This case study is an example of a recent materials handling simulation study completed for an Australian client.
The study objective was to determine the sustainable capacity given a proposed increase in production for the total minerals material handling system. This involved evaluating various options aimed at minimising the capital outlay for the expansion of the materials handling system.
The simulation model developed included the mining operation through to the processing stockpile. The operation was broken into four modules that represented the interfaces between the system components.
These were defined as hauling, primary crushing, secondary crushing and reclaiming / conveying / processing stockpile. Detailed data analysis was undertaken to ensure all data and logic rules used accurately modelled site operations. Planned and unplanned outages for all the fixed and mobile plants were included.
To achieve the proposed increase in tonnes, a process of bottleneck identification and shifting was undertaken. To ensure the mine could meet the demands of the increased tonnes the mining operation was tested using different truck capacities and variable sized fleets.
Once the mining operation had sufficient capacity to meet the target tonnes the bottleneck shifted to the conveying system. Sensitivity analysis was undertaken to determine the impact the operating hours, operating rate, scheduled maintenance and random breakdowns had on the system. Both a conservative and optimistic maintenance plan were tested at two different conveyor operating rates.
The simulation model provided the solutions to ensure that the operation would achieve the production target. This was achieved while minimising the capital expenditure required. The study showed that the most gain in trying to reach the production target was achieved through increasing the conveyor capacity and by revising the maintenance plan for the conveyor.
A number of areas provided detailed information for the client to make an informed decision regarding capital outlay. This included assessing the truck fleet to ensure the mines could produce sufficient feed to the conveyor. The model allowed fleet and truck sizing recommendations to be made to minimise the number of trucks required to meet current and future targets.
By using these proven methods, the case study participant now has the real problems are identified, and further opportunities for improvement were uncovered. In addition, the participant has a model which can be used through the entire life of the project to optimise performance and minimise costs.
Typical study benefits include:
- Providing a valuable source of information to assist the owner’s team with key design criteria
- Evaluating the sensitivity of major design settings and quantifying their impact on sustainable production
- Providing operational insights into the system’s behaviour under varying conditions
- Assessing the component interfaces and the impact on the total integrated system
- Providing confidence in the final design’s ability to achieve production targets
Simulation modelling can be used to accurately predict the behaviour of any system, operating or proposed, to:
- Solve production problems
- Eliminate bottlenecks
- Minimise queuing
- Deal with variations in supply and demand
- Confirm the most effective expansion path
- Utilise existing assets more effectively
- Understand why certain events occur
- Aid in strategic planning
- Communicate the understanding and ideas behind proposed changes
TSG models and analytical consulting services have helped Boards and management executives of major companies come to grips with the complex issues involved in both new projects and existing operations.
Better decisions can be made when the right facts can be examined, various options explored and conclusions tested. Simulation modelling and scheduling are the tools required to make this process work.