This experiment type is probably the most complex since the model run results are passed into an optimizer, which then generates the next set of model input values to be run based on the already executed run results. At that time, we believed it would not take long to implement it. In 2017, when AnyLogic Cloud was first released, users could choose “Optimization experiment” in the New experiment menu, and then a “Coming soon” message would appear. Genoa presented this case study at the AnyLogic Conference 2021.Since the very beginning of our AnyLogic Cloud product, we eagerly wanted to support an optimization experiment. ![]() Finally, to simulate the movement of the trucks in detail, they could use AnyLogic Road Library instead of schematically drawing the routes. They can also analyze the mine’s performance with different truck and equipment fleets and simulate shift and maintenance policies.įor further model improvement, the team considered modeling mines as a population in AnyLogic, which would help scale the model for other scenarios. Vale can now use the simulation model to assess different mining operations scenarios and visualize and compare results. Using an external optimizer, they determined the best truck fleet size and maximized the amount of coal that could be transported, while also considering the transportation of waste and tailing constraints. Genoa built a simulation model of coal mining operations in Moatize, Mozambique. To simulate truck behavior in detail, they also used agent-based modeling and statecharts. The team used discrete-event modeling as the main approach for modeling equipment and machinery movements. ![]() Using the optimization results data, the engineers built a simulation of coal mining operations that showed how the mine’s processes could be improved. Thanks to AnyLogic’s capability to import external Java libraries, the team could import and use the data from their optimizer directly inside the simulation model. Operator shift and maintenance planning.Ĭoal mining simulation and optimization model (click to enlarge).Utilization levels for the trucks, loading equipment, and crusher.Cycle times of trucks: travel time, queue before loading, loading time, queue before unloading and unloading time.Uncertainties like equipment failure (trucks, loading equipment, and crusher).In addition, the software also allowed the analysis of other key open-pit management metrics, including: In AnyLogic, the engineers visualized the results provided by the optimizer using charts, diagrams, and timelines. 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. Vale is a Brazilian multinational corporation engaged in metals and mining.
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