simulation study in the rio tinto west angelas iron ore mine

DISPATCH® Simulation Study in Rio Tinto Iron Ore’s West Angelas Mine

West Angelas Unlocking Project

Roberto Urzúa – Specialist Mine Engineer - Modular Mining Systems, Chile

Samuel Lawrance – Mining Systems Specialist - Rio Tinto, Australia

[email protected]

Simulator – What is it?

Simulation DefinitionIt’s a useful tool to obtain conclusions about the behavior of a system (mine) by studying a model of it

Objectives Evaluate the behavior of a system (mine) under

various operating conditions Obtain a measure of a system (mine) in terms of

performance to determine the best operating strategy comparing different alternatives (scenarios)

Anticipate events before they happen ...

How much increase in production can be generated by adding a new shovel to the operation of the mine?

Is this increased production enough to justify the cost of acquisition of the new shovel?

Will the existing trucks be enough to take full advantage of the now increased number of shovels?

Simulator – What is it?

Simulator – How it works?

DISPATCH® Simulator is an application/module that emulates amining operation in real time.

Use the same philosophyof DISPATCH®

DatabasesOptimization algorithmsDispatch® reports Interaction with other modulesEtc…

MINE1 MINE2

t1 t2

simulation

The Simulation Module simulates theoperation of loading and haulingunits for a period of time using the"shift" as the basic unit.

Simulator – How it works?

Some Benefits

Help in making decisions (making decisions in

advance to save time and money)

Ability to generate multiple tests with little effort

Applicable to short, medium and long term

planning

Evaluation of potential scenarios (what-if)

Possibility to verify operating strategies

Some Applications

Calculation of optimum equipment fleet

Equipment performance

validation/estimation (KPI’s)

Analysis of mine design

Compare fixed/dynamic systems

Dispatchers training

Capacity modeling

Mine Plan modeling

West Angelas Simulation Study

Scope of work

RTIO to nominate 5 historical shifts for calibration

MMS to calibrate the simulation utility

– Recorded material movements are within 5%

– Within 8% variance against individual loading units

Run the shifts in a "locked" scenario (calibrated shifts)

Run the shifts in an "unlocked" scenario (simulation scenarios)

Report on

– the impact - material movements, production KPI’s and truck management metrics, loading unit wait on truck (calibrated vs. simulated)

Inputs:• Pitdatabase

• Shift Databases

• Site visit Operation feedbackWest Angelas

Location: 110km from Newman, West Australia. Operation: Open pit operation with site-based processing facilities. Capacity: 29.5 million tonnes total railout per annum Products: Pilbara Blend Lump and Fines. Geology: Marra Mamba Bedded Iron Deposit.

Assets Mobile fleet:• 14 x 730E Komatsu (190t) haul trucks.• 24 x 830E Komatsu (220t) hul trucks.• 9 x loading units (3 excavators, 2 shovels, 4 front end loaders).

Crushing and screening plant.Train loadout capability.Relaimer and stacker.(Information as of Dec 2010)

PIW Simulation- Methodology

I. Building the Virtual Model

II. Base Case Calibration

III. Optimized Model

IV. Analysis of Results

Virtual mine constructionLayout, grades, dump and loading locations, equipmentparameters, events handling, etc.

Setting the virtual mine set in the previous stage to theoperational reality of the mineSimulation results are obtained in the expected range(production, productivity, KPI, etc..). The simulationsrepresent reality

Operational optimizationThe simulations consider a less restrictive environment,using Dispatch® optimization tools (unlocking truck toshovels)

Reporting systemsThrough Dispatch® report utilities the results obtained withsimulations (production, equipment productivity andothers) can be analyzed to facilitate decision making

Base CaseGeneration

PIW Simulation- Methodology

STOCK

STOCKSTOCK

CRUSHERSTOCK

STOCK

DUMP

BLAST

BLAST

BLAST

DUMP

BLAST

BLAST

DUMP

PIW Simulation- Results (Base Case)

REAL SIMULATEDShovel Shovel

% Variance

HG LG W HG LG W HG LG W HG LG W

07R03 34 54 0 6.322 9.450 0 07R03 36 58 0 6.675 10.449 0 0,8%

07R06 111 0 0 20.640 0 0 07R06 77 0 0 14.872 0 0 -3,6%

07R29 0 0 0 0 0 0 07R29 0 0 0 0 0 0 0,0%

07R36 0 0 103 0 0 20.350 07R36 0 0 116 0 0 22.010 1,0%

07R37 44 0 59 9.202 0 11.800 07R37 70 0 58 13.838 0 11.005 2,4%

15R01 0 0 135 0 0 26.475 15R01 0 0 130 0 0 25.930 -0,3%

15R04 124 0 0 23.881 0 0 15R04 133 0 0 26.825 0 0 1,8%

15R05 0 0 57 0 0 11.400 15R05 0 0 54 0 0 10.380 -0,6%

15R10 0 0 105 0 0 21.102 15R10 0 0 99 0 0 19.485 -1,0%

Total 313 54 459 60.045 9.450 91.127 Total 316 58 457 62.210 10.449 88.810 0,5%

REAL (23-04-10-D) Calibrated Shift (23-06-10-D)

Loads Tons Loads Tons


% Variance


07H99 0 35 0 0 6.157 0 07H99 0 29 0 0 5.737 0 -0,3%

07R06 57 0 0 12.557 0 0 07R06 72 0 0 13.845 0 0 0,8%

07R36 0 0 116 0 0 19.245 07R36 0 0 99 0 0 19.100 -0,1%

07R37 93 0 13 20.043 0 2.600 07R37 58 0 43 11.783 0 8.355 -1,5%

15R01 0 0 151 0 0 29.815 15R01 0 0 153 0 0 28.185 -1,0%

15R04 45 0 42 8.460 0 7.315 15R04 58 0 54 11.981 0 10.800 4,2%

15R05 0 0 201 0 0 40.200 15R05 0 0 204 0 0 39.855 -0,2%

15R10 97 0 0 20.848 0 0 15R10 114 0 0 22.938 0 0 1,2%

Total 292 35 523 61.908 6.157 99.175 Total 302 29 553 60.547 5.737 106.295 3,2%




Loads Tons Loads Tons % Variance


07H99 0 0 53 0 0 9.655 07H99 0 0 57 0 0 11.120 1,0%

07R03 16 0 0 2.966 0 0 07R03 28 0 0 5.432 0 0 1,6%

07R06 0 98 0 0 17.866 0 07R06 0 95 0 0 17.393 0 -0,3%

07R36 0 0 72 0 0 13.495 07R36 0 0 74 0 0 14.450 0,6%

07R37 96 0 0 20.220 0 0 07R37 102 0 0 20.709 0 0 0,3%

15R01 0 0 135 0 0 27.000 15R01 0 0 111 0 0 22.060 -3,3%

15R04 0 0 38 0 0 7.482 15R04 0 0 49 0 0 9.485 1,3%

15R05 0 0 119 0 0 23.730 15R05 0 0 111 0 0 22.025 -1,1%

15R10 128 0 0 27.301 0 0 15R10 127 0 0 25.385 0 0 -1,3%

Total 240 98 417 50.487 17.866 81.362 Total 257 95 402 51.526 17.393 79.140 -1,1%

REAL (25-04-10-D) Calibrated Shift (25-06-10-D)REAL SIMULATED

Shovel Shovel

Loads Tons Loads Tons % Variance


07R03 43 26 0 7.955 4.550 0 07R03 43 25 0 8.318 4.791 0 0,5%

07R06 17 37 30 3.499 7.187 5.545 07R06 18 42 36 3.474 7.856 6.535 1,3%

07R36 0 0 95 0 0 18.720 07R36 0 0 102 0 0 19.805 0,9%

07R37 0 0 105 0 0 19.425 07R37 0 0 106 0 0 20.815 1,1%

15R01 0 0 113 0 0 22.005 15R01 0 0 83 0 0 16.425 -4,4%

15R09 0 0 39 0 0 7.800 15R09 0 0 50 0 0 9.790 1,6%

15R10 0 0 154 0 0 30.730 15R10 0 0 165 0 0 32.300 1,2%

Total 60 63 536 11.454 11.737 104.225 Total 61 67 542 11.792 12.647 105.670 2,1%



% Variance


07R03 0 97 0 0 16.975 0 07R03 0 81 0 0 11.550 0 -5,5%

07R06 0 14 0 0 2.450 0 07R06 0 12 0 0 1.400 0 -1,1%

07R36 0 0 32 0 0 6.155 07R36 0 0 38 0 0 7.690 1,6%

15R01 0 0 59 0 0 10.995 15R01 0 0 68 0 0 10.900 -0,1%

15R04 0 0 75 0 0 14.440 15R04 0 0 88 0 0 16.510 2,1%

15R05 0 0 138 0 0 27.390 15R05 0 0 142 0 0 26.710 -0,7%

15R09 0 0 100 0 0 18.985 15R09 0 0 92 0 0 19.065 0,1%

15R10 0 0 4 0 0 730 15R10 0 0 10 0 0 1.660 0,9%

Total 0 111 408 0 19.425 78.695 Total 0 93 438 0 12.950 82.535 -2,7%


Calibrated Shift (27-06-10-D)REAL (27-04-10-D)

Total

High Grade Low Grade Waste Total High Grade Low Grade Waste Total Difference

Real Shift 313 54 459 826 60.045 9.450 91.127 160.622

Calibrated Shift 316 58 457 831 62.210 10.449 88.810 161.469

Real Shift 292 35 523 850 61.908 6.157 99.175 167.240


Real Shift 240 98 417 755 50.487 17.866 81.362 149.715


Real Shift 60 63 536 659 11.454 11.737 104.225 127.416


Real Shift 0 111 408 519 0 19.425 78.695 98.120

Calibrated Shift 0 93 438 531 0 12.950 82.535 95.485

1

2

3

4

5

Loads Tons

0,5%

3,2%

-1,1%

2,1%

-2,7%

Unlock ScenarioGeneration

PIW Simulation- Methodology – Assumptions (Unlock Scenario)

The unlocked scenario was run in an open mode, this means that all the locked trucks to shovelconditions were erased so any truck was available for assignment to any shovel

The operational status changes for all loading, haulage, and dumping locations occurred at the sametime, according to the events specified in data from the historical shifts

Dump locks were used for excavators to ensure the representative cycles were respected

The pit layout was identical to that used in all other simulation cases

The potential gains were only due to a better truck assignment

PIW Simulation- Methodology – Simulmod Menu

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PIW Simulation- Results

1 2 3 4 5

PIW Simulation - Conclusions

Variance between the base case and real shifts is significantly small so itcan be establish that the base case is representative for West Angelasoperations, therefore the potential gains from an unlock scenario weremeasured with confidence from this model

As expected, each unlock case provided further increases inproductivity, this is a direct result of reducing the constraints on thesystem. As the constraints are removed, the algorithm is provided withbetter optimization opportunities

For all shifts in the unlock scenario there is more material movement interms of loads and tons (increasing the TKPH as well), and also there isless queue time of trucks at shovels which means a better managementof the haulage fleet

PIW Simulation - Conclusions

This improvement is representative of the real improvements availableto West Angelas through a less restrictive situation.

Even better results are expected than presented in this analysis, dueto a potential better interaction between the dispatcher and thesystem optimization tools according to different operating conditionsof the operation

Simulation analysis should be used by mine planning departments inorder to support the decision making process

The above could involve: design changes, adding new equipment,benefits quantification of operational changes, among others

Simulations tools help to make informed decisions and minimize risk,avoiding significant loss of time and money

…adding value!

Thank You

Questions?

DISPATCH® Databases

The pit database contains real time continuous data. It contains an “image” of themine at any given moment. The DISPATCH® system continuously revises thisdatabase as it receives and updates data.

The Pit database is used to make real time operational decisions.

The Shift database is also a real time database until the end of shift when theDISPATCH® system then stores that database as a shift file with the shift date andcreates a new shift database for the current shift.

The Shift database contains all statuses, events and information that occurred for that shift.

DISPATCH® Optimization Algorithms

In order to perform optimal allocation assignments,

DISPATCH® operates as a real-time problem solver tool using

three models (mathematical algorithms)

This is the determination of the bestavailable path between two points andworks on shortest distance as thecriteria.

It allocates haulage resources toexcavating activities based on truck-dependent loading rates andmaximization of overall truckproductivity.

D.P. works to achieve “balance andsynchronization” while meeting theL.P. flow rates. D.P tries to achievethe L.P. “Master Plan”

Events Editor Screen Set Up

Distribution Time Screen Set Up

Spot timeDig Rates

Dumping time

simulation study in the rio tinto west angelas iron ore mine

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