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Optimization & Linear Programming in the Mine’s Material Haulage
Optimization & Linear
Programming in the Mine’s
Material Haulage

Andree Röttig

Gerente General

Modular Mining Systems Chile

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Outline

Introduction

Dispatch Optimization Strategy

Fleet Management Case Studies

Cost Based Optimization

Problem

How

can

we

avoiding:

maximize

the

production

by

1. Shovels without trucks 2. Trucks waiting at shovels

and by respecting:

3. Operational restrictions

Father of Linear Programming

George Bernard Dantzig (Nov 8, 1914 May 13, 2005) was an American mathematician, and the Professor Emeritus of Transportation Sciences and Professor of Operations Research and of Computer Science at Stanford.

George Dantzig is known as the father of linear

programming and as the inventor of the “simplex method,” an algorithm for solving linear programming

problems.

Matrix form of the simplex algorithm

Source: Wikipedia

Elements of the Dispatching Problem

In the design and development of a real-time dispatching system, accurate information on the following, among others, must be taken into consideration.

mine topography and haul route network profile shovel locations and dig rates dump site locations and capacities material quality and grade information on ore deposits vehicle-shovel matching restrictions

This information is utilized by algorithms embedded in DISPATCH to address

key optimization issues; their outputs integrate for the generation of optimal

truck assignments.

DISPATCH

DISPATCH is a mine management system for the real-time dispatching of

vehicles for open-pit mining operations.

DISPATCH truck assignment decisions are generated with a multi-tiered solution procedure designed for maximal productivity optimal utilization of haulage resources while satisfying production requirements and operational constraints.

DISPATCH DISPATCH is a mine management system for the real-time dispatching of vehicles for open-pit mining

Outline

Introduction

Dispatch Optimization Strategy

Fleet Management Case Studies

Cost Based Optimization

A Dynamic Optimization Strategy

Mining operations are dynamic, resulting in non-static resource levels and

performance quantities. DISPATCH is cognizant of this.

A Dynamic Optimization Strategy Mining operations are dynamic, resulting in non-static resource levels and performance quantities.

BP, LP & DP

Linear Programming B.P. Options

BP, LP & DP

DISPATCH System Selected Paths

Dispatch Optimization Strategy LP Model

The LP model creates a theoretical master plan for maximizing overall truck productivity in the mine, it contains optimized production circuits that indicate:

Which dumping points should provide haulage resources (empty trucks) to shovels, the specific truck types, and the feed rates at which the resources should cover the shovels.

Which shovels should provide haulage resources (loaded trucks) to

 

which dumping points and the feed rates at which the resources should

cover the dumping points

LP decides which circuits to create by assigning a “truck productivity” weight

LP calculates number of trucks required for each LP Path.

Solution Techniques

The Plan: Linear Programming and the Simplex Method

DISPATCH uses a simplex- based procedure

The Simplex Method exploits Dantzig’s Corner Point Theorem: an optimal solution is located at an

extreme point of the

feasible region of the problem.

Other methods with very good theoretical and complexity properties in particular, interior-point methods have been developed.

Source: Wikipedia
Source: Wikipedia

Dispatch Optimization Strategy DP Model

Dynamic Program (DP) attempts to enforce, in real time, the production

circuits in the theoretical LP solution.

DP builds a Truck and Shovel need lists. DP works to achieve “balance and synchronization” while meeting the LP flow rates.

Truck-shovel pairing evaluations are made not only with respect to the

truck requiring immediate assignment, but also for trucks in the system that

are projected to require assignments within a time frame.

DP also builds “future” scenarios when generating assignments. Also

considering:

Locks, bars, fuel levels…

Outline

Introduction

Dispatch Optimization Strategy

Fleet Management Case Studies

Cost Based Optimization

Productivity Reported by our Customers

Case Study Kleinkopje Mine (AKK)

In 2008, Anglo installed the Modular Intellimine® System at the

Kleinkopje mine.

As well as installing DISPATCH they used Change Management Consulting Service offered by Modular to ensure a successful

installation.

The broke up the project into two phases

Phase I: productivity analysis following the installation but prior to

decommissioning of any legacy support systems to create a baseline

comparison.

Phase II: maximizing mine productivity within production requirements. This included looking at real-time KPI data and optimizing asset utilization.

Case Study Results

After all the project there were a series of benefits that were realized:

  • 1. Based on TKPH, AKK achieved a total improvement in productivity of 15% through the usage of DISPATCH

  • 2. The labor-intensive process of manual load recording at the crusher was eliminated

  • 3. The previous issue of trucks running out of fuel was virtually eliminated

  • 4. A more effective fleet monitoring system gave Pit Superintendents a better planning strategy

Case Study – Results After all the project there were a series of benefits that were
Cycle Time (min) 60 50 40.7% TimeReduced 40 30 20 10 0 July 25 – Aug
Cycle Time (min)
60
50
40.7% TimeReduced
40
30
20
10
0
July 25 – Aug 2, 08
Dec 8-13,08
Jan 5-10, 09
Feb 2-9,09
Mar 26- Apr 2, 09
Date
Bin(sec)

Outline

Introduction

Dispatch Optimization Strategy

Fleet Management Case Studies

Cost Based Optimization

Cost-Based Optimization

FUEL

TIRES

LABOR

TRUCK COSTS

PARTS & MAINTENANCE

OPERATIONAL

COST - PER - TON

Our Customers

Global and Local

Port

Tucson,

Lima,

Santiago,

Belo

Recife, PE,

Bryanston,

Pune,

Balikpapan,

Tuggerah,

Beijing,

Moscow,

Coquitlam,

Arizona,

Peru

Chile

Horizonte,

Brasil

Republic of

India

Kaltim,

NSW,

China

Russia

BC, Canada

USA

MG, Brasil

South Africa

Indonesia

Australia

¿Preguntas?

¿Preguntas? Dr.-Ing. Andree Röttig Gerente General tel. +56 2 591 3000 e-mail: roettig@mmsi.com http://www.mmsi.com

Dr.-Ing. Andree Röttig

Gerente General tel. +56 2 591 3000 e-mail: roettig@mmsi.com http://www.mmsi.com