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Integrated PlanningA Technical Analysis Using BlendOpt
J. Whitacre, S. Schellenberg and A. Iorio Paradyn Systems Pty Ltd
www.paradynsystems.com
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Holistic Processing Strategies
Strategic Decisions
feed blendingwhat to bypasshow to process
Opex
Washability
Mine Schedule
Plant Operating Capacities
Product Ash
Sales Targets
Feed Qualities
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Pit
CHPP
Blending at
train loading
Blending in
Port Stockyard
Blending onto ship
ROM Blending
Stockp
ile
Blends
Pit Train Vessel
Value Drivers in a Coal Supply Chain
Coal Aging/Oxidation
Cut-points, feed blending, wash or bypass, operating
constraints
ROM StockpilesProduct Stockpiles Port Stockpiles
Rail constraints
Feed Blends
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Integrated Planning Study with BlendOptModel Inputs
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BlendOptOutputs
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Case Study 1Rule-based Processing Strategy
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Case Study 1Results
Rule-based Strategy
BlendOpt• 6.8% higher revenue• 50% less washing
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Case Study 2Processing Strategies using Excel Solver
…Understanding the Limits of Optimisation in Excel
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Case Study 2 Planning by Premium Product
Planning Heuristic: use Excel Solver to optimise in order of price premium
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Case Study 2 Results
Product Ash Spec Price Premium over P3P1 Low 23%P2 Mid 15%P3 High 0%
Tonnage P1 (Mt) P2 (Mt) P3 (Mt) Total (Mt) Revenue ($M)Heuristic 1.03 0.70 0.55 2.28 160.0BlendOpt 0.52 1.86 0.00 2.38 168.5
…Over-washing caused by an over emphasis on premium product
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Case Study 3 DMC Cut-Point Strategies
Objectives
Planning Decisions
• Consistent Met Coal Product Quality • Maximise Revenue
• Cut-point Settings per Seam • Product Blending
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Case Study 3 Results
Baseline 5yr change in product VM ~ 2
BlendOpt
DMC cut-point = 1.45
Processing Product Consistency Revenue
9% increase over baseline
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Other Model Considerations
• Dual-Stage DMC Circuits
• Different Seam Feed Rates
• Managing Data Uncertainty
Plant Modelling• ROM and Product Stockpiles
• Rail Capacity Constraints
• “Wash Only” Contracts
• 3rd Party Coal
• “Energy Based” Contracts
Supply Chain Modelling
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Conclusions
Incremental Adjustments in:• Wash vs Bypass• DMC cut-points • Product Blending
Non-Trivial Improvements to:• Yields• Costs• Revenue
CAN DISCOVER
Holistic View of Processing Uncertainty drives calculated risks not conservativism
…BUT ONLY IF