BOCCOST Modeling
Tracking and Relating Mine and Mill Performance Indicators
in Real Time to Increase SAG Mill Throughput
Dean Pontin and Lim Eka Setiawan
PT Newmont Nusa Tenggara
JL Sriwijaya No. 258. Mataram, Lombok, NTB 83125, Indonesia.
Tel: (62-0372) 635318 ext 47704 Fax: (62-0372) 635318 ext 47917 E-mail: dpon8757@corp.newmont.com
ABSTRACT
The mining and milling groups at Batu Hijau are tasked with
increasing SAG mill throughput by approximately 10%. Avenues
used for this process are, blasting and crushing optimization, ore
blending and predicting SAG mill throughput in relation to the
geological model. This is in line with traditional “Mine to Mill”
studies.
At Batu Hijau, mill and mine sequencing cannot readily be
configured to perform the surveys traditionally required by a
“Mine to Mill” study while meeting the daily production target of
140,000 tonnes per day and processing from varying ore types in
one pit.
A program called BOCCOST (Blasting Optimisation Crushing
Conveying Optimising SAG Throughput) has been implemented
to capture approximately 200 variables from blasting, mining and
milling operations and assign them to a common point in space in
the geological model in real time.
Interpretive analysis of data from BOCCOST is used to model
relationships between the 200 variables to determine which and
how these factors affect SAG throughput. Once these relationships
are determined, the blasting, ore blending and crushing process can
be optimized to generate a product that maximizes mill throughput.
The relationships modeled from BOCCOST are also used to
generate a SAG mill throughput estimator, which can be coded
into the production block model. The block model can be
reconciled with the geological block model for correlation by
geological domain.
Once this relationship is established, SAG mill throughput
domains can then be established for predicting SAG mill
throughput. This SAG mill throughput estimator is then used in
conjunction with revenue calculations to determine an ore cut-off,
which combines these two elements to maximize metal production.
INTRODUCTION
The Batu Hijau project is located on the southwestern end
of Sumbawa Island in the Indonesian Archipelago. It is a
large, low-grade copper-gold porphyry deposit. The project
consists of a open pit mine, concentrator, townsite, port and
power generation facilities. It was commissioned in
September 1999 and currently mines 600,000 tonnes per
day and processes 135,000 tonnes per day.
1
Average production over the 25-year mine life will be
approximately 210,000 tonnes of copper in concentrate and
420,000 ounces of gold per year. During the course of 2003
the mine is budgeted to ramp up to 650,000 tonnes per day
while the mill throughput target will be increased to
155,000 tonnes per day.
One of the projects aimed at increasing mill throughput is
implementation of a “Mine to Mill” program. A team has
been tasked with this project and a three pronged approach
was adopted under the program entitled BOCCOST. This is
an acronym for Blasting Optimisation, Crushing,
Conveying, Optimising SAG Throughput.
The first phase of the program was to improve
communications between the mine and the mill and
introduce a set of protocols to initiate ore blending
practices in the mine to improve mill throughput.
The second phase of the program was to modify blasting
and crushing techniques to produce a product with an
optimum size distribution to maximize SAG throughput.
Both of these phases have been implemented and the
operation is already reaping the benefits of higher
throughput and more consistent feed rate to the mill.
The third phase of the program is to extrapolate
relationships developed between geological, geotechnical,
blasting, mining, crushing and milling parameters,
throughout the mine’s ore body model to predict mill
throughputs. Mill throughput will then be incorporated into
the revenue calculation to determine ore cuts for various
ore types when they are blasted, blended and crushed in
managed configurations.
The key to implementing a program such as BOCCOST is
to successfully capture, store, and utilize data collected
from various sources. This paper addresses how the tools
used to implement the BOCCOST data collection system
has added value to data collected by storing it in a
manageable format, which allows relationships to be better
formed from that data.
Background
A typical Mine to Mill approach is to quantify the leverage
of blasting results of selected individual ore domains to
downstream processes and then optimize them to maximise
overall mine profitability. This is generally accomplished
by:
 Characterizing selected ore domains;
 Reviewing current mining and milling practices;
 Base-lining current drilling, blasting, primary crushing
and grinding operations by conducting quantitative
measurements and process audits to develop site and
ore type specific models;
 Using the developed blasting and downstream models
to design modified drilling, blasting, crushing and
grinding processes to increase grinding circuit
throughput;
 Validating the predicted increase by conducting
further mine and plant surveys;
 Implementing the chosen strategies for monitoring and
maintaining optimum mining and milling process for
maximum profit for the organisation.
This approach has been shown to work well for single
unblended ore types and single mill configurations. It does
not account for the interaction that occurs between blends
of different ore types. The reality is that at Batu Hijau, mill
configuration and ore feed blend are constantly changing.
The challenge to introducing a mine to mill study at Batu
Hijau is the ability to campaign mill whilst trying to
achieve target throughput levels.
More than one loading unit is required to maintain mill
feed rates at 135,000 plus tonnes per day. Current mine
development does not allow a single ore type to be mined
simultaneously from the same source by two loading units.
This means that a blend of material must always be sent to
the mill in order to achieve target throughput. Stopping the
mill for surveys also results in loss of mill throughput.
To maintain throughput and implement a large-scale mine
to mill program a different approach to collecting data and
analyzing data was required.
BOCCOST MODEL
The BOCCOST model consists of data collection tools,
data storage, data relationship management tools, data
interpretation and data extrapolation. The model sources
over 200 data variables from the mine and mill in real time,
filters that data for erroneous data and stores that data in
two relational databases.
The BOCCOST model has two databases as it focuses on
short-term planning issues relating to generating a product
through blasting and blending to increase throughput
within one database. The second database is matched to the
long-term planning model for future SAG mill throughput
predictive work.
The focus of the model is to collect data from the mill,
crusher and mine and relate that data to an X, Y, Z co-
ordinate in the geological ore body model. The ore body
model also contains geological and geotechnical attributes
that can be used to predict SAG mill throughput. If milling,
crushing, blasting and mining attributes can be associated
with the geotechnical and geological attributes, more
precise SAG mill throughput prediction can be achieved.
By making these associations in real time, short-term mine
planning can also assist to increase SAG mill throughput.
BOCCOST provides the ability to associate mining and
milling characteristics to a 25m x 25m x 15m block of ore
that has been mined and sent to the mill. Relationships can
be developed that derive SAG mill throughput of certain
ore types and blends of ore types when mining and milling
conditions are set to increase throughput.
Once these relationships are known, they can be applied
forward throughout the ore body model. This allows mine
planners the ability to predict mill throughput of a certain
ore type or blend when mining and milling conditions are
set up in certain ways. Conversely, mining and milling
conditions can be changed to increase throughput when it is
known in advance that certain ore types are going to be fed
to the mill.
BOCCOST DATA COLLECTION
The BOCCOST model consists of data collection from
geological models, drilling and blasting activities, mining,
crushing and milling. Data is collected and stored in an
Oracle database and consumes approximately 140 KB of
memory for a daily data set. Currently over 200 data points
are being collected from the following sources:
Geological Data Set
The geological data set is contained in two 3D ore body
block models, generated in Minesight geological modeling
software. One model is the exploration model generated
from core drilling and the second is the ore control model
generated from blast holes. Both models are used for mine
planning and contain similar sets of data regarding mill
throughput variables.
Exploration Model
The exploration block model size is 25m x 25m x 15m and
is based on core drilling with 60m to 120m centers.
Geotechnical attributes such as RQD, break spacing and
alterations are determined from core testing. Core is also
used for mill performance indicator testing for predictive
analysis of mill throughput, such as Bond Work Indices.
Both these sets of data are extrapolated throughout the
block model using geostatistical modeling, resulting in
each block being coded with data that influences mill
throughput.
Ore Control Model
The ore control block model size is 12.5m x 12.5m x 15m
and is based on blast hole drilling with 8m to 9m centers.
Geological data such as lithology and alteration is obtained
from blast hole mapping. This mapping better defines the
boundaries of different material types.
Blast hole Drilling Data Set
Each of the blast hole drilled in the mine is equipped with
Aquila machine monitoring and automated drilling
packages. From these packages, information such as
penetration rates and pulldown pressures is gathered for
each hole drilled. This data is transferred via the mine’s
Dispatch radio network to the Dispatch database. From this
database it is transferred to the BOCCOST database.
The collar location of each drill is surveyed and entered
into the BOCCOST database. This survey position is
critical as all the drill information is linked to this X, Y, Z
co-ordinate. This drilling information can now be placed
spacially in the BOCCOST model.
Blasting Data Set
A unique number identifies each individual blast hole. As
each blast holes is loaded with explosives, data such as
hole depth, amount of explosive and type of explosive are
recorded. This information is used to calculate power
factors per hole. This information is currently collected by
manually measuring and recording the data in the field and
keying it into PDAs (Personnel Digital Assistant), which
are downloaded in the office. The mine is currently
introducing wireless connectivity around the mine site.
This will, in the near future, allow automatic collection of
this data from the explosive trucks.
Digging Data Set
Each of the mining shovels is equipped with a High
Precision Global Positioning Satellite (HPGPS) system.
From this system each truck loading at shovel is given an
X, Y, Z co-ordinate. This identifies where that truck came
from in the mine and hence where it came from in the ore
control block model. Each bucket load from the shovel is
located in the block model to sub-meter accuracy and the
average of the positions for each bucket load is assigned as
the truck’s position in the block model.
As the shovel mines through the ore body, the face advance
of the shovel is downloaded to the mine planning software
through the Dispatch system. On a daily basis, each of the
faces that the ore shovels are mining in is digitally
photographed and analyzed with Split Engineering Desktop
for fragmentation size and distribution.
Once this data is obtained, all the ore within that face
advance for the day is assigned that fragmentation data
spatially in the BOCCOST model. Since each truck that
came from that ore face has an X, Y, Z coordinate in the
same model, then the fragmentation data can be assigned to
each truck that carries ore to the crusher.
Crushing Data Set
There are two crushers and four dump pockets. As each
truck dumps in the crusher dump pockets it is time stamped
with an individual identification number.
An ABB Enterprise Data Historian has recently been
installed and commissioned at Batu Hijau to log and
archive process plant operating information.
Approximately 2100 analog and digital data tags are
logged. This is about 25% of the total current plant
Distributed Control System (DCS) Input/ Output (I/O)
capacity. Data stored in the historian archive is extracted
and compiled into Excel spreadsheet templates for input to
BOCCOST.
Primary Crushing plant data such as power draw, mantle
position, surge pile status and crusher product size
distribution are extracted from the historian database and
are attached to the identifier for each truck that dumps in
the crusher. Resolution of this data is on a shift basis.
Product size distribution is digitally monitored and
measured using Split Engineering SplitOnline cameras
mounted on the crusher discharge conveyors.
Milling Data Set
The grinding circuit consists of two SAG mills and four
Ball mills in closed circuit with three pebble crushers and
cyclone classifiers.
As for the primary crushers, grinding circuit operating data
such as fresh feed rate, pebble generation rate, SAG and
Ball Mill power draw and bearing pressure and SAG feed
size distribution are collected from the DCS via the data
historian. SAG feed size distribution is measured using
SplitOnline camera mounted on the feed conveyors to each
SAG mill.
Data resolution is currently on a shift basis however will be
increased to an hourly basis to better tie in milling
performance with ore location. Residence time in the
various stockpiles and surge piles between the primary
crusher and milling circuit can vary up to about one hour so
this is deemed the minimum sensible resolution for plant
data.
Other physical data such as liner and grate configuration
and wear, ball size and charge mass and trommel open area
is manually collected and logged in Excel spreadsheet for
input to BOCCOST.
Each data point type is captured for each of the six mills in
order to analyze the effect of varying mill configurations
on throughput.
BOCCOST DATA CORRELATION
Before data analysis could commence, a system was
devised to cross associate over 200 variables collected, in a
workable database. Variables are linked by associating a
time stamp with an X, Y, Z coordinate in the ore body
model.
All geological, geotechnical, drilling and blasting data
collected is individually identified by blast hole number,
which has an X, Y, Z coordinate in the ore body model. All
digging, crushing and milling data is associated with the
time stamp attached to each truck as it dumps in the dump
pocket. This truck also has X, Y, Z coordinates attached to
it which identify where the ore came from in the ore body
model. These associations provide the ability to match
milling data to a specific point in the ore body model in
near real time.
BOCCOST Data Identification Structure
The BOCCOST data set is arranged to record each
individual blast drillhole and relate it to the SAG mill and
ball mill parameter set. In general, the data set is classified
into two groups based on unique identity.
Geology, drilling and blasting parameters are based on
drillhole identity. The id format is a 9-digit number, The primary crusher is connected to the mill by an overland
outlined as follows. conveyor. The time taken for the ore to travel from the
285055015 primary crusher dump pocket, along the conveyor, through
285  Bench the coarse ore stockpile and into the SAG mill is
055  Drill Pattern
approximately 45 minutes. This 45 minutes is known as lag
time. Mill parameters are assigned to trucks that dumped
015  Hole Number into the crusher 45 minutes prior to the data being
Digging, crushing, SAG mill and Ball mill parameters are collected.
based on a time stamped identity as outlined in the As already noted, SplitOnline cameras mounted on the
following. SAG feed conveyors digitally measure SAG feed
Digging, The id is based on dumping time to crusher. The fragmentation. If these measurements are similar to those
id format is an 11-digit number. on the crusher discharge conveyors, then it is be assumed
20205173605 that the material being dumped into the crusher is directly
feeding the SAG mill.
2  Year
02  Month
Data Flow Sheet
05  Date
17  Hour The data collected for the BOCCOST model enters the
database through two different methods. Data comprising
36  Minutes
geology, drilling and blasting parameters is one group and
05  Second digging, crushing, SAG mill and Ball mill is another.
Crushing, SAG mill and Ball mill have the same id format Figures 1 and 2 outline the two ways that data flows into
in hourly resolution. These parameters do not demonstrate the database.
a great deal of variability over an hourly period. The id
format is in 7-digit number.
2020517
2  Year
Figure 1 – Geology, Drilling and Blasting Flow Chart
02  Month
05  Date
17  Hour
Figure 2 – Digging, Crushing and Mill Flow Chart

closest data point from one dataset to another. This enables

Data QA/QC truck data, which contains all of the mill information, to be
linked to either the drill holes in the exploration ore body
Data analysis is only as good as the integrity of the data set that model or blast holes in the ore control model.
is used for that analysis. Previous data used for preliminary
By setting a search radius in the “find” function, truck data can
mine to mill relationship analysis at Batu Hijau contained
be conditioned to certain blast holes or exploration holes. As
erroneous data. All data that enters the BOCCOST model is
shown in Figure 4, all trucks within a radius of 8.9m from blast
filtered for erroneous data.
hole number 255077004, will have their mill attributes
A third party software package called AcQuire is used as the matched to all the geology, drilling and blasting attributes of
Quality Assurance and Quality Control (QA/QC) of the data that blast hole. By setting a search radius this process will
used for analysis. AcQuire software is configured to accept eliminate excessive distance “matched” data.
data, which has the correct units and precision, and also checks
to ensure it falls between predetermined maximum and
minimum values. Figure 3 contains an example of the data BOCCOST DATA ANALYSIS
entry table for a drilling data set, outlining the entry By constructing a mechanism to relate over 200 variables in
configuration. Data that does not fall within limits is compiled near real time with the geological and geotechnical attributes of
in an exception report and edited or rejected manually. an ore body model, statistical relationships that influence SAG
mill throughput can be evaluated. The effect of changing
BOCCOST Data Linking and Matching variables, such as blasting, can be tracked in relationship to any
other variable within the BOCCOST model. Relationships
BOCCOST data from the geological exploration model is developed between variables can be tested with actual mill
defined by a survey point in space. Drilling and blasting data throughput data.
related to blast holes is also related to a survey point in space.
One of the aims of BOCCOST is to develop two multi variable
Digging and mine fragmentation data is identified by truck
predictive regression models. One model will focus on
load and the position of the truck is related to a point in space
correlating relationships for short-term SAG mill throughput
by HPGPS coordinates. As previously outlined, this same truck
scheduling by utilizing variables associated with the blast hole
is time stamped as it dumps into the dump pocket. This time
data in the ore control model. The second model will focus on
stamp is also attached to crusher and mill data. Linking the
the relationships between variables and the exploration model
time stamp to the HPGPS coordinate of the truck then places
to predict long-term SAG mill throughput.
the mill data in the same X, Y, Z coordinate system as the
exploration and blast hole ore body models.
To be able to utilize the ability of having exploration, blast hole
and milling data in the same coordinated system, data needs to
be matched to allow interpretive analysis. The mine planning
software used at site has a “find” function that associcates the
 CONCLUSION
At the time of writing approximately 90% of data collection
mechanisms were in place. Analysis of data had yet to begin.
Quality of the data collected is most important to the
conclusions drawn from the analysis and this has been a major
focus of project setup.
The dynamic nature of BOCCOST modeling will allow
continuous measurement and correlation of variables that effect
mill throughput as those variables are changed to maximize
mill throughput. Data collected will also be used to model
variables other than mill throughput. Prediction of drilling
consumables use, for example, will be made possible as this is
tracked in the BOCCOST model throughout the ore body
model.
The BOCCOST model is unique in that it attempts to capture
the local variability of mill throughput. Unlike campaign
milling, which attributes ore throughput values to voluminous
areas of the deposit, BOCCOST will attribute a throughput
value at an SMU (Single Mining Unit) scale.
ACKNOWNLEDGEMENTS
The authors would like to acknowledge the contributions made
by the Batu Hijau BOCCOST site team, particularly Nebojsa
Zurkic and Karen McCaffery in the preparation of this paper.
They would also like to thank the management of PT Newmont
Nusa Tenggara for allowing presentation of this paper.

Figure 3 – Drilling Data Set

Unit Minimum Maximum Precision Description

Hole_ID N/A N/A N/A ID for drill hole, #bench#block#drillhole

Drill Number TD001 through TD006
Penetration Rate meter/hour *1000 0 200000 0.1 drill meter per effective drilling time
Hole Diameter mm 100 300 0.1 bit diameter in mm
Drill Hole Depth meters *100 0 3500 0.1 drill hole depth based on drill rod penetration
Bit Serial Number bit number
RPM rpm *1000 0 300000 0.1 rpm of drill rod when penetrating the drill hole
Pull Down Pressure psi *1000 0 3000000 0.1 pull down pressure of drill rod when penetrationg the drill hole
Torque psi *1000 0 3000000 0.1 torque of drill rod when penetrating the drill hole
Air Pressure psi *1000 0 100000 0.1 air pressure when penetrating the drill hole

Figure 4 – Matching Diagram

MINE(BH) MINE(Truck) Distance (m)

255077001 20205173605 5.1

255077002 20205174015 5.2

255077003 20205174325 6.1

255077004 20205174713 8.9