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ABSTRACT:
In open pit mining operations, the diesel consumption of haul trucks represents roughly 50% of the total operating costs.
To reduce operating costs, the trucks must be allocated and dispatched efficiently. In this study, a simulation model of
open pit copper mining has been enhanced using Visual Basic for Applications (VBA) programming, which can be used
to test and create a truck dispatching control table to satisfy a mining plan. By combining the simulation technique with
the utilization of Excel and VBA programming, the enhanced simulation model could aid managers in mining operations
decisions.
KEYWORDS: Open Pit Mining, Simulation, Truck Dispatching, VBA Programming
Excavation Standard
Mining Plan
Geological Plan
and Strategy
This Study
Feedback
Transportation Control
Scope of
System with GPS
Technology
Feedback
Financial Data Feedback
Figure 1: Simplified process map for open pit mining operation in Company A
Drillers
Number of Units Held 5 units
Number of Operation Shifts 2 shifts
Bulldozers
Number of Units Held 2 units
Number of Operation Shifts 3 shifts
Excavators
Number of Units Held 8 units
*
Average Productivity per Hour 331.4 m3/h
Operation Shifts 3 shifts
Operators 30
Dump Trucks
Number of Units Held 24 units
Capacity 130 tons
**
Amount per Transportation TRIA(90,130,147) tons
*
Average Distance in a One-way Transportation 3.26 km
*
Average Velocity when Loading 24 km/h
*
Average Velocity when Unloading 40 km/h
Operation Shifts 3 shifts
Operators 80
Shifts
Shift No.1 8:00-1600
Shift No.2 1600-2400
Shift No.2 2400-800
Note: * Measures actually vary.
** TRIA indicates a triangular distribution.
certain measures as averaged values.
Although the GPS technologys transportation 4 DEVELOPMENT AND ANALYSIS OF THE
control information system primarily functions to SIMULATION MODEL
control fuel consumption, weight capacity, and speed
of the dump trucks, dispatching a truck to an excavator 4.1 Parameters and Construction of the Simulation
has not yet been automated due to the complexity Model
involved in dispatching trucks. As described above, to
Simulations can provide a visual and dynamic system
maintain continuous production in the enrichment plant,
operation description to help mining project managers
the content of ore fed to the plant must be kept
understand the systems behavior and optimize it
approximately constant to the required average, a
through various strategies (Chinbat and Takakuwa,
challenging goal. As Table 1 shows, different mining
2009). We apply the computer simulation technique to
points and locations have different copper content.
support operations management in company A. The
When calculating the dispatching of a truck to an
simulation model is programmed in Arena (Kelton et
excavator, dispatchers must determine the trucks
al., 2010) and overlaid on a scaled mine layout. As
optimal destination to satisfy the production
described, company A has implemented a mining
requirements and its transportation amount.
transportation control system with GPS technology.
Simultaneously, the dispatchers must consider the
The GPS tracking data and other associated
progress of transportation at each mining point,
information update the simulation at 1-minute
because to satisfy the entire mining plans
intervals; the important parameters, such as the truck
specifications, both the transportation of ore and waste
location, its fuel level, and load weight are shown on
soil must be completed on schedule. Currently, the
the open pit map.
transport control staff dispatches trucks manually using
Figure 2 illustrates the overall structure and flow
wireless walkie-talkies and information from the GPS
of the simulation model. To understand the current
transportation control information system, which is
(As-Is) state of mining operations, we initially
displayed on their computer monitor in real time.
construct the As-Is model as the basis for experimental
In this study, to facilitate fleet management in
analysis. Then, to estimate company As maximum
open pit mining, we attempt to embed the logic of
mining capacity, we construct an experimental model
truck dispatching and automate the dispatching
for capacity testing. Tan and Takakuwa (2012)
systems. Thus, after the mining plan is complete, when
presented details on the construction and analysis of
we run the model, the program automatically generates
the simulation model for company A. Figure 3
the truck dispatch control table.
illustrates a screen image for running the As-Is
simulation model. In this study, we focus on integrating
Creation of Classification and Truck Loading Transportation Ore Feeding and Tally and
Entities Assignment of with Excavators with Dump Disposal of Waste Sstatistics
Entities Trucks Collection
(Read mining plan (Classify entity types (Assign an excavator to (Plan the next dispatch (Collect and insert
from an Excel file) and assign attributes a truck and calculate while monitoring the the defined statistics
to an entity ) the amount of loading) content of ore fed) to Excel file)
START
Apply Calculate
Calculatethe theoptical Calculate
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theoptical
Applythethevalue
valueof
ofthe
the loading amount
optical
of ore loading amount
optical
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valueof
ofthe
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variable of Weight
variable of Weight toto loading amount of ore loading amount ofore
ore variable
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loading amount of ore. totoachieve
achieve the
theplanned
planned to
toachieve
achieve the
the planned
planned loading amount of ore.
loading amount of ore. content of copper. content of copper. loading amount of ore.
The
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Thevariable
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Weight
isisgenerated
generatedininArena.
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Increase
Increasethethepriority
priorityofof Note: C Bun ker refers to the content of copper contained in the Increase
Increase the priorityof
the priority of
the
thetransportation
transportationof ofthe
the mixed ore in the bunkers; the
thetransportation
transportationofofthe
the
ore with low content
ore with low content of of ore
ore with low contentof
with low content of
copper. C Planned refers to the content of copper in ore that had been pre-
copper. copper.
copper.
planned in order to achieve the production plan of the plant;
COre refers to the content of copper contained in the primary
ore.
Figure 4: Algorithm for calculating load capacity when dispatching trucks to excavators
dispatch heuristic. Figure 4 presents an algorithm for to another experimental model with Arena VBA
calculating the optical loading amount when programming. Figure 5 displays a section of this VBA
dispatching trucks to excavators. To illustrate this procedures code.
algorithm, for convenience, we provide a simple
example. At the mining point Z, the content of copper 4.4 Simulation Experiment and Results
contained in the ore is 0.60%. To maintain stable
After building the simulation model, we validated it
production in the enrichment plant, the ore must be
through an interactive process between the company
stable and continuous at the averaged content of 0.53%.
staff and the modeler. This interactive process
Thus far, 100 tons of ore have been transported to the
compared the models output with the actual GPS
bunker and the averaged copper content in the bunker
tracking data. After confirming the models reliability,
is currently 0.48%. The question is how much ore with
we ran the simulations and analyzed the results. Table
0.6% copper content should be transported to the
3 displays the results of comparison between the
bunker? Here, the maximum load capacity of the truck
manual and proposed VBA enhanced dynamic
is130 tons.
dispatch methods. Table 3s values are averaged
To solve the optimal transportation amount of
execution results at the 95% confidence interval. We
0.6% copper content ore (hereafter, Q), we generate a
executed the simulation for 10 replications. Figure 6
loop for Q from one ton to 130 tons with one-ton steps.
presents a portion of the truck dispatch control table
While Q is looping, we calculate and estimate the
output by the VBA enhanced simulation model, which
copper content (hereafter, Cut%) after Q tons of 0.6%
can be used to achieve the mining plan.
ore content being fed to the bunker, and calculate the
The results shown in Table 3 demonstrate that the
error between 0.53% and Cut%. Then, the Q yielding
VBA enhanced dynamic dispatch method improves the
the smallest value of this error solves the problem.
performance indicators values. First, the simulations
To verify the effectiveness of the proposed
duration, as well as the time taken to complete the
dynamic dispatch method, we revised the As-Is model
Table 3: Comparing results of manual dispatching and VBA enhanced dynamic dispatch method
Avg
Min Max
Obervation Intervals 95%CL
Manual Dispatching
Performance Indicators Dynamic Dispached Method with VBA
(Historic Value)
Expected Excavation Plan of Ore (tons) 593,670
Expected Excavation Plan of Waste (tons) 422,612
The Length of Simulation / Total Time Taken 11,532
11,442 11,594 11,502
to Complete the Expected Excavation Plan (min.) 11,519 11,545
8241
Number of Transportations (round trips) 8227 8262 8,347
8232 8246
593670
Total Weight of the Transported Ore (tons) 593670 593670 593,670
593670 593670
422,612
Total Weight of the Transported Waste (tons) 422,612 422,612 422,612
422,612 422,612
Average Weight of Loading per Transportation (tons) 122.9 122
60.0 146.9
122.7 123.1
Average Transportation Time Spent in a Single Trip (min.) 9.57 11.8
4.50 21.47
9.55 9.62
12362
Total Transportation Distance of Ore (km) 12214 12566 13,332
12343 12372
8304
Total Transportation Distance of Waste (km) 8267 8460 11,423
8290 8322
99.81
Average Truck Scheduled Utilization (%) 99.73 100 71.2
99.73 99.85
Private Sub VBA_Block_12_ _Fire()
Set s = ThisDocument.Model.SIMAN
Dim myStation As Arena.station
Figure 5: VBA procedure for truck dispatching and calculating optimal loading amount
Figure 6: Truck dispatching table output by VBA enhanced simulation model (partial)