Professional Documents
Culture Documents
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Objectives of today
Understand reconciliation key issues and
terminology
Consider the components of a reconciliation
system
Activity: Brainstorm the features of an ideal
system
Reconciliation systems analysis
Activity: Case study systems analysis and
design
Activity: Charting your system
Review of best practice in reconciliation
Desired outcomes
Understand the elements of a reconciliation system
Take raw production data and generate meaningful
reconciliation measures
Differentiate an ideal system from what is practically
achievable
Understand the shortcomings of the various data
sources and measurements
Use a set of tools to analyse data flow and design a
system
Analyse the results and know what corrective action
to take
Produce a process map of current data flow
Understand best practice in reconciliation
Reconciliation
- Areas for consideration
Stakeholders
Geology Superintendent performance of resource
model, KPI
Senior Mine Geologist performance of grade
control model
model, KPI of self and staff
Senior Mine Planning Engineer success of mine
plan, KPI for self and staff
Mining Manager performance of mining operation,
possible KPI for contract
Mill Superintendent performance of plant,
optimisation of feed, KPI for self
Resident Manager performance against target and
budget, KPI
Head office Commercial Manager performance
against budget responsible to directors and
shareholders
Managing Director are we meeting production and
cashflow targets? responsible to shareholders
Dispatch systems
Truck counts
Load cells
Databases
Intermediate stockpiles/ore
passes
Skip weighing
Moisture!!
Variable density of material
Frequency of survey
Ore ramps in pit
As planned versus asmined
At the mine
At the mill (mill pad)
After the crusher
Etc.
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Basics of
Reconciliation
Reconciliation defined
C
Causes
off poor reconciliation
ili ti
Capturing the physical data - tonnes and grade
Terms and definitions
Coping with multiple ore sources
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What is reconciliation?
Dictionary term: The act of making
compatible or consistent
In a mining sense - the act of comparing
various measures of production to make them
consistent
Comparing a prediction (eg. a grade control
estimate) with a measurement (ie. the millf t i d tonnes
factorised
t
and
d grade)
d )
The mill is the final arbiter! (you cant argue
with gold bars)
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Mill
Performance
MINE
CLAIMED
mine 1
ORE
RESERVES
MINE
BREAK
U/G
STOCKPILE
MINE
SURFACE
STOCKPILE
MINE
CLAIMED
mine 2
PRODUCT
MILL
STOCKPILE
MILL
HEAD
TAILS
MINE
CLAIMED
mine 3
Mine
Performance
CRITICAL AREAS
Why reconcile?
A measure of performance - allows assessment
of the grade/tonnage performance of various
mines
Especially important when comparing disparate
production sources
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Significant
S
g ca t nugget
ugget e
effect
ect
Sampling/subsampling, eg. blastholes vs RC
Analytical errors
Poor angle of intersection of drilling
Methodology issues, eg. polygonal, averaging vs kriging
Incorrect ore boundary (ie. cut-off grade too high)
Poor grade estimation practice
Block layout inaccuracies
Database errors or inadequate database
Human errors pressure of production
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Metal
eta hang-ups
a g ups within
t
p
plant
a t
Analytical inaccuracy
Overcompensation by process control system
Instability in mill processes
Poor knowledge of process cycles
Mill not optimised for blend of ore supplied
Infrequent/non-calibration of flowmeters and
weightometers
i ht
t
Poor subsampling at laboratory
Reconciliation carried out over too short a timeframe
Poor/insufficient sampling of residue or tails
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Production
Can be easily measured, eg. Room and Pillar mining
May be impossible to measure
measure, eg
eg. Block Caving
CMS pick-up is the ideal situation, but may rely on fired volumes
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Underground
In the pit
On the surface
At the mill
After crushing
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Reconciliation definitions
Mine reconciliation:
Milled tonnes x Mill Delivered grade
Delivered tonnes x claimed grade
This is a METAL reconciliation
Also known as the MINE CALL FACTOR
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Two solutions:
1. Batch or campaign treatment of different
ore sources
Cons:
Plant needs a blend of material for optimum
performance
It may take time to purge the circuit
Any campaign must be limited
2. Separate dedicated crushing and
sampling plant
Cons:
Expensive!
Essence of reconciliation
Ore Reserve
Performance
Mill
Performance
MINE
CLAIMED
mine 1
ORE
RESERVES
MINE
BREAK
U/G
STOCKPILE
MINE
SURFACE
STOCKPILE
MINE
CLAIMED
mine 2
PRODUCT
MILL
STOCKPILE
MILL
HEAD
TAILS
MINE
CLAIMED
mine 3
Mine
Performance
CRITICAL AREAS
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Reconciliation
what can go wrong?
Case study
Open pit and underground gold mine
Narrow
a o mineralisation
e a sat o
High grade
Lithological control on mineralisation
Open pit and underground mining commenced prior
to start-up of treatment plant
Small open cut, larger underground mine
Development of levels followed by longhole open
stoping
Claimed grade by face sampling of development
Snowden called in to review mine geology and
reconciliation practices
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After review
Tonnage milled (weightometer) was 9% higher than
depleted reserve tonnage
Reconciled metal (gold bars plus tailings) was 2.1%
greater than depleted reserve (-5% grade)
Face sampling in upper levels showed a slight
positive grade bias compared to mill reconciled
grades (grade control claimed overstating grades)
This overstatement increased substantially with depth
with move from supergene to primary mineralisation
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Reconciliation findings
Before review:
Perception of ore loss occurring
After review:
Mine is either generating additional material at
lower grade (mining dilution or incorrect
selectivity) or resource model is wrong
Observations:
Development is 5% wider and higher than reserve
on average
Grade control is overstating grades, potentially
leading to mining more tonnes which are really
lower grade
Lessons
Distinguish measurements from calculations in
system
Keep the system as simple as possible
Review face sampling direction versus mineralisation
orientation
Always need to question reconciliation inputs:
Resource model
Reserve conversion factors
Grade control sampling issues
Even mill figures (how are they derived?)
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Objectives
Learn techniques for mapping your current system
Apply
A l these
th
to
t the
th production
d ti off a process map for
f
a gold mine
Input the reconciliation data and generate key
reconciliation results
Analyse the results obtained
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Designing a system
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Why? Why?
There is more than one reason
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Process Map
Start end with
circles (or
ellipses)
Processes in
boxes
Decisions in
diamonds
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Suggested approach
1.
2.
3.
4.
5.
6.
7.
8.
9.
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Best practice
reconciliation
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Equivalence
Reconciliation
System
Plant control
System
Data structure
A spreadsheet is not a database
Spreadsheets
Spreadsheets > 1Mb in size have > 80% chance
of including serious errors (Panko, 2000)
Underlying engine is a database, which should be
industrial-strength
SQL server, Oracle, DB2, etc.
Redundancy, backup, checkpoints, rollbacks
Links in and out of databases (ODBC, etc.)
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Resource models
Reserve models
Budgets, forecasts, short-term plans
Dig outlines
Survey information
Truck Dispatch information
Weights
Destinations
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Accessibility
All stakeholders have access to data which is meaningful
to them
No more or less data than each stakeholder requires
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System automation
As much data as possible is gathered
automatically
Truck dispatch, load cells, weightometers, plant
control systems, SCADA systems
User intervention is to validate data and resolve
errors
Avoid tasks which rely on users initiation
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Example of output
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P ro d u cctio n (kt)
120
100
80
60
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Gains
Losses
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Plan/Actual
0
Planned
Equipment
Availability
Reserve
Change
Plant
Availability
Operations
decision
Planning
Issues
Forward analysis
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Actual Mined
Systems integration
Reconciliation uses data from many independent
systems
DATA from these systems is integrated in a
reconciliation database via seamless transfer
Avoid the creation of a single system use best of
breed and replace components as required
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Useful References
Fouet, T., Riske, R., Morley, C., Cook, A., Conti, D., & Centofanti, J. (2009).
Standardising the Reconciliation Factors Required in Governance
R
Reporting.
ti
S
Seventh
th IInternational
t
ti
l Mi
Mining
i G
Geology
l
C
Conference
f
P
Perth,
th WA
WA, 17
- 19 August 2009. pp 127-139.
Morley, C. (2003). Beyond Reconciliation A Proactive Approach to Using
Mining Data. Fifth Large Open Pit Mining Conference Kalgoorlie, WA, 3 - 5
November 2003. pp 185-191.
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