doi:10.36487/ACG_repo/2435_O-09 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 Northparkes E26 L1N block cave – progress to date L. Snyman, S. Webster and M. Flynn Northparkes Operations, Parkes, Australia ABSTRACT Northparkes underground operations consist of E26 sub-level cave and E48 Lift 1 and the E26 Lift 1 North block caves. Two open-cut mines blend with underground ore in the processing plant to produce a copper and gold concentrate. E26 block cave mining began in 1997, and the ability to extend cave footprints and utilise existing infrastructure has provided continual ore and value, along with several technical challenges. The E26 Lift 1 North block cave extraction level and undercut wraps around the historic E26 L1 block cave. Development commenced in 2019, and extensive re-design occurred due to the variable ground conditions of the existing cave and historic development around the footprint. The undercut start-up sequence against the existing cave commenced in a post-undercut form to overcome substantial pillars between historical development, then shifted to an advanced undercut as the pillars reduced to an acceptable size. We present the finding of the inclined saw-tooth undercut design, which allowed a reduction in the undercut development drives, reducing the duration and cost of the construction. The production phase commenced in early 2022, and construction was completed five months early compared to the feasibility study. The cave extension geometry amongst existing infrastructure and the overlying subsidence crater made L1N cave growth a unique cave during its cave establishment and breakthrough, posing monitoring challenges. This paper looks at the progress of the cave from feasibility study, construction, cave establishment and essential considerations for monitoring the growing cave through to full production. 1 INTRODUCTION The E26 Lift 1 North (E26L1N) Feasibility Study identified that a potential 41.7Mt of low grade copper and gold ore can be extracted from E26L1N by means of the block caving mining method. Now constructed, production from E26L1N in the Life of Mine Extension Plan runs from 2021 until 2033 to replace the ore that was produced by the E48 block cave and the E26 sub-level cave (SLC). The E26L1N block cave is described as a remnant mine extension adjacent to the existing E26 cave (Webster et al. 2020), the first underground mine developed at Northparkes Operations. The extraction level at an RL of 9760 sits beneath the E26L1 extraction level (9800m RL) and above the E26 Lift 2 North (E26L2N) cave (Talu, 2010). The E26L1N development area forms part of the larger E26 orebody, which was mined initially as a small open pit, then underground by block-caving in two central lifts (L1 and L2), with a subsequent extension (L2N). Currently a sub-level cave operation is recovering peripheral ore from the southern upper portion of E26L2, where cave propagation was incomplete. The E26 orebody plunges steeply (83-84°) to the northeast in line with the strike axis of the orebody. Copper-gold mineralisation at E26 occurs within stockwork quartz veins, disseminations and breccia associated with the intrusion of pipelike quartz monzonite porphyries. 1344 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 E26L1 unexpectedly experienced surface saprolite and clay on the extraction level some months after the air blast event in 1999 (Ross and van As, 2005). Clay was first evident as a smear then progressed to chunks. The E26L2 began production in 2002 and produced clay on the level in June 2006, roughly one year after breakthrough into E26L1 in August 2005. Initially there was minimal impact of the clay on the production rates due to the clay handling issues, with production rates maintained in excess of 5.5Mtpa. However, large-scale mining operations were suspended in August 2007 following early dilution of the ore-stream with surface clays that had been drawn down from surface through the E26L1 and E26L2 cave volumes. Through experimentation, operations established that a clay content of <10-15% mixed with fresh rock had to be consistently maintained to ensure downstream material handling infrastructure did not become blocked with clay. Once the majority of drawpoints had reached >15% clay in E26L2 ED1-6, no further draw from E26L2 cave was possible without creating repeated blockages of both underground and surface material handling equipment (that is crusher, chutes, ore skips and transfer points). In addition, clay rushes occurred at a number of transfer points both on the surface and underground, resulting in significant safety hazards to mine personnel. Northparkes decided in July 2007 that attempting to feed ore with >15% clay material was not sustainable and that other ore sources needed to be secured. The strategy for draw control of E26L1N is predominantly to manage ingress of old cave material, promote caving and limit clay reporting to the material handling system and mills. 2 DESIGN Northparkes has incrementally mined larger extensions to its initial block cave footprints in the areas of E26 lift 2 with three additional extraction drives, E48 lift one with one south and two northern extraction drives and now E26 lift one north with 11 extraction drives. The challenges of designing a cave footprint amongst existing infrastructure and caved rock, limits the orientation options and requires a rethink of undercut geometry and extraction level ventilation and loader automation zones. The design challenges are discussed in Webster et al 2020, whereas this paper focuses more on the undercut geometry and caveability after the construction and early years of caving. 2.1 Sawtooth undercut design The Northparkes Step Change Project (Wyllie and Webster, 2012) focused on innovations and efficiencies in block cave design to expand the production at Northparkes with four new caves. All undercut designs for these caves involved an advanced undercut narrow inclined ‘sawtooth’ pattern with a single drill drive above the drawbell and offset from the extraction drive. This single drill drive per drawbell reduces the development metres required when compared to other undercut designs requiring two drill drives per drawbell. Major benefits include the speed of constructing the undercut and reduced time to first ore production. The drawbell major apex was designed at 50 degrees which was flatter than previous Northparkes caves but designed to minimise the blast hole length which is the limiting factor of this undercut geometry. As the angle reduction reduces the volume of the pillars in the major apex, the separation between the extraction level and the undercut was increased again from 14m to 17m. E26L1N however had height restrictions due to remnant development of lift one, connections to existing material handling transfer points and the E26 lift 2 north cave beneath. For these reasons, the height of the sublevel was returned to 14m, and the angle of the major apex reduced to 45 degrees. The design of the incline sawtooth was adapted to a long and short configuration to allow a wider overlap, less prone to bridging. To further mitigate potential for bridging that can happen to any undercut shape, the ring designs were overlapped, and the short holes were over-drilled by minimum 1.5m into the long side of the adjacent undercut. 1345 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 Figure 1 Long and short undercut shape. A development since the Step Change Project design is the implementation of WebGenTM (wireless boosters) which were first trialed in the Northparkes E26 Sub Level Cave and have justified advantages in safety and productivity gains (Hawkins, 2021). The option of using WebGenTM, given it is wireless, can be precharged and has long sleep times, allows optionality of firing of the drill pattern, a feature that provides options for forming the complex geometries of an undercut and drawbell. E26L1N being amongst remnant drives, drill patterns required bespoke designs and adjustments to the rings of the undercut, again WebGenTM provided optionality in these areas. Advanced undercut geometry was preferred for E26L1N due to the ability to remove swell material from undercut without having to rely on drawbell and undercut slot availability. As the poor ground condition around the existing E26 cave would potentially prohibit drawbell and undercut slot establishment at the area directly adjacent to the cave, the post undercut method could complicate cave extension initiation. This was a learning from E48 cave extensions which utilised a post undercut geometry. 2.2 Extraction level drainage The gradient applied to the undercut sublevel and extraction level ranges from 1% to 2% to allow water to flow naturally from the drifts to the extraction level access or undercut sublevel access and eventually down to the sumps. The sumps are strategically located at the start of the developed accesses to allow mining uphill, reducing pumping requirements during development. The water runoff from the west extraction level access, northern part of the east extraction level access and drifts 1 to 6 are captured by sump 1. Similarly, the water runoff from drifts 7 to 11 are captured by Sump 2. The changing gradient direction of some drives required the undercut ring lengths to be adjusted 1346 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 to ensure connection of the undercut between drives. being more massive and more elastic. Hydrofracturing of the BQM was recommended so as to: • Increase cave propagation which in turn reduces ingress of old cave material; • Facilitate caving at the same rate as the volcanics on the north; • Reduce arching over of the caveback; • Reduce risk of cave stall; • Reduce oversize reporting to drawpoints; and • Reduce magnitude of seismicity within the hydrofractured region. Figure 2 Northparkes has performed hydraulic fracturing at E26 and E48 block caves with success. Extraction level drainage. Treatment prior to undercutting is believed to be the most effective. Numerical simulation results show that the hydrofracturing improves the caving in the area with an approximate 5% increase in material availability. Figure 3 Changing extraction level heights and location of undercut rings to be adjusted. Hydrofracturing of the BQM was performed from the eastern side of the subsidence crater as shown in Figures 4 and 5. The holes were drilled and hydrofractured by the same contractor under guidance of the CSIRO. Figure 2 shows the layout of the E26 Sub level cave (south in pink), lift two cave (centre) and E26L1N Feasibility footprint (north in green). The blue lines indicate the split drainage directions across the footprint. Figure 3 shows the changing extraction level heights due to drainage directions and the locations of undercut rings to be adjusted. 3 DEVELOPMENT Stress measurements indicate that the major principal stress is 30MPa sub-horizontal towards 111deg at the extraction level. No issues with stress or seismicity were encountered during development of the extraction and undercut levels. Figure 4 From the caving assessment, it was recognised that Biotite Quartz Monzonite (BQM) has been difficult to initiate continuous caving due to it 1347 Aerial view of hole collars on the east side of the crater for hydrofracture. 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 void ratio. The solution was to initiate with a post-undercut form and transition to an advanced undercut, utilising pre-charging and wireless detonation to complete the final firing. Figure 6 shows a section view through one of the initial drives with the firing sequence in the transition from post undercut to advanced undercut. Figure 5 As-drilled hydrofracture holes overlain on footprint. Developing through pre-conditioned ground, developing up against the existing cave, and developing undercut drives into the existing cave were all well managed and without incident. The previously pre-conditioned ground was only a challenge from an operational perspective – drilling in automation, bulletproof glass and barricading precautions were all part of the controls. There were expectations that when developing up against the existing cave there would be a zone of highly fractured and loosened rock encountered. This was not the case. In some areas there were indications that the cave was close when weathered and oxidized zones were intersected, but in two of the undercut drives development cuts were taken beyond the boundary into the consolidated cave material – a combination of oxidised clay and rock that was not too dissimilar rock in appearance to intact. 4 Figure 6 Sequence of firing as illustrated in Figure was: • Fire the drawbell from the extraction level, • Remove enough material for the following firing from the drawpoint, • Charge the remaining shots from the undercut level or abandoned infrastructure levels, which consists of a conventionally charged downhole portion and a precharged uphole portion. • Fire the downhole conventionally, mucking the material to make void and then • Firing the pre-charged uphole shot wirelessly, before stepping over to the next drawpoint. UNDERCUT The E26 L1N undercut is an inclined sawtooth shape with a short and long side in each drive, connecting to form a continuous area. 4.1 Post Undercut to Advanced undercut transition The undercut for E26L1N adjoins the E26L1 cave footprint and has abandoned infrastructure drives running through the undercut design. Part of designing around this existing infrastructure caused the drawbell heights to be varied and for the south-western section they were too high to be fired in a single firing due to having a low Sequence of Post-Undercut to Advanced Undercut transition. The transition between post and advanced undercut occurred when the height of the drawbells were low enough to support a single firing and at that point the undercut firings were all conventionally fired with wired electronic detonators and the drawbell firings delayed until the undercut had advanced beyond them. The additional complexity required and additional risks to be managed at the execution of the transition compared with changes to the design of undercut level that could have been 1348 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 made to remove the additional complexity highlights the importance of thorough planning and risk assessment at the earliest point in the planning process 4.2 Dealing with hangups and poor material flow During the execution of this plan, there were several issues encountered around the mass firings where the material became compacted and hung up. The general strategy applied when trying to remove these issues was to: • Fire adjacent rings • Detonate a small explosive charge in the drawpoint (bombing the drawpoint) • Drill slashing rings from adjacent drives and fire • Fire the next ring and repeat if required. Similarly with the angle of the undercut being 45 degrees, the material did not always rill easily from the left and right side, leaving material that could not be left behind without fear of losing the connection between the undercut. “Bombing” of the drawpoint was successfully used in most cases to get material to rill from the drawpoint again. In the case of Figure 7, a drawpoint was hung for a significant period of time, remedial actions taken included firing adjacent rings, bombing and drilling of slashing rings from the adjacent drives (which broke through into broken ground). After consideration of the risks, the next rings were fired and material was recovered successfully, indicating that the material was broken, but too tightly packed to flow and when that pressure released, material was able to flow freely. Figure 7 A CMS of a hung drawpoint after mass blasting. 4.3 Verification of undercut connection between drives At the beginning of undercutting, the rings were over-extracted to allow for a cavity monitoring survey (CMS) to be completed, which confirmed the connection between the short and long arms of the undercut design as shown in Figure 8. However, this was only confirmed in a small set of rings and not rigorous for the entire undercut - the presence of pillars that could put load on the extraction level were not able to be ruled out. Since completion of the undercut in Q1 2022, there has been no evidence of loading on the extraction level that has been tied to poor undercut performance. This performance may be better attributed to the favourable ground conditions and setting for undercutting rather than rigorous quality assurance and control with the undercutting process, considering this, future undercutting should include regular checks for the connection of the undercut between drives to ensure the desired performance is achieved, with other proxy performance indicators used in between. The extraction target of the rings fired was used as a proxy for the performance of the blasted shape, if the desired 30% extraction was not achieved and the brow opened, the process used to deal with hangups and poor material flow was used. If the extraction target was achieved without the brow opening, the ring's 1349 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 performance was considered high enough to fire the following ring. Figure 9 Figure 8 Connection of the short and long arms of the inclined sawtooth undercut was observed through CMS. 4.4 Verification of connection to existing cave As the undercut was designed to butt against the older E26 L1 cave, there were several areas where it was required to ensure that no pillar was left behind, to ensure free flow of material and avoid the potential for sudden failure of the pillar at a point in the future. There were two scenarios: Rings reaching over to connect with the existing cave on the left hand side. In both situations, the connection to the existing cave was confirmed by evidence of the E26L1 material at the drawpoint, which was distinct from the fired and freshly caved material in that it was very fine material with a distinct red colour as shown in Figure 10. The larger boulder sized material was also an indication that caving was occurring in fresh rock as opposed to the fired material from the undercut. • The L1 cave directly ahead of development • The L1 cave to the side of development Where the cave was directly ahead of development, stand up rings (where the rings start at 45 degrees and progress to 10 degrees to build height) were used. Where the development came alongside the cave, additional rings reached over to blast the pillar as shown in Figure 9. Figure 10 Connection to the existing cave was confirmed through drawpoint material observations. 4.5 Evidence of caving The abandoned conveyor drive, CV07, was also able to be used as an inspection level for the undercut and confirm that caving was occurring above the height that was originally fired, before being sealed with a thick cemented wall used as an airblast plug to prevent the flow of air into CV07. 1350 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 The amount of value that was gained from these surveys was key in developing a mass balance model for the operation and verifying assumptions about how the cave was progressing, especially in the initial stages to mid stage of the undercut progression where the cave had not progressed high enough to trigger other cave indicators and markers. Consideration should be very high for future projects to design in ways to gather these surveys as shown in Figure 11. growth which matched closely with the predicted rate. Figure 12 Undercut fired and open hole breakthrough with cave interpretation. Draw call Figure 11 Evidence of caving observed from the level above the undercut. 5 The draw call design for E26L1N has three primary functions: • Promote caving away from the existing cave to prevent arching into E26L1 • Prevent the ingress of E26L1 material into L1N • Provide good fragmentation through differential drawdown of material DRAW STRATEGY The draw strategy in L1N during and immediately following the undercutting was to limit the draw as low as possible to give sufficient time for the ground to fail naturally and reduce as low as possible the airgap between the caveback and muckpile. This gradually ramped up as more evidence of caving and the muckpile height growing was observed. The initial draw strategy used the smart marker recovery as a guide to caving occurring and the draw call from the area was adjusted to keep the airblast risk as low as possible in the early stages, where little evidence was able to be collected on the caving progress. Once the cave progressed high enough to reach the open holes from the surface (Figure 12), the same strategy was used to increase the production rate from the cave and also to determine an estimate for the rate of vertical The way that this is achieved is by increasing the draw call in each drawpoint as the distance from E26L1 increases, drawpoints close to the cave are bogged with low calls and the perimeter of L1N has the highest draw call, as shown in Figure 13. The exception is only made in one extraction drive where some convergence was evidenced but has been kept under control through increased bogging in the area. While the highest grade for the block is in the areas where the lowest bogging is occurring, the need to ensure complete caving and preventing the ingress of material from L1 has taken priority over the head grade. Once the cave has been established and broken through completely to the surface, the bogging strategy will change to give the highest long-term value. 1351 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 holes from the surface (6 triaxial geophones) (Figures 15 and 16). Figure 15 Plan view of sensors (blue are new installs for L1N). Figure 13 Draw call design for E26L1N. Figure 14 Modelled cave growth of L1N. 6 MONITORING The unique layout of the L1N cave wrapped around the existing L1 cave and infrastructure and located vertically below the eastern flank of the existing subsidence crater, with no intersecting underground excavations resulted in limited ability to monitor the pillar between the crater and the cave back. Monitoring systems in place for L1N include a seismic system, open holes, cave tracker beacons and tiltmeters as well as surface subsidence monitoring by drone photography. The IMS seismic system includes 18 sensors installed from both underground (6 triaxial geophones and 6 uniaxial geophones) and in Figure 16 Section view of sensors. Only one open hole was initially drilled to monitor cave growth. It was drilled from north to south. This hole held water for 5 months after completion of undercutting and then started sucking in May 2022. From May to October that year the caveback progressed steadily every week until in October a small airgap of no more than 11m was measured. Unfortunately, the hole was lost due to the failure of a wireline dipper down the hole that could not be retrieved. A further 6 holes were then drilled to provide coverage across the cave – at an angle steep enough to allow the camera to run down the hole, at a safe distance from the edge of the 1352 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 crater, but also to a target depth that would give meaningful caveback information over time. Two holes were drilled in the north and four in the east. The open holes are certainly the simplest and most useful form of monitoring the caveback as long as they remain open. Weekly changes to the muckpile sighted down choked open holes have given confidence that rilling is occurring within the cave and that an excessive airgap is not present (Figure 17). Cave tracker beacons were installed in surface holes drilled from the eastern side of the orebody. Of the 64 beacons installed, 17 have been extracted or stopped spinning to date. Unfortunately, no beacons have been physically recovered. The remaining beacons are located outside of the modelled final cave shape and will provide information on the lateral growth of the cave, if any. The beacons have given valuable flow data within the muckpile – the harder draw on the perimeter of the cave to promote cave propagation and prevent arching has resulted in the beacons being drawn across to that side within the muckpile as shown in Figure 18. Figure 17 Progressive change of muckpile material at bottom of open hole over time. Smart markers that were leftover from the E48 block cave were installed in holes drilled from the undercut. Two holes were installed vertically into the gap formed by the sawtooth undercut pattern (Figure 19). Each hole had smart markers installed every 2m from the toe of the hole down. These markers indicated that the undercut had progressed beyond the fired ring. Two or three rings of markers were installed in every second undercut drive as shown in Figure 20. 228 of the 393 smart markers installed have been recovered to date. Figure 18 Cave tracker beacons flow within muckpile. 1353 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 surface infrastructure to monitor the stability of the pillar as the cave develops and breaks through to surface. No tilt has been measured at the time of writing. A Wingtra fixed wing drone is used to capture aerial photographs (and surface topography) of the subsidence zone. There is no safe access to the edge of the crater and drone photography is the only means to identify changes within the crater. Figure 19 Smart marker between undercut rings. installation holes and Sections drawn across the crater show that the eastern slope which is directly above the L1N footprint has progressively subsided over the last 12-16 months. There is no evidence of a chimney or “glory hole” within the crater at this stage. N-S section view across E26 crater Figure 20 Smart marker undercut level. rings across NE-SW section view across E26 crater Figure 21 Placement of smart markers on 9830 level. 57 smart markers were placed on the floor of the 9830 level, as shown in Figure 21, (50m above the undercut level) to track the caveback progress through the existing infrastructure. Several of these markers have been recovered to date. The Geo4Sight tiltmeters were installed into a hole in the pillar between the cave and the Figure 22 Sections through E26 crater and plan. New technology, not available in Australia when L1N was developed, has subsequently been installed in two sacrificed open holes. Optic 1354 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 fiber cable for micro-seismic monitoring, strain cable for detection of small rock movements and geophones have been installed. Of particular interest is the Gypsum Leached Zone (GLZ), a highly fractured and broken rockmass at the top of the stratigraphy. All holes drilled through this layer have to be cased with steel casing in order to keep the holes open. It is therefore not possible to monitor any changes in the hole conditions in the GLZ section using an open hole camera, and it is also unlikely that seismic events would occur in this rockmass. Core from a diamond drill hole through the GLZ is shown in Figure 23 to give an indication of how broken it is and Figure 24 shows seismicity immediately after undercutting and then a few monthly snapshots during caving. The GLZ horizon, extraction level, undercut level and L1 stall height are shown on the graph for reference. There are opportunities to use new technology and develop new methods to determine the location and growth of the caveback in block caving mines. The use of geophysical methods is currently being explored which will eliminate challenges faced with complex geometries. Figure 23 GLZ core. Figure 24 Graphical representation of seismic events looking west. 1355 9th International Conference and Exhibition on Mass Mining, Kiruna Sweden 17-19 September 2024 7 CONCLUSIONS The key findings in this paper are: The advance sawtooth undercut is a viable design for reducing the number of development drives required to establish an undercut. The authors note that the performance may be attributed to the favorable ground conditions and rigorous quality assurance and control is still recommended. Constructability of a cave extension amongst remnant development and variable ground conditions brought complexity to drill and blast that required more detailed planning at the earliest point in the planning process. Talu, S, van As, A, Seloka, W & Henry, R. (2010). Lift 2 North extension cave performance. Y Potvin (ed.), Caving 2010: Proceedings of the Second International Symposium on Block and Sublevel Caving, Australian Centre for Geomechanics, Perth, pp. 407–421 Webster, S, Samosir, E & Wyllie, A. (2020). Learnings from mining cave extensions at Northparkes Mines and new technology to improve the value of future cave designs. R Castro, F Báez & K Suzuki (eds), MassMin 2020: Proceedings of the Eighth International Conference & Exhibition on Mass Mining, University of Chile, Santiago, pp. 92–102, Wylie, A., Webster, S. (2012). Northparkes Mines – Step Change Project. MassMin 2012: Proceedings of the 6th International Conference and Exhibition on Mass Mining, Sudbury, Ontario Canada. Expectations of cave growth in cave extensions should remain pragmatic to the prospect of arch over and draw calls focused on promoting cave growth take precedence. Monitoring locations opening into the cave are not always available due to the installation of cement plug walls as an air blast risk management requirement. The cave extension wrapping around the lift one cave and beneath the subsidence zone limited locations to install cave monitoring and redundancy of open holes should be planned for. New technologies will certainly help to eliminate the monitoring complexities experienced with the L1N cave. ACKNOWLEDGEMENT The authors would like to thank Evolution Mining for allowing the publication of the learnings from the development and execution of L1N – a unique block cave in our industry. REFERENCES Hawkins, E. (2021). Optimisation of blasting practices in caving operations. Master of Philosophy (Mining Engineering) thesis, School of Civil, Mining, and Environmental Engineering, University of Wollongong, 2021. https://ro.uow.edu.au/theses1/1233. Ross, I. & van As, A. (2005). Northparkes mine – design, sudden failure, air blast and hazard management of the E26 Block Cave. Proceedings of the 9th Underground Operators Conference, Australia, Australasian Institute of Mining and Metallurgy, Melbourne, pp. 7–21. 1356