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Thermal Fragmentation – An Innovative Process for Mining

Narrow High-Grade Precious Metal Veins
D Brisebois1

ABSTRACT fragments 0 - 13 mm in size. The leftover rock between

fragmented holes is broken loose using soft explosives and a
The mining of high-grade narrow vein deposits is a predominant field of
activity in the precious metal sector. These types of deposits are located
narrow mining corridor with widths of 30 cm to 1 m is thus
throughout the globe and have a significant presence in mining extracted. Since the waste walls are left intact, the dilution factor
operations. The principle factor that has undermined the profitability and and the inefficiencies associated with traditional mining methods
effectiveness of mining such ore zones is the substantial dilution that are greatly reduced.
occurs when blasting with explosives during extraction.
In order to minimise ore dilution, the thermal fragmentation mining LEVEL
L EVEL 45
method enables the operator to extract a narrow mineralised corridor,
30 cm to 1 m wide (according to the true width of the ore vein). By
inserting a strong burner powered by diesel fuel and air into a pilot hole
previously drilled directly into the vein, a thermal reaction occurs spalling

gra de

grade
Low grade

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the rock and enlarging the hole to 30 - 100 cm in diameter. This patented

Low gra
method produces highly concentrated ore, resulting in 400 - 500 per cent

Low

Low
less dilution when compared to conventional mining methods. The
mining method was conceived with the aim of mining ounces, not tonnes.
This method of extraction, reduces the environmental impact of mining
operations since much smaller quantities of rock are displaced,
stockpiled, and treated using chemical agents. The fully mechanised L EVEL 70
LEVEL
equipment operated by a two-person team, maximises the effectiveness of
skilled personnel, increases productivity, and reduces risks of injuries.
Important economic benefits are generated for large- and small-scale
mining operations alike. For large-scale operations, the mining method
increases mining reserves, lowers the cost per ounce, and increases the
total profitability of existing mine operations. The method also
significantly lowers costs and risks of developing and mining small-scale
deposits, requiring less investment capital, shortening the payback period,
thus reducing the lending risk. Combined with a small modular
processing unit able to process between 100 - 300 tons per day, the
method substantially lowers the financial break-even point for small-scale
mining operations in a narrow vein environment.
The company has been working with the technology at its Rocmec 1
mining site; results achieved and future developments are discussed.

INTRODUCTION
The mining of high-grade narrow vein deposits is a predominant
field of activity in the precious metal sector. These types of
deposits are located throughout the globe and have a significant
presence in mining operations. The principle factor that has
undermined the profitability and effectiveness of mining such ore
zones is the substantial dilution that occurs when blasting with
explosives during extraction. There is a clear need to develop
mining techniques that minimise ore dilution and development
costs in order to make the mining of high-grade narrow vein ore
deposits more profitable. The thermal fragmentation mining
method has been conceived to mine a narrow mineralised
corridor in a productive and cost efficient manner in order to
solve this particular challenge. The following describes this
mining method in depth and outlines its successes in improving
the extraction process of such orebodies.
THERMAL FRAGMENTATION MINING METHOD
A strong burner powered by diesel fuel, is inserted into a six inch
pilot hole drilled into the vein using a conventional longhole
drill. The burner spalls the rock, quickly increasing the diameter
of the hole to 30 - 100 cm (Figure 5) and producing rock
1. President and CEO, Rocmec Mining, 1 Holiday Avenue, Suite 501,
Tour Est, Pointe-Claire QC H9R 5N3, Canada.
Email: dbrisebois@rocmecmines.com
FIG 1 - The method.
The burner
The burner powered by diesel fuel and compressed air, creates a
thermal cushion of hot air in the pilot hole which produces a
thermal stress when coming in contact with the rock (Figure 2). A
spalling effect occurs (Calaman and Rolseth, 1968), and the rock
is scaled off the hole walls and broken loose by the compressed
air. This technology has been used for over 40 years in large-scale
open pit operations for the enlargement of blastholes.
The fragmented rock
The process of fragmenting the rock is optimal in hard, dense
rock. The spalling process produces rock fragments 0 - 13 mm in
size. Figure 3 illustrates the difference in size of the fragmented
ore in comparison to ore that has been extracted using
conventional blasting methods. The finely fragmented ore
requires no crushing before entering the milling circuit and can
be more efficiently transported since it consumes less space than
ore in larger pieces.

Narrow Vein Mining Conference Ballarat, Vic, 14 - 15 October 2008 123

D BRISEBOIS
FIG 2 - The burner.
Conventional Thermal
Ore Fragmentation
FIG 3 - The fragmented rock.
Drift development and stope layout
Drift development is performed directly into the ore at intervals
of 15 to 20 metres in accordance with the geology of the
orebody. Using a re-suing method, the ore is blasted and
recovered in the first cut then the waste is blasted and hauled
away in the second cut.
Following the creation of two sublevel drifts, a pilot hole is
drilled between the two levels and enlarged by way of thermal
fragmentation. The mining layout is applicable for low dip veins,
as the unit also operates horizontally (drilling flat).
The unit is designed to operate in a compact underground
environment in a drift or sublevel as small as 1.5 m wide by
2.5 m high (Figure 4). The unit designed and manufactured by
the Kubota and its approximate dimensions are 125 cm wide,
275 cm long and 165 cm high.
Ore extraction – selective and continuous
The thermal fragmentation mining method allows for selective
ore extraction; high-grade sections can be prioritised and
extracted first. The method extracts a narrow corridor (30 cm to
1 m wide) leaving waste walls on each side of the mineralised
zone intact and minimising the damage caused to the drift
structure. The area mined can be easily rehabilitated using cables
and panels to cover the narrow opening in the hanging wall of the
undercut drift. Mine residue is then used to fill the extracted zone
and a cement floor is laid, if needed, on the footwall of the
overcut drift to permit future access. Using this method, the
stability of the rock is maintained and access to the orebody is
never compromised.
124 Ballarat, Vic, 14 - 15 October 2008
FIG 4 - Stope layout.
FIG 5 - Fragmented hole.
Furthermore, thermal fragmentation is a continuous mining
method; it uses no explosives and is operated in a continuous
chain, with one person first drilling a pilot hole, followed by a
second who enlarges it by way of thermal fragmentation.
Mining ounces not tonnes
The method produces highly concentrated ore, resulting in
400 - 500 per cent less dilution when compared to conventional
mining methods. Table 1 compares the quantity of rock extracted
when mining a 50 cm wide vein using the thermal fragmentation
mining method as opposed to a shrinkage mining method.
Table 1 shows that approximately four times less rock needs to
be mined for the equivalent mineralised content. This method of
extraction allows mine operators to solely extract mineralised
zones thus significantly reducing dilution factors and as a result,
optimising mine operations.
REDUCING ENVIRONMENTAL IMPACT
There is a growing need to develop sustainable mining methods
that minimise the environmental footprint left behind by mining
operations. In all corners of the world, local populations have
expressed their concerns about mine operations being established
in their region, as awareness about the negative impact of
industrial activities has spread.
Narrow Vein Mining Conference
 THERMAL FRAGMENTATION – AN INNOVATIVE PROCESS FOR MINING NARROW HIGH-GRADE PRECIOUS METAL VEINS

TABLE 1 TABLE 2
Tonnage calculation; comparing thermal fragmentation and Productivity (one thermal fragmentation unit); comparing thermal
shrinkage. fragmentation and shrinkage methods.
Tonnage calculation of a Thermal Shrinkage Tonnage calculation of a Thermal Shrinkage
40 m by 20 m ore block fragmentation method 40 m by 20 m ore block fragmentation method
Width in situ (m) 0.5 0.5 Width in situ (m) 0.5 0.5
Mining width (m) – final result 0.5 1.8 Mining width (m) – final result 0.5 1.8
Planned dilution 0% 260% Planned dilution 0% 260%
Height (m) 20 20 Height (m) 20 20
Length (m) 40 40 Length (m) 40 40
Density 2.8 2.8 Density 2.8 2.8
Total volume (t) 1120 4032 Total volume (t) 1120 4032
Number of workers 2 2
While developing the thermal fragmentation mining method, Productivity per 12 hour shift (t) 30 30
important efforts were made to address and reduce the Tonnes extracted per 24 hours 60 120
environmental effects mine operations have on the surrounding
Days needed to extract ore block 18.7 33.6
areas. Using the method, mine development is performed directly
into ore resulting in less waste rock being extracted and
displaced into large piles at the surface. By solely extracting the Table 2 demonstrates that for the equivalent amount of mineral
mineralised zone, only the necessary excavations are made. As content, it takes approximately half the time to mine the ore zone
shown in Table 1, four times less rock needs to be mined for the using the thermal fragmentation mining method than when using
equivalent mineral content. a shrinkage mining method. Furthermore, since less rock needs
As a result of less rock being mined, fewer tonnes need to be to be mucked, and hauled from the stope, fewer personnel are
processed at the mill to extract the precious metals. The quantity needed for handling the ore. In total, we estimate that to extract
of chemical agents needed in the process is greatly reduced. an equivalent amount of precious metal ounces, the method
Furthermore, the quantity of energy needed to process the ore is reduces the personnel needed for mine operations by 30 - 50 per
also greatly diminished since less rock is sent to the mill. The cent when compared to conventional mine operations.
reduced quantity of energy for hauling and processing the ore
results in fewer greenhouse gases being emitted. The mining Mechanisation and employee safety
residue that remains once the precious metal contents are removed
Each unit is completely mechanised, reducing the risk of injuries
is four times less abundant, using the example above, meaning
and strain caused by manual manipulation of heavy equipment.
much smaller tailing areas need to be constructed, maintained, and
The operator stands at a safe distance from the mining stope,
rehabilitated once mining operations have ceased. The space
virtually eliminating the risk of flying debris and falling loose
needed to host the mine site is greatly reduced, the alterations to
rock from the waste walls. Furthermore, unlike shrinkage mining
the landscape are significantly diminished, and the result is a
methods, smaller excavations are made (0.5 m compared to 2 m)
cleaner and more responsible approach to mine operations.
so the occurrence of falling loose rock is greatly diminished.
The company is moving forth with an environmentally Each unit is equipped with sensors capable of identify the
responsible approach at its Rocmec 1 mine site. A small presence of seven harmful gases (such as carbon monoxide,
processing mill (75 t/d) will be installed in an underground sulfides, etc), important safety measures when mining in an
section of the mine, using a gravity and flotation circuit, no underground environment. When designing the equipment,
chemical agents will be used to treat the ore. The mining residue feedback from members throughout the organisation was
created will remain underground and will be returned to the gathered, and the final result is a tool that is well adapted to the
stope, thus eliminating the need for tailings at the surface. Such needs of those who operate the machinery and leads to a safe and
innovations are made possible by drastically reducing dilution comfortable work environment.
through the use of the thermal fragmentation mining method.
ECONOMIC BENEFITS FOR EXISTING MINE
MAXIMISING EFFECTIVENESS OF SKILLED OPERATORS
PERSONNEL
By rendering a greater number of narrow mineralised zones
Given the current shortage of skilled personnel in the mining economical to extract, the mining method has the potential to
community, it is essential to find ways to increase productivity convert a substantial portion of the mineral resources of an
per worker while improving working conditions in order to operating company into mineral reserves. A large number of
attract and retain skilled miners. It is with this thought in mind mines currently in operation today contain narrow, precious
that the thermal fragmentation mining method was conceived metal veins throughout the orebody, but unless these veins are of
and developed and with which we will continue to refine the significant width (usually 1 m or greater) or very high grade they
equipment. are often overlooked. As the mine operator develops the zones to
be extracted, high-grade, narrow orebodies are often uncovered,
Productivity but not extracted since it is uneconomical to mine such orebodies
using conventional mining methods (shrinkage, long hole, room
The work group required to operate one thermal fragmentation and pillar, etc). Table 3 demonstrates the cost savings per ounce
unit consists of a two person team (one thermal fragmentation of using the thermal fragmentation mining method in comparison
operator, one drilling operator). Table 2 shows the time needed to to the long hole method. The study was done by Canadian
extract an ore block using the thermal fragmentation mining Institute of Mining using 2001 exchange rate figures (Poirier
method in comparison to using a shrinkage mining method. et al, 2003).

Narrow Vein Mining Conference Ballarat, Vic, 14 - 15 October 2008 125

D BRISEBOIS

Table 3 shows, it is approximately 45 per cent less costly to
mine a narrow vein orebody using the thermal fragmentation
mining method that using a conventional mining method. Overall
profitability of mine operations is increased since more precious
metals can be economically mined for the same level of
development expenditures.
SMALL-SCALE MINE OPERATIONS
(LESS THAN 300 T/D)
Small-scale producers have a tightly limited milling capacity to
process mineral ore and require high-grade mineral content to
cover expenses. Since there is little extra capacity to process
low-grade ore, reducing dilution when extracting narrow vein
orebodies is critical for the profitability of the project. The
thermal fragmentation mining method offers the possibility of
dramatically increasing the productivity of such small-scale
mining operations. As shown in Table 1, the ratio of tons
extracted for an equivalent in mineral content is approximately
4:1, meaning that for the same mineral content, nearly four
tonnes need to be extracted to produce the equivalent of one
tonne using thermal fragmentation. Hence, a 200 t/d operation
using thermal fragmentation has the capacity to produce as much
precious metals content as an 800 t/d operation using
conventional mining methods.
Project financing
This increase in productivity has important implications for
project financing. The low capital requirements needed to start a
project that utilises the thermal fragmentation mining method,
when compared to traditional mining operations, means less
money is at risk for an equivalent potential benefit (smaller mill,
less development costs). This also results in a shorter payback
period and a lower lending risk. The substantial start-up costs for
mining operations as well as the scarcity of capital available in
the marketplace have always been important barriers for the
mining industry. By introducing a technology that aims to lower
the financial barrier and increase the profitability of mining
start-ups, the goal is to bring a greater number of high-grade
precious metal orebodies into production in a financially,
sustainable manner and with a lower investment risk.

TABLE 3
Estimate cost comparison between underground thermal fragmentation and longhole.

Tonnage calculated on the basis of a 60 m by 60 m reserve block Thermal drilling 3024 t Long-hole drilling 3024 t
Grade in situ (g/t) 35.00 35.00
Width in situ (cm) 30 30
Minimum width (cm) 30 140
Planned dilution 0% 367%
Geological reserves 3024 14 112
Reserve grade (g/t) 35.00 7.50
Mining
Wall dilution 5% 35%
Stope recovery 79% 90%
Ore development 544 2540
Planned mining reserve 1961 14 606
Grade (g/t) 33.25 4.88
Mill recovery 96% 96%
Produced ounces 2013 2198

Thermal drilling Long-hole drilling

Unit cost $/M Total cost $/M Unit cost $/M Total cost $/M
Development
Drifts 1000.00 180 000.00 1000.00 180 000.00
Subdrifts 1000.00 120 000.00 1000.00 120 000.00
Raises 1000.00 60 000.00 1000.00 120 000.00
Drawpoint 1000.00 1000.00 60 000.00
Mining cost ($/t) 113.50 222 600.00 19.00 277 516.00
Mucking 8.00 15 690.00 4.00 58 424.00
Transportation 12.00 23 535.00 6.00 87 636.00
Milling 16.00 31 380.00 20.00 292 122.00
Environmment 2.00 3922.00 2.00 29 212.00
Backfilling 5.00 73 030.00
Total 657 127.00 1 297 940.00
$ per tonne 335.06 88.86
$ per ounce 326.49 590.59
US$ per ounce 0.65 212.22 383.88

126 Ballarat, Vic, 14 - 15 October 2008 Narrow Vein Mining Conference

 THERMAL FRAGMENTATION – AN INNOVATIVE PROCESS FOR MINING NARROW HIGH-GRADE PRECIOUS METAL VEINS
THE TECHNOLOGY AT WORK – ROCMEC 1 MINE
In 2005, Rocmec Mining purchased the Russian Kid
underground mine located near Rouyn-Noranda in Abitibi,
Quebec (renamed Rocmec 1), to showcase its unique patented
thermal fragmentation mining method and use the technology to
verify the grades contained within the mineralised structures in
the most cost efficient manner. Since late 2006, a 44 000 tonne
bulk sampling program is underway at the Rocmec 1 mining site,
and several thousand tons of ore have been extracted by way of
Thermal Fragmentation in high-grade narrow vein zones.
Development work or drifting was completed on two
superimposed levels (110 and 130 m) and the mineralised
structure between these levels was extracted by way of thermal
fragmentation. The company has analysed the performance data
and is quite pleased with the results. A mining corridor was
extracted with precision, minimising dilution of the mineralised
zone. As a result, important cost savings as well as impressive
productivity gains were realised.
In addition, a number of mine site visits have taken place and
industry participants have demonstrated an important interest
towards the new mining method. Discussions with mining
producers are ongoing and negotiations to introduce this new
mining method within their mining sites are underway. These
discussions were undertaken with the purpose of offering
services to mining companies currently in production and extract
ore using the thermal fragmentation mining technology in their
existing operations.
Through exploration efforts the company has newly uncovered
promising ore structures and future developments at the Rocmec
1 mine include further underground drilling to define the gold
Narrow Vein Mining Conference Ballarat, Vic, 14 - 15 October 2008
bearing potential of the property. The company is installing a
small-scale processing mill to process the ore on site and bring
mine operations to full-scale production using the thermal
fragmentation mining method.
CONCLUSION
Many variations and adjustments have been made to
conventional methods of mining narrow precious metal veins, but
the serious shortfalls brought upon by dilution remain. The
thermal fragmentation mining method is a new and innovative
way of mining narrow vein orebodies and a foremost solution to
solving the problem of ore dilution. It uses a unique tool, a
powerful burner, to mine with precision, a narrow mineralised
corridor in an effective and productive manner. The technology is
positioned to meet the growing challenges of skilled labour
shortages, tougher environmental guidelines, and the depletion of
traditional large-scale ore deposits mined using conventional
methods. As the technology continues to develop and spread
through the mining community, the objective remains to optimise
the productivity and profitability of mining narrow high-grade
precious metal orebodies and to make a substantial, lasting
contribution to this sector of activity.
REFERENCES
Calaman, J J and Rolseth, H C, 1968. Surface Mining, first edition,
Chapter 6.4, pp 325-337 (Society for Mining, Metallurgy and
Exploration Inc: Littleton).
Poirier, S, Fecteau, J M, Laflamme, M and Brisebois, D, 2003. Thermal
rock fragmentation – Applications in narrow-vein extraction, CIM
Bulletin, 96(1071):66-71.
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