Domain-specific Mining Simulation Software Tool for the World’s Second Largest Nickel Producer

Problem:

Mid-term and operational planning in mining is an area where simulation has become a de-facto standard. Simulation copes well with the planning of mining operations: with its hundreds of interacting machines, overlapping maintenance activities, complex layouts of mine fields, and limited capacity of bunkers and conveyors.

As soon as you create a simulation that considers thousands of parameters and diverse types of equipment, you need a lot of data from various sources to run it. It is a challenge to input, maintain, and update all this data. A mine layout changes daily, as soon as you advance through the stopes, and it becomes too complicated for mine planners to update the data and apply simulation in routine operations. That is why the world’s leading mining companies frequently ask for integrated simulation-based tools, with user-friendly interfaces, to support their mid-term and day-to-day operations planning. This was the way the world’s 2nd largest nickel producer followed.

Mining process simulation

The process inside stope works is cyclic: drilling, then blasting, then finally cleaning, then drilling again. The main constraint here is that all the blasts are done at the same time throughout the mine, two times a day. This is because making a blast requires the evacuation of the whole mine for evident safety reasons. If the drilling and cleaning teams have not completed, the blast is skipped until the next day and production capacity is lost.

Process inside a stope

A good example of everyday challenges is choosing the optimal depth of blast holes. Deeper blast holes give the advantage of using jumbo drills more efficiently, but shorter blast holes lead to less risk of skipping the blast.

The trade-off between deeper and shorter blast holes has no global solution, since:

Simulation experiments needs to be run at least every week of the mining process. That is why a domain-specific tool that simplifies the simulation experiment is required.

Solution:

Amalgama developed a domain-specific mining simulation solution to be regularly used by mine planners. The tool is an application, featuring the following functionalities:

Mining simulation tool

Technically, the tool creates an AnyLogic simulation model using a UI that supports mine manager needs. Commercially, such usage is a typical OEM application, where the AnyLogic engine is used within another vertical application.

The mining tool dashboard shows how the production capacity depends on the blast depth for each mine stope in each situation.

Ore Production with Various Blast Hole Depths

Blast hole length optimization is obviously not the only challenge that the mining simulation tool is used for. The tool is also used to support weekly planning and to find bottlenecks in the underground transportation system. The simulation demonstrates that the rescheduling of activities and the rerouting of underground transport helps increase the throughput of the mine and ensure the stable flow of ore to the processing plant.

Outcome:

An underground mine is a complex system with many constraints and interdependencies. Simulation copes well with the complexity. The AnyLogic model replicates interactions between movable equipment units, as well as the operation of conveyors with continuous flows of ore.

Mining models require a lot of input data that is hard to maintain by mine planners. To simplify the usage of simulation on a regular basis, the new software tool was created. The tool consists of a domain-specific graphical user interface for mine planners and the AnyLogic mine simulation model.

This tool opens the way to efficient simulation usage in mine operations to support a wide range of decisions, from daily operations scheduling to the return on investments calculation.

Project presentation by Andrey Malykhanov, Amalgama

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