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POTENTIAL HAZARD MAP FOR THE WET MUCK FLOW PREVENTION AT THE
DEEP ORE ZONE (DOZ) BLOCK CAVE MINE, PAPUA, INDONESIA

Conference Paper · January 2012

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 PROSIDING TPT XXI PERHAPI 2012

POTENTIAL HAZARD MAP FOR THE WET MUCK FLOW

PREVENTION AT THE DEEP ORE ZONE (DOZ) BLOCK CAVE MINE,
PAPUA, INDONESIA
DANNY Satrio Wicaksono, PORMANDO Silalahi, IWAN Sriyanto,
LASITO Soebari, ANDHIKA Ekaputra, Geoffrey DE JONG

Underground Mine Geology Department, PT Freeport Indonesia, Tembagapura, Papua

Email: Danny_Wicaksono@fmi.com; Pormando_Silalahi@fmi.com;

Iwan_Sriyanto@fmi.com; Lasito_Soebari@fmi.com; Andhika_Ekaputra@fmi.com;
Geoffrey_Dejong@fmi.com

ABSTRACT

The Deep Ore Zone (DOZ) Block Cave Mine lies at Tembagapura (Papua), one of the third
lift of block cave mines in the East Ertsberg Skarn System (EESS) after the Gunung Bijih
Timur (GBT) Surface Mine and the Intermediate Ore Zone (IOZ) Block Cave Mine. This
mine is an underground mine that utilizes the gravity flow system and has produced about 150
million tons of ore with 1.06% Cu and 0.81 ppm Au, operated since 2000 with production
was about 58k tons/day and production is being ramped up to 80k tons/day by the end of 2009
until now. The increase of production arose various challenges and the most dangerous one is
the wet muck flow. Potential impact of the wet muck flow is relative to fatality and economic
loss. There are three main aspects that influencing the wet muck flow formation, such as wet
muck material forming, triggering mechanisms, and wet muck flow potential. Conditions of
the wet muck material forming are analyzed from drawpoints mapping and water balance data
from the Underground Geology and Hydrology, there are fine grain (grain size < 5cm) with
more than 20% grain size > 5cm, loose grain (less than 90% optimum density), and saturated
or near saturated (80%). In addition, the high intensity of rainfall at the active mining area
influences the wet muck material forming. Triggering mechanisms are caused by mining
activities such as mucking and blasting, analyzed based on the Engineering Cave
Management data. The combination of both aspects show the wet muck flow potential that
summarize into a potential hazard map. The potential hazard map is calculated and divided
into high, medium and low risk. The calculation will combined with status of drawpoints and
showed the wet muck flow potential area in 2D map. This map will help the Operation to see
the concern area of mucking pattern for preventing the potential impact of the wet muck flow.

Key words: wet muck material, wet muck flow, DOZ Block Cave Mine, East Ertsberg Skarn
System, Papua, Indonesia.

INTRODUCTION

The Deep Ore Zone (DOZ) Block Caving Mine is an underground mine that utilizes the
gravity flow system at three main levels, which are (1) the Undercut Level at 3146 meters, (2)
the Extraction Level at 3126 meters, and (3) the Haulage Level at 3079 meters. The undercut
level is useful for induce a cave and provide a facility to reduce effects of the induced
abutment stress. The cave zone of the DOZ Block Cave Mine and overlaying the Gunung
 88

Bijih Timur (GBT) Surface and the Intermediate Ore Zone (IOZ) Block Cave Mines have
merged and penetrated to the surface at about the 3900 meters elevation. The extraction level
is the production area which is composed of drawpoints with columns height up to 500
meters. The ore is mucking from drawpoints, dumping into the grizzly, and through to the
haulage level by gravity flow system for transports the ore to the conveyor (Laubscher, D.,
2000).

This mine has produced about 140 million tons of ore with 1.06% Cu and 0.81 ppm Au,
operated since 2000 with production was about 58k tons/day and production is being ramped
up to 80k tons/day by the end of 2009 until now. Along with the increasing of production to
be high tonnages, arouses many challenges in the mine, and the most dangerous one is wet
muck flow. The potential impacts of wet muck flow are relative to fatality (loss of live) and
economic loss (loss of reserve, production, and property). In this paper, we just want to
review about the wet muck material forming which has close related with geological aspects.

EAST ERTSBERG SKARN SYSTEM (EESS)

The DOZ Block Cave Mine lies at the southern area of the Jayawijaya mountain range, Papua.
This mine is the third lift of block cave mines in the East Ertsberg Skarn System (EESS) after
the GBT Surface (active production from 1980 to 1993) and IOZ Block Cave (active
production from 1994 to 2003) Mines. Underneath the DOZ Block Cave Mine, there is the
Deep Mill Level Zone (DMLZ) Block Cave Mine that will be active production in 2015. See
figure 1.

The EESS is located at the southern limb part of a northwest trending syncline. It is the calcium-
magnesium silicate skarn which formed by alteration reaction of carbonate rock from Tertiary Waripi and
Faumai Formations. Both of formations were tectonically deformed following deposition at the
northern Australian passive margin that created fold striking 1100 tens of kilometers. As the
deformation continues, the development of strike slip faults (NE – SW) that formed during
development of fold and thrust faults (NW – SE) most likely post-date fold formation
continued with several hundred meters off-set. These features deformed during first stage of
deformation, approximately from 12 to 4 million ages. The second stage of deformation began
after 4 million ages and resulted in some local zones of NW trending strike slip faults with
left lateral offset and brecciated zones for about 10 meters. In DOZ Block Cave Mine, left
strike slip faults are known as Erstberg 1, Erstberg 2, and South Faults. Those faults
controlled emplacements of Ertsberg Diorite, a 3.25 Ma intrusive, which intruded the southern
flank of syncline and obliterating those pre-existing faults. The intrusion of Ertsberg Diorite
initiate contact metamorphism and followed by metasomatic alteration (Sugiyanto et al.,
2011). Copper and gold solutions migrated into and controlled by faults to produce the EESS
complex of mineralization from GBT Surface, IOZ, DOZ, and DMLZ Block Cave Mines. See
table 1.

The alteration zone that develops in DOZ Block Cave Mine is grouped based on skarn
mineral assemblages such as Forsterite Skarn, Forsterite-Magnetite Skarn, Magnetite Skarn,
HALO (High Altered Locally Ore) and Hornfels. From the characteristic of the Rock Quality
Designation (RQD), these rocks are suitable for the block caving system.
 89

DRAWPOINTS MAPPING, TRACER TEST, AND WATER BALANCE DATA

Drawpoints mapping is conducted weekly at the extraction level and recording rock types
distribution, minerals percentage, sticky material percentage, rate of fragmentation, wetness
condition, and drawpoints status. Rock types distribution and minerals percentage are very
important for grade control in drawpoints and base of all analysis. For example, if the
drawpoint have been low grade (showing by increasing waste materials in this case is marble),
closure drawpoint recommendation is very needed by operation for keeping the stability of
EqCu. Sticky material percentage, rate of fragmentation, and wetness condition have mutual
relation. Low fragmentation domination (grain size < 5cm) merged with water appearance in
drawpoints (wetness condition) create sticky material. High rate of sticky material is
indication of the wet muck material forming.

Tracer test and water unbalance data are produced by the Underground Hydrology. The main
objective of the tracer test is to identify the travel time of water (surface rainfall) from
subsidence surface to drawpoints at the extraction level of the DOZ Block Cave Mine and to
indentify interconnection of the water infiltration at the cave with water which is discharged
from dewatering hole at the peripheral of the EESS. The team used Rhodamine WT dye and
dropped at the top of the EESS. The samples collected at the extraction level and dewatering
drill hole at the peripheral of the DOZ Block Cave Mine and analyzed by Rhodamine DT
sensor (Barito, U., and Putra, F., 2012).

Besides that, the water balance is to calculate the water recharge from subsidence surface
rainfall with the water discharge at the EESS and produce the water variance to know the
water infiltration at the cave. The better understanding of water behavior in the cave will
provide appropriate the automatic rainfall alert system (Barito, U., 2012).

WET MUCK MATERIAL FORMING

Three conditions for the wet muck material forming are (1) the material must be fine grain
(grain size < 5cm) with more than 20% grain size > 5cm, (2) the material has to be loose grain
(less than 90% optimum density), and (3) the material must be saturated or near saturated
(80%) (Nicholas et al., 2011). Fine and loose grains come from low RQD rocks in the DOZ
Block Cave Mine reserve such as Forsterite Skarn, Marble, and DOZ Breccia / HALO (see
table 2). In addition, if the height of draw (HOD) of drawpoints also influence fine materials
forming, in line with increasing height of draw (HOD) the rock thought further migration
process inside the cave so as result fine materials will increase depend on rock hardness and
RQD, beside that old mines rocks from the upper of mine reserve (the IOZ Block Cave and
GBT Surface Mines) migrate into the mine, there are Endoskarn (yellow-green Garnet), Black
Amorph Silica (BAS), and Sill Diorite. All of these materials have good the RQD before, but
long distance of rocks migration have resulted changes of grains shape and size to be fine and
loose grains. The distribution of all these rock types is located from the middle to the north
area of extraction level DOZ Block Cave Mine (see figure 2).

The rate of saturation is influenced by the water appearance. High rate of the subsidence
surface rainfall at the top of the EESS area is the main source of the water. We track the water
movement using the EESS water balance data (see table 3). It shows the EESS has water
trappings or aquifers, there are (1) the fracture Diorite with the low RQD characteristic (RQD
 90

< 50%) at south area, (2) the Limestone units at north area, and (3) the water impermeable
zone in the cave.

HAZARD MAP CALCULATION AND VISUALISATION

Hazard map are calculated from wetness, fragmentation (% fine materials < 5cm), % Clay and
Halo, % materials from previous mine (IOZ materials), height of draw (HOD) and number of
days no mucking activity. All this aspect will be encoded to number so we can calculate and
give weighting, it encoded into 0-100 to get fair weighting. The Fragmentation, % Clay and
Halo, and % IOZ materials was recorded as percentage 0-100 whereas wetness recorded as
Wet, Dry or Moist, Height of draw (HOD) are calculated by Cave Management Group
reported as number from 0-more than 500 and number of days no mucking activity are
recorded as number 0-more than 30 days so it will encoded. The highest possibility od hazard
the number will be higher or near to 100.

All encoded parameter we give limit number from low risk and high risk number base on field
experience and study (See Table 4), after we have all parameter and limitation it calculated
and weighted base on study that we do by historical data and wet muck spill event. The result
of canculation will be devided into low, medium and high risk (Risk of Wet Muck Flow), it
combined with the drawpoint condition (Open, temporary closed, closed, planed) and encoded
it, the formula only used for active drawpoint (Open drawpoint), so we can divede to area
active and non active mucking and be more alert to wet muck spill hazard.

This data visualized with Exel and information coordinate position each Drawpoint. Every
aspect can be visualized here so we can see the Quality data and information that make the
Risk condition of drawpoint such as Distribution of Wetness (see figure 3). The Hazard Map
will showing 2D map and information hazard of each drawpoint (see figure 4).

WET MUCK SPILL TRIGGER

The potential triggering mechanisms leading to the mud mobilization has to be investigated.
The

following triggering mechanisms could cause the mud flow is Excessive rainfall, Collapse of
crater wall/subsidence, Collapse of arched material within the muck pile, Irregular draw,
External failures and inrushes (slimes), Seismic event and mass blasting or hydro-fracturing
(Dennis Laubscher 2000), Base on this study we include wetness, days no mucking and
mucking pattern in our Potential Hazard Map for Wet Muck flow. Wetness and days no
mucking activity already include in calculation and we insert mucking pattern to showing
distribution of mucking in drawpoint area. The irregular draw showed by mucking pattern
contour, based on our study we interpreted that margin of high mucking and less mucking was
unstable (see figure 5) and it potentially spill if the drawpoint condition meet the requirements
for wet muck to spill/flow. The Hazard Map for wet muck flow prevention will show in 2D
map combine map from calculation and contour mucking pattern with area that potential
Spill/Flow (see figure 6).
 91

CONCLUSION AND DISCUSSION

The potential hazard map is calculated from weekly data that already collected and manage as
historical data base. The Map will show area that potentially spill or flow, it will help
operation to avoid impacts of the wet muck flow.

Area that potentially wet muck flows are (1) at the northwest, (2) at the middle, and (3) at the
northeast (see figure 7). This area will need special treatment and strategy of mucking to
avoid impacts the wet muck flow.

DOZ Underground Geologists have learned about wet muck material forming in the DOZ
Block Cave Mine, we trying to anticipate with hazard map. Hazard map calculated from wet
muck forming and triggering, but the system still need to improve by adding another factor
like blasting. Sustainable study about wet muck characteristic is very important to increase
our vigilance and resolve problems that will arise tomorrow.

ACKNOWLEDGEMENTS

We wish to thanks the management of PT Freeport Indonesia for permission to publish this
paper, DOZ – Underground Mine Geologists whose support field works observations, Dian
Zilalil Hakim in assisting the development of system and ideas, also other parties (DOZ –
Underground Geotechnical and Hydrology and etc.) for data supporting.

REFERENCES

Laubscher, D., 2000, A Practical Manual On Block Caving, ICS, pp. 80-84, 155, 306.

Sahupala, H., Brannon, C., Annavarapu, S., Osborne, K., 2008, Recovery Of Extraction
Pillars In The Deep Ore Zone (DOZ) Block Cave PT Freeport Indonesia, 5 th International
Conference and Exhibition on Mass Mining, Lulea Sweden, pp. 208-209.

Sugiyanto, A., Hakim, D., Sriyanto, I., Soebari, L., 2011, South Fault, Reactivation Of A
Rehealed Fault In The Deep Ore Zone (DOZ) Mine, Papua, Indonesia, 36th HAGI and
40th IAGI Annual Convention and Exhibition, Makassar, Indonesia, pp. 1-2.

Nicholas, D. E., Standridge, L,. Rachmad, L. I., 2011, Technical Review Of Possible Cause(s)
Of The 18 April 2011 Muck Spill In Panel 2 At PT Freeport Indonesia’s DOZ/ESZ Mine,
6p.

Barito, U., Putra, F., 2012, Internal Report: DOZ Tracer Test Result 2011, Tembagapura,
Papua, Indonesia, pp. 1-6.

Barito, U., 2012, Internal Report: DOZ Water Balance 2011, Tembagapura, Papua, Indonesia,
1p.

Silalahi, P., Wicaksono, D., Sriyanto, I., Soebari, L., De Jong, G.,, 2012, Geological Aspects
For The Wet Muck Material Forming At The Deep Ore Zone (DOZ) Block Cave Mine,
 92

Papua, Indonesia, The 41st IAGI Annual Convention and Exhibition, Yogyakarta,
Indonesia.

Fig.1 – The EESS map (red circle at Papua legend) showing location of GBT Surface, IOZ,
DOZ, and DMLZ Block Cave Mines.

Deposit Footwall (Southwest) → Hangingwall (Northeast)

GBT Monticellite → Calcite - Garnet → Marble

Forsterite → Forsterite - Magnetite → Calcite -

IOZ
Garnet → Marble

Forsterite - Diopside → Forsterite - Magnetite →

DOZ
Magnetite → Marble

Forsterite - Diopside → Forsterite - Magnetite →

DMLZ
Magnetite - Anhydrite → Marble

Tab. 1 – The EESS mineralizations from GBT Surface, IOZ, DOZ, and DMLZ Block Cave
Mines.

Rock Type RQD Q-System

Diorite 80 – 90 20 – 45

Forsterite Skarn 50 – 80 10 – 40

Magnetite Skarn 70 – 80 8 – 40

Forsterite - Magnetite Skarn 50 – 60 8 – 30

DOZ Breccia / HALO 10 – 40 0.1 – 4

Marble 10 – 40 0.1 – 4

Tab. 2 – RQD and Q-system for rock types of the DOZ Block Cave Mine (Sahupala et al.,
2008)
 93

Fig. 2 – DOZ dominant rock types distribution in April 2011

Tab. 3 Subsidence surface rainfall vs EESS water balance in 2011

Fig.3 DOZ wetness condition distribution in April 2011

 94

Tab. 4 The parameter of wet muck hazard weighting and risk boundary.

Fig. 4 The Wet Muck hazard distribution result from calculation will show it low, medium
and high risk of wet muck spill.

Fig. 5 The mucking patern showing by contour.

 95

Fig. 6 The wet muck spill potential showing by red star indicates by combine wetmuck
calculation with mucking patern.

Fig. 7 The wet muck spill potential hazard zones (circle) at DOZ Block Cave Mine.

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