How to set up a new PCBC project

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PCBC has been upgraded to include improved functionality and an easier workflow for better planning and scheduling of Block Cave mines.

Today’s article outlines the keys steps required in setting up a new PCBC project in GEMS v6.8.3 onwards.

This is a summarized set of notes to provide guidance around key inputs and general setup for a PCBC project. It should not be used as a substitute for proper user training.

The following sections are covered.

  • PCBC project setup
  • Basic block model requirements
  • Footprint Finder
  • Creating a Draw Point layout and Draw Cone geometry
  • Generating Slice Files
  • Calculating the Best Height of Draw
  • Sequencing and Scheduling

 

Summary of PCBC workflow:

 

STEP 1: Setting up a PCBC Project

    1. Create PCBC Block Caving Workspaces (Workspaces->Create or Modify Workspace)
    2. Create a SETUP Advanced Profile (PCBC->Projects->Advanced Profiles-> SETUP)
    3. Create a Grade elements list profile (PCBC->Projects->Advanced Profiles->GRADE0)
    4. Create a Economic profile (PCBC->Projects->Advanced Profiles->ECO0)
    5. Save Caving Area (Right click on Caving Area -> Save)
    6. Create Rock codes (Format->Other Profiles->Rock Codes)
    7. Create General Display Profiles (Block attributes, Tunnels, Lines etc.) (Format->…)
    8. Create Plan Views to represent the levels (View->Vertical Section)
    9. Create Vertical sections (View->Plan View)

 

STEP 2: Setting up the block model

    1. Check the Density attributes ( all blocks should have a density value except Air blocks)
    2. Percent attribute should be set to 100%
    3. Check the Grade attributes
    4. Create other block attributes if needed (Footprint Finder, Ore, Dilution, NSR)
    5. Calculate Net Smelter Return (NSR) block attribute (optional)
    6. Check the Rock types attribute

 

STEP 3: Footprint Finder – Determines elevation and footprint shape

1. Create and setup a Footprint finder caving area (Right click on Caving Area -> New Area)

2. Update NSR block model attribute using simple manipulation script (Block > Edit > Simple manipulation). If no NSR model available then use the ECO0 profile and calculate economic/dollar model (PCBC->Applications->Footprint Finder->Update Economic/Dollar Model).

3. Create and save clipping polygon around area of interest ( Edit -> Clip -> Create Clipping Boundary; Edit -> Clip -> Save Clipping Boundary)

4. Create and fill out FF2 Advanced Profile (PCBC->Projects->Advanced Profiles->FF2)

      1. Enter assumptions for FF parameters (i.e. vertical mining rate, draw point cost per area, production targets, etc.)

5. Run Footprint finder (PCBC->Applications->Footprint Finder-> Run Footprint Finder with Specified Surface)

6 Set-up for a Mini-Schedule

      1. Initialize SECTORS attribute in block model ( Right click on attribute -> Initialize)
      2. Create shape profile (PCBC->Projects->XY Curves)
      3. Set-up sequence sheet (sequence.xlsx) in Footprint Finder excel file

7. Run Footprint finder (PCBC->Applications->Footprint Finder-> Run Footprint Finder with Specified Surface)

8. Change name of excel file in FF2 advanced profile each time Footprint Finder is run so that excel file results does not get overwritten.

 

 

STEP 4: Draw Points Generation – Determines draw point locations

a. Option 1: Layout Generation Tool

  1. Create clipping polygon for layout (Edit -> Clip -> Create Clipping Boundary; Edit -> Clip -> Save Clipping Boundary). Usually determined from footprint finder results.
  2. Create and fill out LAY advanced profile and enter design criteria (PCBC->Projects->Advanced Profiles->LAY)
  3. Update the properties of the draw points. Select draw points and edit selected draw points (PCBC->Select Draw Points->Select All; PCBC->Select Draw Points-> Edit Selected Draw Points)
  4. Save caving area (Right click on Caving Area -> Save)

 

b. Option 2: Import the Draw Points from Excel

  1. Setup the Excel file to have the below header row, update the columns with draw point information. The columns highlighted in yellow are the minimum requirements, the orange column needs to be a unique value and the green columns are placeholders for the cone shape, production rate curve and draw point status.

 

 

2. Import the Draw Points (PCBC -> Draw Points -> Import Draw Points from Excel)

3. Update the properties of the draw points. Select draw points and edit selected draw points (PCBC->Select Draw Points->Select All; PCBC->Select Draw Points-> Edit Selected Draw Points)

4. Save caving area (Right click on Caving Area -> Save)

 

 

STEP 5: Define Draw Cone Geometry

  1. Create Draw Cone Profile (PCBC> Project >XY Curves)

 

 

2. Applying Draw Cone Type profile to the draw points. Select draw points and edit selected draw points (PCBC->Select Draw Points->Select All; PCBC->Select Draw Points-> Edit Selected Draw Points)

3. Save Caving Area (Right click on Caving Area -> Save)

 

 

STEP 6: Create Slice File – Transfer block model information to the draw points

  1. Create and fill out the SF Advanced Profile (PCBC->Projects->Advanced Profiles-> SF)
  2. Switch off the MIX_SLICEFILE keyword so that a NOMIX Slice File is created first.
  3. Build slice file (PCBC->Slice File->Build Slice File)
  4. Save the NOMIX slice file (PCBC->Slice File->Slice File Utilities -> Current to Save)
  5. Switch on the MIX_SLICEFILE keyword the SF Advanced Profile so that a VMIX Slice File is created next.
  6. Create and fill out the VMIX Advanced Profile (PCBC->Projects->Advanced Profiles-> VMIX)
  7. Build slice file (PCBC->Slice File->Build Slice File)
  8. Save the slice file (PCBC->Slice File->Slice File Utilities -> Current to Save)
  9. Save Caving Area (Right click on Caving Area -> Save)

Note:

  • A new slice file needs to be created when the either of the following are changed, the block model, draw point layout, draw cone shape or grade list.
  • Template Mixing uses a NOMIX Slice File and Vertical Mixing uses a VMIX Slice File.

 

 

STEP 7: Run Best Height of Draw (BHOD) Tool – Determine minable reserves

  1. Check if the BestHOD multi-field bucket workspace is existing in the project. Results are saved to this workspace (Workspaces->Create or Modify Workspace)
  2. Create and fill out the BHOD Advanced Profile (PCBC->Projects->Advanced Profiles-> BHOD)
  3. Run BHOD (PCBC->Planning and Scheduling ->Best HOD)
  4. Register BHOD buckets using button on BHOD tab
  5. Display results from buckets (Display Tab -> Display profile)
  6. Save caving area (Right click on Caving Area -> Save)

 

 

STEP 8: Create Mining Sequence – Determines direction of mining

Option 1: Generate Sequence by using a XY curve.

  1. Create XY Curves for face shape (PCBC->Projects->XY Curves)

 

 

2. Set up Sectors, Group, or Production Block in draw points. Select draw points and edit selected draw points (PCBC->Select Draw Points->Select All; PCBC->Select Draw Points->Edit Selected Draw Points)

3. Save Caving Area (Right click on Caving Area -> Save)

4. Set up the xlsx file. In the Input sheet match up the sector name, xy curve shape, azimuth and x,y start point. Use the Periods to dictate how many draw points to open in each period.

 

 

5. Generate mining sequence. (PCBC->Planning and Scheduling-> Sequencing -> Generate Sequence using XY Curves)

6. Register the sequence bucket (PCBC-> Buckets-> Register Bucket Data)

 

 

Option B: Generate Sequence by Production Block

1. Create a line to represent mining sequence (Polyline->Create->Contour Line). Note: Digitize line from left to right in the direction of mining.

2. Export line to ascii format. (File->Export->Selected Lines->ASCII File)  Note: No other lines should be opened while exporting.

3. Set up Sectors, Group, or Production Block in draw points. Select draw points and edit selected draw points (PCBC->Select Draw Points->Select All; PCBC->Select Draw Points->Edit Selected Draw Points)

4. Save Caving Area (Right click on Caving Area -> Save)

5. Set up sequence.xlsx file. In Input sheet fill out information below:

 

 

6. Generate mining sequence. (PCBC->Planning and Scheduling-> Sequencing -> Generate Sequence by Production Block)

 

 

STEP 9: Run Production Schedule

  1. Create a Production Rate Curve (PRC) profile (PCBC->Project->XY Curves).

 

 

Note: Y-axis of graph is in units of t/m2/day or t/ft2/day and X-axis of graph is in units of %Extraction.

 

2. Assign PRC profile to the draw points. Select all draw points and EDIT selected draw points (PCBC->Select Draw Points->Select All; PCBC->Select Draw Points->Edit Selected Draw Points).

3. Save Caving Area (Right click on Caving Area -> Save)

4. Create a prodtons.xlsx excel file and set up the INPUT and TABLE sheet. Below is an example of the Input and Table sheet:

 

 

5. Run Production Schedule. (PCBC->->Planning and Scheduling->Run Production Scheduler)

 

More Information:

For more information on PCBC introductory and advanced training courses, contact your local GEOVIA office.

To upgrade your software and take advantage of the new PCBC functionality, download GEMS 6.8.3.1 from the GEOVIA Support Forum.

 

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Thirusha Pillay

Knowledge Consultant GEOVIA at Dassault Systèmes
Thirusha is a qualified Geologist with over 7 years' experience. She specializes in project assistance, system audits and software training. Her areas of expertise are in GEOVIA GEMS and Surpac. She is based in Johannesburg, South Africa.