M AXIMIZING THE VALUE OF O RE

A D ATAMINE W HI TE P APER
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Mineral Industries Computing Limited

This edition published May 2003
Copyright 2002-2003 Mineral Industries Computing Limited

Maximizing the value of ore: Datamine OreController (ii)

T ABLE OF C ONTENTS
ABSTRACT ................................................................................................................................................................... 1
INTRODUCTION......................................................................................................................................................... 1
WHAT DO ORE CONTROL SYSTEMS DO? .......................................................................................................... 1
TYPICAL ORE CONTROL SYSTEMS ............................................................................................................................... 1
REQUIREMENTS FOR A WELL-DESIGNED SYSTEM ........................................................................................................ 2
UNDERSTANDING THE PROCESS......................................................................................................................... 2
IDEF0 ACTIVITY MODELING ..................................................................................................................................... 2
CAPTURING AND IMPROVING THE PROCESS ................................................................................................................ 2
THE DATA HIERARCHY .......................................................................................................................................... 2
TRANSFORMING MODELS INTO REALITY ....................................................................................................... 2
INDUSTRY STANDARDS .............................................................................................................................................. 2
DATAMINE ORECONTROLLER .................................................................................................................................... 2
CASE STUDY: GEITA GOLD MINE ........................................................................................................................ 2
INITIAL PROCESS STUDY ............................................................................................................................................ 2
IMPLEMENTING THE DATA HIERARCHY ..................................................................................................................... 2
BUILDING THE SOFTWARE .......................................................................................................................................... 2
CUSTOM INTERFACES ................................................................................................................................................. 2
DATAMINE ORECONTROLLER FUNCTIONS .................................................................................................... 2
PLANNING GRADE CONTROL HOLES .......................................................................................................................... 2
PREPARE DRILLING DATA FOR INTERPRETATION ....................................................................................................... 2
INTERPRETATION OF MINERALIZED ZONES AND LITHOLOGICAL UNITS ..................................................................... 2
CREATION OF A BLOCK MODEL.................................................................................................................................. 2
DESIGN AND EVALUATION OF ORE BLOCKS ............................................................................................................... 2
RECONCILIATION........................................................................................................................................................ 2
CONCLUSION.............................................................................................................................................................. 2

Maximizing the value of ore: Datamine OreController (iii)


A BSTR ACT
Each mining operation is unique. Because of this
simple fact, no out-of-the-box software solution to
common mining problems is possible. Software
must be adapted to suit different procedures for
geological logging, sampling and assaying, orebody
interpretation, modeling, ore block design and
reconciliation. We cannot expect any of these
procedures to be adapted to suit the software.
Fundamental to the successful implementation of
any computerized system is a thorough
understanding of the processing involved. This
must be done in a formal and rigorous manner, to
create a concise, accurate description of the process.
This description of the system can then be
implemented in software, using a combination of a
flexible development framework, state of the art
software tools, and industry standards.
This paper describes how Mineral Industries
Computing Limited has approached the problem,
and describes the methods used with reference to the
development of a computerized ore control system,
Datamine OreController.
W H AT DO O RE C ONTROL
I NTRODUCTION
During the life of any mine, the geometry and the
quality of the orebodies are repeatedly assessed.
Huge decisions are made on the back of these
estimates.
Day by day ore control procedures represent the
final stage of orebody estimation, and determine
which material is sent for processing, and which is
dumped as waste. While the consequences of
sending a single truck load to the wrong destination
are not catastrophic, the consequences of
consistently getting it wrong certainly are. Thus,
the procedures for sampling, mapping,
interpretation, modeling and design must be
carefully designed in order to maximize the value of
the ore in the ground.
Accurate daily prediction of ore and waste requires
an estimation method that best suits each individual
orebody. Consequently, the processes employed in
ore control at each mine are unique. Indeed,
different processes are sometimes used in different
parts of the same mine.
By definition, computer assistance has to come from
customized systems too. The software has to be
able to implement the procedure that has been
designed to best exploit the orebodies. It cannot be
the other way around.
There are further complications. Because of its
routine nature, ore control analysis and prediction is
often carried out by staff with only moderate
training and skills. Software solutions have to be
Maximizing the value of ore: Datamine OreController
easy to use, despite the fact that the underlying
analysis and modeling will employ state of the art
techniques.
Because large volumes of data are involved, the
process may have to be operated by a number of ore
control officers, so the software system must
provide for multi-user access and sharing of data.
In addition, the process should be reviewed
periodically, to ensure that the best possible
predictions are made, and that new advances in
technology are incorporated where practicable.
Finally, ore control systems do not operate in a
vacuum. They must routinely integrate with other
planning and production functions: resource
modeling, long term and short term planning, survey
systems, and so on. The integration must be
seamless, and implemented in such a way that it can
be easily adapted when changes to these other
systems are made.
All these factors and more must be taken into
account when designing and implementing a
computerized system for ore control.
SYSTEMS DO ?
Despite the differences between mines, there are
many similarities that characterize the ore control
process:
Detailed sampling of the orebodies. This
involves planning, sampling and assaying drill
holes or channels, together with geological
mapping.
Careful interpretation of the results of the
mapping and sampling, and construction of
detailed 3-D models of the deposits.
Delineation and evaluation of ore and waste
blocks using the 3-D model. The design may
need to include blending from different mining
areas to satisfy mill feed requirements.
Close control of the mining process.
Periodic reconciliation to validate the
interpretation, modeling and design processes
used.
These steps outline the scope of many typical ore
control systems, in either open pit or underground
mines.
Typical ore control systems
Ore Control systems evolve over time. As mining
proceeds, more and more is learned about the
orebodies, and procedures must be revised and
improved as a result of the additional knowledge
Page 1
 gained. As this process takes place, the software implementation should aim to provide
system will be revised as well. approximately sixty to seventy percent of generic
software components. The remainder will consist of
In a poorly designed system, this can lead to a
custom modules.
hotchpotch of procedures, involving numerous
pieces of software, and a combination of interactive The software must also provide a flexible model of
use and out of date customizations. The result is a how the data is to be organized, as well as an ability
requirement for highly skilled operators, and to allow for future changes in the organization of the
unnecessary reliance on their subjective judgment. data.

Requirements for a well-designed system U NDERSTANDING THE PROCESS

The ore control process is a complex one, and unless The first stage in designing and implementing an ore
it is fully understood and documented, the software control system is to understand and document the
system will be. The first requirement, therefore, is existing system. For a new mine, where there is no
for the software analyst to completely understand existing procedure, this can be done by comparing
the ore control process. This can be achieved by the project against peer operations.
constructing a model.
Understanding the existing process is best carried
Constructing a model, using methods that have been out by conducting interviews with ore control
validated many times in many industries, ensures officers and their technical managers. The results of
that the design of the system is carried out in a these interviews allow the process to be carefully
systematic and formal manner. A model is of great documented.
value in communicating an understanding between
the analyst and the other stakeholders, and serves as IDEF0 Activity Modeling
a specification for the software system.
Datamine uses a modeling methodology called
Once the software specification has been defined, a IDEF0 for this purpose. IDEF0 was developed by
flexible software architecture is required, so that the the U.S. Air Force as a way of understanding and
modeled process can be implemented in the managing its complex manufacturing streams.
software. The software system must provide a basic IDEF stands for Integration DEFinition, and
set of functions, like building blocks, which may be defines both a hierarchical diagramming method and
modified or customized as appropriate to match the rigorous analysis technique for modeling processes
requirements of the process. It must also allow for such as ore control.
components to be added, to implement activities that
are unique to the mine. As a guide, the The process is captured in a series of diagrams,
which are organized into a hierarchy and break the

I2 I3 C1
Current Pit Limit Wireframe (PTWF) Standard Drilling Pattern
Geological Resource Block Model (RMRC)

Current Pit Limit Strings (PTST)

Design Drilling Drillhole Boundary String (DBND)
I1 Boundary

A11

Planned Drillhole Collars (PLHC)

Design Grade
Control
Drillholes
Planned Drill Holes with Identifiers (PLHL)

A12

Export Area Boundary (EBND)

Define Export
Area
Boundaries
(EBND)
A13

Collar coordinates (Geodimeter)

O2

Export Planned Collar Coordinates (Excel)

Drill Holes

Collar Coordinates (CSV)

A14

Planned Drill Hole Location Report

O1
Generate
Planned Drill
Hole Report

A15

Datamine Ore Controller Datamine Ore Controller Customisation

M1 M2

Figure 1: IDEF0 Activity Modeling Example

Maximizing the value of ore: Datamine OreController Page 2

 whole process down into a series of activities. This
analysis allows us to understand the constraints on
each activity, which show what data passes between
activities, and what data must be available before
that activity can be carried out.
Capturing and improving the process
The first model is an As-Is model, whose purpose
is to describe the existing ore control process. A
draft model is drawn following interviews and
workshops with ore control staff and management.
It is then reviewed and corrected as necessary until
agreement is reached over its validity.
With the As-Is model at his disposal, the analyst
and stakeholders can identify improvements that can
be made. The model also allows the key activities
to be identified, and design of the new or improved
system will concentrate on improving these key
activities and removing bottlenecks. During this
process, the analyst can contribute suggestions
based on his knowledge of peer systems that have
been installed elsewhere.
The result of this process is a new IDEF0 To-Be
model, which serves as a system specification. The
models also clearly identify specific new software
development that will be required. The model
guarantees understanding of the system
Figure 2: Datamine OreController
Maximizing the value of ore: Datamine OreController
requirements by all parties, and allows reasonable
estimates to be made of the development and
implementation effort required.
T HE D ATA H IERARCHY
Another aspect of any process that must be captured
during the modeling study is how the data is
organized. In all operations, there is some form of
grouping of data, but the details of how the grouping
is done will vary. For example, one open pit mine
might use a pit name or code as the first level or
organization, subsequently grouping information by
bench and mining area. At another operation, the
first level might also be based on a pit name, but the
next level of grouping might refer to a cut
number, pushing mining area and bench to a lower
level. Also, where a specific grade control drilling
program is carried out, the data organization may be
different during the drill hole planning and
interpretation phase from the modeling, evaluation
or reconciliation phases.
The software must allow for these differences, for
example by making use of an external set of rules,
modeled in industry-standard XML. XML tags can
define which data items are collections of other
items. By encapsulating the description in XML,
changes to the organization of the data may be made
Page 3
 without any changes to the processing whatsoever.
T R ANSFORMING MODELS I NTO
RE ALI TY
Armed with a detailed system specification, the next
task is to accurately transfer the design into
software.
The successful implementation of an ore control
system relies most heavily on the availability of a
highly flexible and modular software system. The
system implementer must be able to rapidly piece
together a custom system for a mine, using standard
modules where appropriate. Additional, custom
modules can be added where necessary, thus
achieving the best trade off between development
cost and time.
configuration is implemented using a number of
XML files. The Datamine mining software system
is used to power the system, by providing industry
standard tools for design, modeling and evaluation.
C ASE S TUDY : G EI TA G O LD M INE
In June 2001, Datamine International was
approached by Geita Gold Mining Limited, to assist
them to improve their geological database system,
data collection systems and ore control process.
Geita Gold Mine is a 50/50 joint venture between
AngloGold Ltd and Ashanti Goldfields Co. Ltd, and
is located approximately 50 km south of Lake
Victoria, in Tanzania.

Industry Standards
Software applications with a large user base become
industry standards. Microsoft Excel is one example,
and where industry standards exist there are great
advantages in using them. For example, the use of
industry standard software applications reduces the
requirement for user training. Using industry
standard databases and data access methods
improves interoperability and reduces development
time.
Figure 3: Geita Gold Mine, Tanzania
Datamine OreController
The Datamine Mining Software system provides Following initial discussions, the following
improvements were identified and agreed upon:
such a framework for implementation. Datamine
Studio is recognized for not only providing best in
class orebody modeling and mine design features, E XI S T I N G I M PR O V ED
but for its unrivalled facilities for customization. It
Database None (text and Century Systems
provides a complete Microsoft automation interface
Datamine files) Inc. Fusion
to all of the Datamine functions. This means it is
easy to develop software applications that can Assay Laboratory Text files Direct to database
access all the Datamine functions, but which are Sample Transfer
completely customized for a particular purpose.
Any modern programming language, including Geological Paper Century Systems
JavaScript, Visual Basic and Delphi may be used for Logging DHLogger
the customization. Ore Control Datamine macros Datamine
The customized system is installed inside the OreController
Datamine Studio interface. All the unnecessary Geological Paper (limited) Century Systems
toolbars and other user interface objects from Mapping MineMapper
Datamine Studio are removed, so that the user is
presented with a software environment that is Survey Geodimeter Geodimeter
designed specifically for the ore control tasks that he
has to perform. This makes the system easy to
Initial Process Study
learn, and enforces the documented processing rules.
An Initial Process Study was carried out late in
Datamine Software has used this framework to 2001, and detailed specifications were agreed for
implement ore control systems using the methods each of the above process improvements. An As-Is
and tools described above. The resulting product is IDEF0 model was prepared, and this was used as a
called Datamine OreController. baseline for describing process improvements, as
Datamine OreController uses a combination of well as a way of identifying all the various
Visual Basic and JavaScript modules. The system

Maximizing the value of ore: Datamine OreController Page 4

 integration points*. In this way, a To-Be IDEF0
model was completed, which became part of the
system specification document.
Implementing the Data Hierarchy
IDEF0 is designed to capture the activities that go
together to make up a process. It is not designed to
model the data hierarchy that must be implemented.
A separate model was therefore created, using
standard tools for describing organizational charts,
to capture the data hierarchy to be implemented.
Data hierarchy is not captured by IDEF0, and has to
be modeled separately. For example, the IDEF0
model shows that the activity of designing ore
blocks produces two main outputs: The coordinate
strings that define the extents of the ore blocks, and
the results of evaluating those blocks. It does not
show, however, that ore blocks are grouped into
different case studies (a feature identified through
discussions with mine staff), and are further grouped
by the bench on which the design is made. The
identification of the various groupings of data is
ideally done by drawing a standard organization
chart for the data.
Building the Software
The To-Be model and the corresponding data
organization chart were subsequently translated into
XML files by Datamine Software Limited in order
to complete the detailed specification of the system.
Each of the activities in the model was translated
into a specific software module for development,
and each of the connecting arrows in the IDEF0
model found its place in the hierarchical XML
description of the data that is used by Datamine
OreController.
The combination of the IDEF0 To-Be model and the
hierarchical description of the data proved to be
ideal for specifying and controlling the custom
development required. Software development was
undertaken in both the United Kingdom and
Australia, and software modules were assembled
before testing and release.
Numerous releases were made, for both in-house
and on-site testing. This was a deliberate decision,
to allow for a rapid reaction to feedback from
testing. Changes to individual modules, and to the
overall organization of the data could be easily
accommodated with reference to the models.
* holes as they become available.
Integration Points are instances of where one
software system needs to connect to another. For
each integration point, a generic or custom data
connection will be required.
Maximizing the value of ore: Datamine OreController
Custom interfaces
A familiarity with Microsoft automation
technologies allows highly sophisticated software
modules and interfaces to be completed. A good
interface is one that is invisible, so that the user is
unaware of and undistracted by connections between
different software systems.
D AT AMINE O RE C ONTROLLER
F UNCTI ONS
Datamine OreController forms the core of the new
ore control system at Geita. Datamine
OreController is a highly modular system, which
allows it to be customized for use at any mine, both
open pit and underground. The system is divided
into a number of primary options, which are
described in an XML file. Each primary option
contains a number of secondary options, or
modules. The XML file describes the code
module to be loaded to execute the module, together
with a description of the data objects that are used
by and created by that module. In this way,
modules may be reconfigured and reused, by
supplying them with different data.
The primary OreController options as implemented
at Geita are:
Plan Grade Control Holes
Prepare Drilling Data for Interpretation
Interpretation of Mineralized Zones and
Lithological Units
Creation of a Block Model
Design and Evaluation of Ore Blocks
Reconciliation between Ore Control model
and Resource Models
Planning Grade Control Holes
In this installation, the primary source of data for
ore control comes from a program of reverse
circulation drilling carried out in advance of mining.
OreController provides a number of modules to
allow the operator to lay out patterns of drill holes
within any boundary the user might define.
Features are provided for editing the designed holes,
including modifying the planned depth of any or all
holes.
Once the operator is satisfied with the planned
holes, they may be exported directly to the survey
instrument for setting out, and to the Fusion
database where they will be updated with actual
Page 5
 Prepare Drilling Data for Interpretation
As grade control holes are drilled, they are logged to
identify changes in mineralogy, and sampled at
regular intervals. The samples are sent for assay,
and the mineralogical logs are gathered by means of
a Palm logger.
The logger uses software from Century Systems,
Inc., and the geologists logs are transferred directly
into the central database by simply placing the Palm
computer into its docking cradle.
Sample assays sent to the lab are managed by
Comlabs CCLAS laboratory management system.
The geologist may query the laboratory system at
any time, to automatically merge assay results into
the central geological database.
The actual location of each drill hole is surveyed,
and the collar locations are also transferred from the
survey instrument to the central database.
The geologist responsible for overseeing the grade
drilling process is required to sign off each drill
hole, and the system ensures that only holes for
which a complete set of data is available (collar
coordinates, assay results and geological logs) are
released to the OreController system for further
processing. This greatly improves the reliability of
the data used for orebody interpretation and
modeling, and decreases the time required before
ore block designs are completed.
The OreController system links directly into the
central database, and extracts all available drilling
data within a 3-D volume specified by the operator.
The operator then defines a polygonal area on each
bench to start the process of interpretation of the
geology. The OreController system slices the data
into a set of vertical and horizontal sections which
align with the drill holes, which allow the operator
to complete the process of interpretation of the
orebody.
Earthworks Present is used to print high quality
drawings of each section, showing assay values,
lithology, mineralization or alteration data.
Interpretation of Mineralized Zones and
Lithological Units
The Geita installation of OreController provides a
number of modules to guide the operator through
the process of developing wire frames and control
strings which will be used to constrain the block
model that is to be built.
The details of this process are quite specific to the
Geita mine, but the software modules used are
general and may be reused in other implementations.
Maximizing the value of ore: Datamine OreController
Creation of a Block Model
Once the interpretation of the ore bodies has been
completed, Datamine OreController provides a
series of custom steps for building a block model for
subsequent evaluation of ore block designs.
The block modeling process has to be unique for
each mine, and the custom procedures are
implemented through Datamine scripts and macros.
These macros are run in the background by the
OreController system, to ensure that the steps are
completed in the correct order.
OreController them provides modules for displaying
the resulting model, and for the calculation of
statistical parameters.
Design and Evaluation of Ore Blocks
Once a block model has been prepared, the
OreController operator can carry out the process of
designing and evaluating the ore blocks which will
be mined.
This is done interactively, and may optionally use
polygons generated by the Datamine Mineable
Reserve Optimizer system (MRO) as a starting
point.
Datamine MRO implements a sophisticated
algorithm for automatically designing mineable ore
blocks, taking into account economic, geometric and
equipment operating constraints. Currently, MRO is
run as a separate system from OreController, as a
number of what if cases need to be run in order to
gain the best understanding of the orebodies.
Once a best practice for MRO at Geita has been
established, a new module will be added to
OreController to execute the MRO algorithm using
the parameters established by the case study
analysis. In this way, subjective decisions from the
OreController operator are minimized, but the
quality and automation of the ore block design
process is maximized.
During the detailed design of ore blocks, the
operators are able to carry out their own what if
analysis, through the quick-evaluation features
provided.
Microsoft Excel is used to summarize and print
evaluation results, using the sophisticated pivot table
features provided by that program. Datamine
OreController writes directly into an Excel template
file (which forms part of the OreController
configuration), so that the operator only has to
perform a minimum number of key clicks to view,
summarize and print the evaluation results.
Earthworks Present is again used via automation to
prepare printed output of the bench plans showing
the completed ore block designs.
Page 6
 Reconciliation
At Geita, Datamine OreController provides two
separate reconciliation modules. These implement
procedures that were developed specifically for this
operation. One module is used to compare the
results of prediction of ore blocks using the resource
and the grade control block models, while the other
is used to compare predictions from multiple models
within any polygonal boundaries.
The latter of these two methods is completely
general and has been implemented in other
OreController installations.

C ONCLUSIO N
Industry standard methods for documenting
complex processes can be applied to the
understanding of mining processes and can
contribute to the successful development of
computerized systems for use by technical operators
with limited training. IDEF0 diagrams are easy to
understand and form an ideal platform for
communicating complex processes, and for
designing improvements. An IDEF0 study should
form an integral part of the overall design process
and system documentation.
The process of capturing information about a
process and transforming it into software can itself
be formalized. Use of these ideas is not limited to
the problem of ore control in open pit mines. It can,
in fact, be applied to any application of software to
technical mining problems. This can be a very
efficient way of developing software.

Maximizing the value of ore: Datamine OreController Page 7