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Then they used the optimization model’s outputs as inputs for the mining operations simulation model. In the mining model, the engineers also considered the shift times of staff working on the site, as well as equipment failure and maintenance.ĭuring the first stage of the project, Genoa built an optimization model with an external solver to maximize the transportation capacity in the mines. The tailings are moved to a silo by a conveyer and then to the tailings dam by a truck. The plants produce three types of products: thermal (steam) coal, metallurgical (met, coking) coal, and a subproduct called tailings. Along with coal, mining extraction machines also retrieve waste that has to be transferred by truck to waste deposits.Įxtracted coal passes through a crusher and then goes to plants where it is processed. Retrieved coal is moved by trucks either to the crusher or the ROM pad next to it. One ROM (run-of-mine) pad, one crusher, and one tailing silo per mine.Ĭoal mining process diagram (click to enlarge)Įach mine has several mining fronts from which various coal types are retrieved.80 trucks with various capacity, speed, and failure profiles.8 concurring mining fronts operating simultaneously.Solution: Optimizing and simulating mining operationsĮngineers from Genoa built a model of two open-pit coal mines. To test different scenarios without disrupting the operations, Vale opted for simulation modeling and contracted with Genoa, a decision support company specializing in optimization and simulation. The company wanted to maximize the productivity of its open-pit coal mines in Moatize, Mozambique. It is also one of the largest logistics operators in Brazil.
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Vale is a Brazilian multinational corporation engaged in metals and mining.