Optimization & Linear Programming in the Mines Material Haulage

Andree Rttig
Gerente General
Modular Mining Systems Chile

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Copyright 2012 Modular Mining Systems, Inc. All rights reserved.

Outline

Introduction
Dispatch Optimization Strategy Fleet Management Case Studies Cost Based Optimization

Problem

How can we maximize the production by avoiding: 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.

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.

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 simplexbased procedure The Simplex Method exploits Dantzigs 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

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
Cycle Time (min)

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 5. Truck cycle times were reduced over 40%
Bin(sec)

60

50

40.7%T im eR ed u ced
40

30

20

10

0 July 25 Aug 2, 08 Dec 8-13,08 Jan 5-10, 09

Date

Feb 2-9,09

Mar 26- Apr 2, 09

Outline

Introduction
Dispatch Optimization Strategy Fleet Management Case Studies Cost Based Optimization

Cost-Based Optimization

FUEL

TIRES

LABOR

OPERATIONAL
COST - PER - TON

TRUCK COSTS
PARTS & MAINTENANCE

Our Customers

Global and Local

Port Coquitlam, BC, Canada

Tucson, Arizona, USA

Lima, Peru

Santiago, Chile

Belo Recife, PE, Bryanston, Horizonte, Brasil Republic of MG, Brasil South Africa

Pune, India

Balikpapan, Kaltim, Indonesia

Tuggerah, NSW, Australia

Beijing, China

Moscow, Russia

Preguntas?

Dr.-Ing. Andree Rttig

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