Newcrest Mining will install a large-scale Cave Tracker System at its Cadia East mine in New South Wales.

Developed and manufactured by Brisbane-based Elexon Mining, the Cave Tracker System was conceived in collaboration with Newcrest, CRC Mining and Rio Tinto. Newcrest hosted the earliest trials of the prototype system at its Ridgeway Deeps mine.

Elexon Mining Product Manager Simon Steffen said, “The Cave Tracker System is a big step forward for the mining industry. It will enable mining companies to improve their capabilities to successfully ramp-up and operate cave mines, maximising safety and economic outcomes.”

“Newcrest’s order is another step forward for Elexon, proving that a collaborative approach to product development delivers innovative and value-adding solutions. Elexon is expecting that the world leaders in caving, Rio Tinto and Newcrest, will lead the way to higher performing cave projects through embracing innovative products such as Cave Tracker.”

Cave Tracker provides a real-time insight into cave flow and cave propagation. This insight closes a feedback loop that was not previously available. Cave Tracker greatly enhances a mine operator’s ability to proactively manage risks of cave mine projects.

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Dylan Whiteman and Simon Steffen with a crate load of Cave Tracker beacons destined for Newcrest’s Cadia East mine.

Some of the Elexon Mining team: John Ruys, Jared Millane, Dylan Whiteman, Simon Steffen

Cave Tracker system being activated

About the Cave Tracker System
The Cave Tracker System enables mines to more accurately determine the extent of the cave and track ore flow. Through the data gathered with the Cave Tracker System, the Mine Management team are able to make better decisions to protect the mine asset and keep it working as it should; safely and efficiently. The system operates through a series of beacons that are embedded in the mine, which can be tracked in 3D as they move with the fragmented rock of the ore-body. The data generated from Cave Tracker allows the Mining and Geotechnical Engineers to determine which parts of the cave are moving and which parts are not, and make proactive changes accordingly. The rate and direction of movement can also be established. Read more HERE.

About Elexon Mining
Elexon Mining is a Brisbane-based technology company that develops innovative geotechnical monitoring systems for underground and open pit mines. Elexon Mining’s products enable mines to better manage geotechnical risks that can impact safety and productivity in mining operations through enhanced understanding of ground movement.
Elexon Mining is a division of Elexon Electronics.
Website: www.elexonmining.com

About Newcrest Mining
Newcrest is one of the world’s largest gold mining companies and operates mines in four countries.

Newcrest’s mission is to deliver superior returns from finding, developing and operating gold/copper mines. Our vision is to be the Miner of Choice™.

We will lead the way in safe, responsible, efficient and profitable mining.

Website: www.newcrest.com.au

About CRC Mining
CRC Mining is an industry-driven, global leader in mining research and innovation. We develop and deliver breakthrough innovation and technologies that transform the productivity, sustainability and safety of the mining industry. CRC Mining partners with universities and mining companies to collectively drive innovative development. These developments involve new and modified mining methods and processes, new mining technology and equipment. We accelerate commercial outcomes from research, and ensure they are available to the industry as rapidly and effectively as possible.

Note: from October 2016 CRC Mining announced a new operating name and structure – Mining3.

Website: www.mining3.com

Ernest Henry Mining in north-west Queensland has transitioned from an open pit to an underground sub-level caving operation late last year, with Xstrata utilising Elexon’s Smart Marker technology to maximise ore recovery, while reducing dilution.

The Smart Marker system is a blast resistant, long-life radio frequency identification (RFID) device, which has the ability to measure ore flow electronically, in particular in sub-level and block caving operations.

Xstrata Senior Strategic Planning Engineer Alex Campbell’s role involves overseeing the caving and geotechnical aspects of the cave start-up and the transition to underground mining at the copper, gold and magnetite mining operation. “We recently started using the technology as of last week [end of November], and have installed the Smart Markers within the crown pillar between the underground and open pit operation,” he says.

The blasted ore material within the crown pillar forms an ore blanket above the sub-level cave. The purpose for installing Smart Marker system in this region is to track the flow of ore and to identify areas of potential dilution. The data from the Smart Makers can then be used to adjust the mine’s draw strategy to maximise ore recovery, while minimising dilution and ultimately improving the company’s financial return.

A second Smart Marker system will be used at the mine in 2013, to assist in characterising the flow properties of the sub-level cave blast rings, Campbell says. “The main things we are trying to focus on include, characterising width and depth of draw, as well as primary, secondary and tertiary flow behaviours over multiple levels.” The system will also assist to determine drill and blast performance including the back break and apex recovery, which has an impact on overall cave flow.

Xstrata has invested $A589 million to extend the life of its Ernest Henry operations by at least 12-years. The Smart Marker system allows the team at Xstrata to better understand what is happening inside the sub-level cave. Campbell says, like all caving operations the goal is to maximise ore grade and recovery, while minimising dilution within the geotechnical constraints of the operation.

At the moment, Xstrata are trucking ore from the underground mine via a decline at a rate of about three million tonnes per annum. This is expected to ramp-up to 6Mtpa once the hoisting shaft is commissioned in late 2013. The technology is currently being used at mine sites around the world. In Australia the technology is being used at Newcrest Mining’s Cadia East operations, as well as at Rio Tinto’s Northparkes operation in New South Wales, to name a few.

Meanwhile, Campbell says Elexon’s reputation in Australia, is one of the reasons Xstrata engaged the mass mining technology specialist. “The company’s technology is easy to use and track, plus the process involved with collecting the data is quite simple,” he says.

Elexon is also involved in the Mass Mining Technology research group, which is headed up by mining engineer and Professor at the University of Queensland Gideon Chitombo. “Having individuals with their expertise based in Australia is very helpful when it comes to customer service, and getting people out on site to assist with the installation and use of the technology,” Campbell concludes.