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1. PIT SHELL

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2. DRILLHOLES

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3. OREBODY

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4. BLOCK MODEL

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5. GRADE CONTROL

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Efficiency in mining is the optimum separation of ore from waste rock without dilution, and its inclusion in the production cycle in its purest form. It is essential that the ore body identified through exploration is monitored in detail during production and its geological continuity is regularly tracked.

The Generalized Grade Control Cycle, which maximizes efficiency, consists of the following stages:

• Continuous Mapping and Archiving: Up-to-date mapping of ore position and geological boundaries as production advances, and recording them digitally.
• Systematic Sampling: Sampling of the mineralization in-situ with the most accurate methods based on current mapping data.
• Rapid Data Evaluation and Planning: Optimizing the excavation or drill-and-blast direction by evaluating assay results and geological data without interrupting production.
• Execution and Reconciliation: Comparing planned versus actual production; identifying deviations and executing detailed excavation or corrective actions.
• Grade and Tonnage Determination: Precise calculation of the average grade value and total tonnage of the excavated material.
• Stockpile Management: Dumping the hauled ore into appropriate stockpile areas (feed, intermediate, or low-grade stockpiles) according to grade groups and keeping the inventory up to date.
• Blending and Haulage: Blending ores of different grades at specified ratios to meet the target quality required by the plant, either for plant feed or direct sales.
• Mine-to-Mill Reconciliation: Comparing plant feed data with stockpile data; controlling the stockpile input-output balance and production efficiency.
• Forward-Looking Drilling Planning: Conducting in-pit drilling parallel to the production plan to forecast the next bench or phase.
• Metallurgical Forecasting: Proactively identifying potential issues within the ore (impurities, alteration, etc.) that could reduce plant recovery and developing solutions.
• Geotechnical and Structural Monitoring: Forecasting structural problems (faults, joints, etc.) for pit safety and production continuity, and implementing early prevention mechanisms.

In this entire grade control cycle, the Mine Geology Department, acting as a bridge between operational units, manages these processes to ensure the most efficient, sustainable, and error-free production.

You can find information and answers in our recent articles listed below.

Grade control in open pit mining is an inspection mechanism that directly impacts mine economics and is active at every moment of the production process. The cornerstones of the process are:

• Delineation of Boundaries: Using geological data and assay results, the boundaries between ore and waste are accurately marked in the field. This clarifies for equipment operators exactly where to stop and where to load the material.
• Prevention of Dilution: Mixing of ore with waste rock or accidental routing of valuable material to the waste dump during excavation is prevented. This maximizes the profit obtained per unit tonnage.
• Feed Stabilization: There is a specific quality standard required for the efficient operation of the plant or crushing-screening unit. Grade control prevents the plant from encountering surprises by blending material from different locations.
• Data and Model Updating: As production progresses, samples taken from the field feed the general geological model. This continuous flow of information reduces uncertainty about what to expect in the next excavation bench and prevents planning errors.
• Operational Bridge: Through this cycle, mine geologists establish a technical link between the planning department and the production team. Consequently, the underground resource is brought into the economy with minimum loss and maximum purity.

Grade control in underground mining is a highly sensitive process carried out in much narrower spaces and more complex geological structures compared to open pits. The basic functioning of this process consists of the following items:

• Face and Vein Tracking: As advancement is made in underground drifts, new surfaces (faces) exposed after each blast are geologically mapped. The strike, dip, and thickness of the ore vein are instantly tracked to guide the excavation direction.
• Systematic Sampling: The true value of the ore at that point is measured using samples taken from drift backs, sidewalls, or production faces. This data is used to define the economic boundaries of the production stopes.
• Dilution Control: In narrow vein mining, the amount of waste rock excavated along with the ore is strictly controlled. Since space is limited underground, the mixing of waste into the ore affects haulage costs and plant recovery much more negatively than in open pits.
• In-Production Core Drilling: With short-hole drilling conducted from existing drifts toward the sides or upper-lower levels, the continuity of the vein and potential structural interruptions (such as faults) are detected in advance.
• Precise Stockpile and Haulage Management: Materials of different grades extracted from underground must be managed without mixing them in confined areas. It is ensured that the ore is directed to the correct silos or stockpile areas during the hoisting process to the surface.
• Refining the Geological Model: Instant data from the field is incorporated into 3D block models. This allows the mine planning team to make decisions with higher confidence regarding the tonnage and quality of the next block to be mined.

During ore and waste excavation, you have reached many new and reliable data sets that you could not obtain from surface drilling, which naturally present new opportunities. It is possible to test these with shorter drill holes planned from your current depth. By testing specific levels, as well as the lateral and vertical extensions of your ore body from both underground and surface with new drilling, you must ensure sustainability. While this process continues, structural elements in your pit (faults, fractures, shear zones, boudinage, etc.) affect your production and your ability to meet your commitments on time.

These faults and other similar adverse geological elements have the potential to jeopardize your operation in the future. If they were overlooked in the past and not included in the plan, geotechnical problems may knock on your door unexpectedly in the future.

Efficiency in mining is the optimal separation of ore from waste rock and bringing it into the economy with minimum dilution. The sustainability of technical success depends on a procedure-oriented management approach that does not compromise Occupational Health, Safety (OHS), and Environmental policies.

Operational Process and Audit Cycle:

• Grade Control and Mapping: As production advances, ore locations are continuously mapped and digitally archived. By performing systematic sampling appropriate to the mapping, the excavation or drilling direction is planned without losing time.
• Stockpile and Feed Management: The grade and tonnage of the excavated ore are determined precisely. To achieve the quality required by the plant, correct blending ratios are applied among different stockpiles, and the feed is executed.
• Development and Reserve Expansion: The next phase is projected through drilling conducted at locations suitable to the production plan. The life of mine is extended by developing reserves through Near Mine Exploration activities.
• Corporate Discipline and OHS: Beyond public relations, occupational safety and environmental policies are the foundation of the operation. Recording all procedures and ensuring that personnel implement these rules without negligence is maintained through a strict auditing mechanism.

In conclusion;
An experienced mine geology team acting as a bridge between departments in the production cycle keeps this established system under monitoring and auditing, ensuring the most efficient, safe, and trouble-free production.

To increase administrative efficiency, you can structure the stockpile tracking and plant feed system with the following fundamental steps:

Production and Zone Tracking
These are the data that must be entered into the digital system at the end of each shift to prevent irregular paperwork traffic:

• Location Identification: From which elevation, production bench, or geological zone (e.g., oxide zone, sulfide zone) the ore comes must be recorded instantly.
• Production Volume: The daily Run-of-Mine (ROM) production volume must be entered into the system via truck tally or weighbridge data.
• Grade/Quality Information: Sample results taken from the field must be digitized by matching them with the relevant production location.

Dynamic Stockpile Management
To monitor the real-time status of piles in the ore yard:

• Periodic Inventory: Volumetric controls of stockpiles should be carried out via drone surveys or laser scans, and compared with system data.
• Stockpile Classification: Ores should be separated according to their grade groups (high, medium, low) or metallurgical properties to create a "fingerprint".
• Real-Time Status Monitoring: The stockpile balance must be visible at any moment through the difference between input (production) and output (feed/haulage).

Plant Feed and Blending
To maintain the continuity and quality of the ore going to the plant:

• Prescription Feed: It should be planned at what ratios the feed will be provided from different stockpile areas to achieve the target grade required by the plant.
• Feed Records: The tonnage of the ore fed to the crusher or directly to the plant, and from which stockpile it was taken, must be digitally tracked.
• Feedback Loop: Efficiency analysis should be performed by comparing plant output data with feed data.

Haulage and Logistics Records
Provides historical traceability when you need data:

• Digital Weighbridge Integration: All shipments must be automatically deducted from the stockpile via weighbridge tickets.
• Haulage Periods: The amount of ore sent to which customer or unit should be reported on a daily, weekly, and monthly basis.

As GMRTC, for you we:

• Determine the most efficient production method for open pit or underground operations; and provide initial and continuous development training for your white-collar and blue-collar teams.
• Analyze fault and structural elements; identifying risks without jeopardizing operational safety and production.
• Build your grade control model, optimize it for pit production, and continuously update it.
• Establish the necessary cost-friendly system so you can instantly track the status of ore entering and leaving your stockpile area, maximizing your control.
• Analyze the mineralization in your area, helping you to foresee potential metallurgical and production issues.
• Consolidate the scattered and irregular records kept by your personnel into a modular digital environment (server/network) on the axis of ore zone, production-stockpile, and tonnage-grade.
• Plan drilling from your active production areas, enabling you to foresee what awaits you in the next bench or drift.
• Conduct studies for the continuity of mineralization or potential new mineralizations within or around your license area, and organize necessary exploration activities.

Contact us to realize your open pit and underground production in the most efficient way at every step, from pit design to production grade control.

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