Optimization & Linear Andree Rttig

Programming in the Mines

Gerente General
Modular Mining Systems Chile

Material Haulage
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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 simplex-

based 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
Source: Wikipedia
complexity properties in
particular, interior-point
methods have been
developed.
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)
60

3. The previous issue of trucks running out of

50

40.7%TimeReduced
fuel was virtually eliminated 40

Bin(sec)
4. A more effective fleet monitoring system 30

20

gave Pit Superintendents a better planning 10

strategy 0
July 25 Aug 2, 08 Dec 8-13,08 Jan 5-10, 09 Feb 2-9,09 Mar 26- Apr 2, 09

Date

5. Truck cycle times were reduced over 40%

Outline

Introduction
Dispatch Optimization Strategy
Fleet Management Case Studies
Cost Based Optimization
Cost-Based Optimization

FUEL

TIRES OPERATIONAL
LABOR COST - PER - TON

TRUCK COSTS
PARTS &
MAINTENANCE
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?

Dr.-Ing. Andree Rttig

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