adjust and manage the draw and provides the supporting
database, reporting and user interface to facilitate this process. At De
Beers Finsch mine, CMS has been closely integrated with the Sandvik
Automine system.
Figure 9 shows how CMS fits in between the historical tons mined
and the requirement to adjust the plan of the next few months (using
PCBC schedules) in a process called Catch-up to fit in with the long
term plan. (Diering, 2004)
Figure 9. How CMS fits in between historical tons and future plans.
Each draw point can be categorized in a variety of ways (Figure
10), including over-draw, under-draw, normal, draw-bell development,
wet muck (which is a safely concern) or as requiring special treatment.
The tonnage for each category is set accordingly.
Figure 10. Categorization of draw points for priority assignment.
Figure 11 shows an example of daily production data displayed
using Excel. It is important to have a clean interface between the CMS
database and Excel for ease of analysis by the draw control personnel.
Figure 11. Excel map format for draw point result display.
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SME Annual Meeting
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LSQ
The LSQ tool is intended for operating mines. Once a mine has
been in operation for a few years, it will likely have a draw point
sampling program. The draw point assay values can be stored and
sorted per draw point and then composited into 10m or 15m intervals
to provide some averaging of the highly variable assays.
Subject to a variety of constraints, a least squares trend line is put
through the composites and then this can be extrapolated for a short
distance up the draw column into what is essentially the un-mined part
of the column (Figure ).
This becomes particularly useful when the draw point assays
suggest that the draw point should remain open (usually after 100%
draw) when the slice file values suggest that the draw point should be
closed. For draw points where the sample trend differs from the slice
file, then the slice file values are replaced with the sampled values for
selected draw points. This is somewhat similar to the open pit practice
of taking blast-hole samples to improve the local grade of a bench
about to be blasted and mined.
Figure 12 shows a single draw column with sampled values at
various heights (HOD) above the draw point. The graph shows these
together with the trend line and some extrapolated points. Maximum
and minimum grade values are set so that steep up or downward
trends do not generate unrealistic grade values.
Figure 12. Sample compositing and trend line analysis in LSQ.
The LSQ tool can either be run as a stand-alone tool or right
within the PCBC production scheduler.
Operations tools and reconciliation
Once a mine is in operation, there is a variety of useful ways in
which draw point sampling data (grade, geotechnical and geological)
can be displayed and analyzed. A key reason for doing this type of
work is so that we can better understand if or where there is irregular
behavior with the cave itself. Some of the analysis types are listed
below:
Use of draw point assays for grade reconciliation and for
calibration of the model.
Use of draw point assays for improved short term forecasting
using the LSQ tool already mentioned.
Use of geological samples to supplement the reconciliation
process or to better understand horizontal and vertical migration
of material within the cave (Figure 13).
Use of geotechnical (fragmentation) data to better understand the
relationship between draw rate at draw points and rock type or
mining area.
Use of convergence data in production tunnels to help prevent
excessive closure (or collapse) of these tunnels. Freeport has
shown quite convincingly at their DOZ mine that a diligent
program of monitoring convergence in these tunnels is beneficial.
In areas where high convergence rates are observed, adjacent
draw points have an increased tonnage target which tends to
relieve the high stresses.
Seismic data and/or extensometers can be used to help predict
the location of the cave back which can in turn be used to set up
surfaces for simulation of the rilling process which migrates
material non-vertically.
 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

The residual slice file model can be used to re-estimate a block specified which allows this material to be mixed with material higher up
model which can be used either in a multi-lift mining situation or each draw column.
as part of a new block model for a super-pit which some mines
are considering. Table 1. Material mixing options in PCBC.
Method Ease of use Linear? Comment
No mixing base case (In-
No mixing Easy Yes
situ)
Pre-Vertical PCBC Default (includes
Easy Yes
mixing pre-erosion)
Laubscher
Easy Yes Uses Laubscher tables
mixing
Older method, includes
Sequential mixing Harder No
toppling
Most flexible option
Template Mixing Harder No
available
Not yet generally
REBOP interface Harder No
available

Template Mixing was introduced in to PCBC in 2006. (Diering,

2007). It allows a variety of mixing mechanisms to be simulated
including vertical mixing, rilling, toppling and fines migration. (Figure
Figure 13. Example of graphical display of geological data. 15)

Figure 14 shows an example in which the residual slice file (after

simulation of mining the full block cave tons) is used to re-estimate a
geological block model. This block model can then be used for
planning of another future mining block.

Figure 14. Example of residual slice file to block model conversion.

Figure 15. Movement mechanisms in a block cave.
RECENT DEVELOPMENTS
It differs from other material flow algorithms such as discrete
PCBC is over 20 years old and hence should be considered as a
particle and cellular automaton methods. A major advantage of
mature product. As such the basic planning and scheduling work flow
Template Mixing is its speed. Figure 16 shows a few steps in a
is well covered. On the other hand, being mature and with a good
depletion simulation. Blue represents dilution, yellow is ore and the
foundation, PCBC has provided a useful foundation for a number of
intermediate colors represent progressive mixing as the ore is
recent developments which are summarized in this section.
extracted.
Upgrades to material flow tools
Playback utility
Display tools
Each of these is considered in more detail
Material flow upgrades
Material flow is an integral part of the block cave mining (and
material depletion) process. The entry of dilution is a significant factor
in the planning process and modeling of this has proven to be difficult.
As such, a variety of different mixing tools have been developed within
PCBC and users are then given the choice as to which approach they
would like to adopt. This is summarized in Table 1.
The linear methods can be applied with the Best HOD utility to
find mineable reserves before the schedule is run. For the non-linear
methods, the mineable reserve will be a function of the mining
sequence and draw strategy. Therefore, mixing has to be built right
into the production scheduler. This is one of the key differentiators
between PCBC and other commercial scheduling tools. Figure 16. Template Mixing 2D example.
The pre-mix option in PCBC was recently upgraded to allow for Figure 17 shows an example for our sand-box project using
the inclusion of a draw cone erosion mechanism. This is useful as toppling, rilling and normal mixing.
there is increasing evidence that draw cone radii may not be as large
as is often hoped and also that the draw cone radius changes with In 2008, a joint initiative was done with Rio Tinto, Itasca and
time. A fraction of each slice is frozen and then an erosion rate is Gemcom to provide the potential to combine the PCBC and REBOP
programs. This was done using a hand-shake mechanism so as to
5 Copyright 2010 by SME
 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

minimize the changes required to each program and to keep them as

independent as possible to facilitate future development.

Toppling

Rilling

Draw
points

Figure 17. Sandbox example with toppling, rilling and vertical mixing.

Figure 18 shows two examples of REBOP results plotted within

the PCBC program. The results from REBOP are used directly in the Figure 19. Block model used for PCBC/REBOP calibration
production scheduler and also for modification of the slice file.

Cu% Rebop vs PCBC (N2E5)

2.00
1.80
1.60
1.40
1.20
Cu %

1.00
Cu%_M3P3
0.80
Figure 18. REBOP results displayed in PCBC (Markers left and cones
to right). 0.60 Cu% Tm4
0.40
As a separate, but related project, Gemcom worked with Rio Tinto 0.20
to calibrate PCBC and REBOP against one another. Figure 19 shows
0.00
the geometry of the calibration problem. 50 fictitious draw points were
Jan-08

Jan-09

Jan-10

Jan-11

Jan-12

Jan-13

Jan-14
Jul-08

Jul-09

Jul-10

Jul-11

Jul-12

Jul-13

Jul-14

located in this block model for testing purposes.

Results from the calibration exercise were really encouraging,
suggesting ways to improve both the PCBC and REBOP modeling Figure 20. Example calibration curve for PCBC (orange) vs REBOP
processes. A sample calibration curve of Cu grade is shown in Figure (green).
20.

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 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

The original version of PCBC used what we term Laubscher during a production schedule. Figure 26 shows a plot of HOD for the
mixing (Laubscher, 1994). This was replaced by pre-vertical and same mining step.
sequential mixing options in 1994 in PCBC. However, there are still
projects (or people) who like to be able to compare back against the
Laubscher mixing. So it was re-introduced into PCBC in 2008. It is
also useful for comparison against Footprint Finder results which use
the same mixing.
Figure 21 shows an example comparing dilution entry from a
single draw column. PCBC pre-vertical mixing has more of an S-curve
dilution entry where Laubscher mixing has a straight line dilution entry.

Figure 22. Excel map transfer utility example.

Figure 21. Dilution entry. Pre-vertical mixing (top) vs Laubscher

mixing (bottom).
Playback Utility
This tool is used to playback or study results from a production
schedule. Display options include Triangular Irregular Networks
(TINs), contours, pie charting, and 3D columns. Playback examples
are shown in the later sections on Freeport DOZ and Palabora.
Display tools
Over the years, a variety of different graphical display tools have
been developed. The more recent ones are the Excel interface which
allows any draw point related data to be exported directly into Excel in Figure 23. Example of Pie chart display.
the correct cell row and column positions for direct display in Excel as Freeport Grasberg
shown in Figure 22. The Grasberg block cave is scheduled to start production as the
The Excel map format is useful for a single attribute per draw Grasberg open pit slows down at the end of its life. (Figure 27)
point such as HOD. However, if one has multiple attributes (which (Brannon, Casten, & Johnson, 2004) This will be a very large block
sum to 100%), a very useful display option is the pie chart. The cave with production up to 160,000t/d. Numerous scheduling options
program will plot a pie chart at each draw point location using data have been evaluated using PCBC and particular emphasis has been
directly from the underlying database from what is called multi-bucket placed on effective modeling of large open pit failures which will
format (Figure 23). generate additional dilution material.

In addition to the static displays available, a more dynamic display
of selected information for individual draw points by right click or
mouse movement over draw points can be very useful (Figure 24).
Other options are size based plots (Figure 13), 3D draw columns
(Figure 14) and plotting of draw points in appropriate shapes.
Figure 27 shows the proximity of the block cave draw columns to
the large open pit.
Figure 28 gives an idea of the variability of the orebody edges and
also alludes to the difficulties in sequencing and scheduling such a
large orebody (grid size above is 200m!).

PROJECT EXAMPLES Northparkes

PCBC was first used for Northparkes E26 Lift 1 around 1994 and
Freeport DOZ then for Lift 2 planning and currently for Lift 2 North (Figure 29) (Ross,
PT Freeport Indonesia has been using PCBC since around 2000. 2008) and E 48. Each lift has provided surprises and challenges from
They are currently mining close to 80,000 t/d, making it a large block a modeling perspective.
cave mine (T. Casten, 2008). PCBC and CMS are used extensively
for planning and scheduling at the DOZ mine as well as for daily draw
control. Figure 25 shows a plot of forecast rock types at one step
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 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

combined scheduling of multiple mining blocks (Figure 31).

Figure 27. Grasberg block cave in close proximity to the large open
pit

Figure 24. CMS control panel with right click and display
information.

Figure 1. Column values from Footprint Finder used for footprint

assessment.
Figure 25. Forecast rock types at Freeport DOZ mine generated in
Playback tool.

Figure 26. Height of draw profile at Freeport DOZ mine from Playback
tool.
Salvador
The Salvador mine in Chile has used PCBC both for the detailed
scheduling of individual mining panels (Figure 30) as well as for Figure 29. Northparkes E26 mining.
8 Copyright 2010 by SME

Figure 30. Slice file display and layout at Salvador Mine.
Figure 31. Scheduling of multiple mining panels at Salvador Mine.
As this is an older mine, current work is looking to re-estimate the
residual grades in older mined out areas for use with future planning.
Andina
PCBC has been used extensively at Codelcos Andina mine for a
number of years. Challenges in modeling this deposit include the
multi-lift aspect together with reliable estimation of residual grades of
mined out blocks (Figure 32), the effective scheduling of grizzly and
LHD sectors (Figure 33), the sheer size of the project and caving
issues related to primary and secondary rock types.
Figure 32. View of three panels (lifts) at Andina mine.
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SME Annual Meeting
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Figure 33. Plan of Andina third panel showing grizzly and LHD
sectors and existing development.
Palabora
The Rio Tinto Palabora mine in South Africa started block cave
production in 2000. (Moss, Russell, & Jones, 2004)
As the scheduler can work with historical tonnages as easily as
forward looking tonnages, the playback tool can thus also be used for
historical analysis or reconciliation purposes.
Palabora went through a period during which it was difficult to
achieve good draw control. However, more recently, the draw control
has been much improved. (Pretorius & Ngidi, 2008) This is shown
clearly in Figure 34.
Figure 34. Monthly tonnage display (poor draw control (top) and good
draw control (bottom).
Figure 35, also from Palabora, shows a plot of seismic events for
one month together with draw points and the cave Height of Draw
profile (which is different from cave back profile).
Ridgeway
The Ridgeway Deeps Mine of Newcrest used PCBC with the
Template Mixing option to study rilling and how this impacted the
mineable reserve and overall production schedule (Burgio & Diering,
2008) (Figure 36)

Figure 35. Seismic data display example from Palabora.
Figure 36. Section of Ridgeway deeps block cave model showing
irregular cave propagation on right side.
Different scenarios were modeled to see the effect of limited cave
propagation on the East side of the cave.
Cadia East
The Cadia East project of Newcrest provided interesting modeling
challenges as it is a large multi-lift project. (Figure 37) Extensive use
has been made of the Footprint Finder tool to assist with determination
of elevations together with more accurate schedules from PCBC.
Figure 37. Multi-lift example from Cadia East, Newcrest.
Finsch
The Finsch Block 4 block cave is an example of mining beneath
an old open pit (Richter & Diering, 2004) (Figure 38). As mining
10
SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ
progresses, additional pit wall material is failing into the developing
cave. The remaining ore and ore/waste combination has to be
continually updated as additional material fails into the cave.
Figure 38. Schematic of open pit, cave zone and Block 4 draw points
at De Beers Finsch mine.
Figure 39 shows a section with some of the residual draw
columns. These are trimmed against the known topography and the
new failure material (red) then starts to mix with the existing material
(blue). The mixing zone is shown by the intermediate colors.
Figure 39. Addition of new failure material and mixing of this material
with existing cave rock mass.
Figure 40 is similar to Figure except that the sequential mixing in
PCBC is turned off. This example shows the importance of being able
to model this process in a non-linear manner. The final mineable
reserve is required to be adjusted monthly or every time the failure
surface is modified. Additional tools in PCBC allow for the addition of
anticipated material for the remainder of the life of the Block 4 block
cave as well.
CALIBRATION EXAMPLES
Freeport DOZ
A detailed description of the calibration curves in figures Figure 41
and Figure 42 is beyond the scope of this paper. (Villa, Prasetyo, &
Diering, 2008) Figure 41 is for grade and it shows the extent to which
the PCBC model can be changed to improve the fit actual against
actual observations.
Figure 42 is for the Marble rock type. It shows how the original
PCBC marble curve (bottom) can be changed to more closely
approximate the geological draw point observations (higher curves).
Geological observations are made routinely at draw points of up
to 8 different rock types. These were also fed into the geological block
model so that comparisons could be made of the observed vs model
rock types. Figure 43 shows the modeled rock types vs time and
Copyright 2010 by SME
 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

Figure 44 the observed rock types vs time. A detailed study of the graphs show how mixing parameters were adjusted to improve both
differences between the two can be very informative and lead to ways the model results and the confidence in other forecast results.
to improve the model which may not be apparent from the grade model
/ assays. The geological modeling thus provides another dimension
into the calibration process.

Figure 43. Geological composition from block model and PCBC

production schedule.
Figure 40. Addition of new failure material without additional mixing.

Figure 41. Freeport DOZ. Calibration of grade.

Figure 44. Geological composition based on draw point observations.

Figure 42. Freeport DOZ. Calibration of Marble rock type.

Palabora
Work has been done at Palabora to improve the short term grade
estimates using the LSQ tool described above. Figure 45 shows the
improvement in the short term comparing the PCBC LSQ forecast vs
Samples. Figure 45. Measured vs PCBC standard and LSQ adjusted grades.
Figure 46 shows a similar set of graphs, but comparing hang up Example of block model adjustment
frequency. In this case, there was no initial model forecast for hang- In this example (Figure 49, Figure 35), various attempts were
ups, but based on the LSQ approach, a reasonable forecast for short made to calibrate the PCBC results with the observed mill feed grades.
term hang up frequency was achieved. However, the PCBC grades were too high irrespective of the mixing
parameters used. This is an example in which the underlying block
Salvador model is at fault. Re-estimation of the block model with different
Various calibration runs were done at Salvador mine. Two interpolation parameters has largely resolved this discrepancy.
examples are shown in Figure 47 and Figure 48. A detailed
explanation of the curves is beyond the scope of this paper, but the

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 SME Annual Meeting
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Figure 46. Measured vs LSQ modeled Hang-ups.

Figure 49. Calibration example in which the block model required re-
estimation.

Figure 47. Various PCBC runs vs assayed results for IW sector,

Salvador mine for 8 years.

Figure 50. Grade curves measured vs PCBC before adjustment for

mined out area.

Figure 48. Various PCBC runs vs assayed results for ICE sector,
Salvador mine for 17 months.

Example involving old mining areas

This example considered two separate runs. In the first (Figure
50), the block model was not adjusted correctly for historic mining.
Once this had been recognized and appropriate changes made to the
area in which mining had taken place, a much better fit between PCBC
model grades and observed mill grades was obtained. (Figure 51)
CONCLUDING REMARKS
PCBC has been applied to a variety of different block cave Figure 51. Grade curves measured vs PCBC after adjustment for
projects and mines over the last 20 years. Every project has its own mined out area.
unique challenges some of which have been described in this paper. A key component of the modeling and program development
As the program has evolved to meet these new problems, its capability process has been the ongoing calibration of PCBC against
has been enhanced. observations / sampling. This process has clearly indicated that it is
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 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

not always the material mixing which required the most adjustment.
Careful attention is also required in areas of past mining, or for open pit
failure material or even to the geological block model itself.
The calibration examples also clearly show the benefits to be
gained from doing a calibration exercise using both grades and rock
types. In each case, a clearer understanding caving mechanisms is
gained from the work. This type of calibration also strongly justifies the
effort of taking draw point samples for grade and rock types.
The development process for PCBC has been significantly
enhanced by collaborative projects with key clients and this assistance
is gratefully acknowledged.
ACKNOWLEDGEMENTS
The authors would like to thank the following mining companies
for permissions to publish information and figures pertaining to their
projects in this paper: Freeport-McMoRan Copper & Gold Inc., Rio
Tinto, Newcrest Mining Limited, De Beers Consolidated Mines
Finsch mine, Codelco Divisin Salvador, Codelco Divisin Andina and
Palabora Mining Company.
The authors also gratefully acknowledge assistance with the
development of the software from Freeport-McMoRan Copper & Gold
Inc., PT Freeport Indonesia, Rio Tinto, De Beers Consolidated Mines
Finsch mine, Codelco Divisin Andina and Palabora Mining Company.
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