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Research proposal

OPTIMISATION OF SHORT-TERM
SCHEDULING FOR CEMENT
LIMESTONE QUARRY PRODUCTION
Vu Dinh Trong
Content
1. Background
2. Research problem
3. Research gap
4. Aims
5. Mathematical model
6. Solutions
7. Case study
8. Contributions

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Background

Corrective
Purchasing

Cement
Quarry Crushing & Raw material Blending Processing
products
Sizing preblending

A general diagram of cement manufacturing process

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Cao, Al2O3,
Limestone are the primary
raw material for cement
SiO2, Fe2O3 industy

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Quarrying method

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Exploration Ore body modelling Grade estimation

Short-term production
Long-term production
scheduling
planning

Steps in quarry production planning

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Research problem

Bench 1 Time horizon:


short term (3-6 months) Corrective
Period: 1-2 weeks Purchasing
Bench 2

. Crushing Raw material Processing


Quarry Blending
& Sizing preblending
.

.
Cement
Bench n MINIMIZE COST = Mining cost + Corrective purchasing cost
Products

Block 1 Block 2 ... Block n

1.6 tons of raw


= 1 ton of cement
materials

Save $1 per ton of = Save $ billions


raw materials
Research Gap
Studies on short term production
scheduling in mining industry
Fail
Metallic
ore mining
Quarring
Current manual methods

Cao

SiO2 Al2O3


Fe2O3 MgO
Economic
LOI
value
Quarry block model input Open pit mining block model input
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Aims

New optimization model

Practical case study


OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Research method

Bench 1 Time horizon:


short term (3-6 months) Corrective
Period: 1-2 weeks Purchasing
Bench 2

. Crushing Raw material Processing


Quarry Blending
& Sizing preblending
.

.
Cement
Bench n Products

Block 1 Block 2 ... Block n


INPUT

Objective
Minimize (mining cost + additive
purchasing cost)

Mathematical Model

Constraints:
- Quantity;
- Quality;
- Mining sequencing
MIXED INTEGER PROGRAMMING MODEL

Decision Variables:

t 1, if block i is mined by machine m and sent to stockpile s in the period t


xims ቊ
0, otherwise
ytjs = Quantity of corrective j used in the period t (tonne)

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Objective function

Mining cost Corrective


purchasing cost

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Quantity
 Machine capacity constraint

 Mining production requirement

 Quantity of correctives constraint

 Stockpile capacity

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Quanlity

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Mining sequencing

 Precedence constraints
a, 1:5 slope
pattern: to
mine block 6
in level two, 5
blocks in level
1 are mined
first
b, 1:9 slope
pattern: to
mine block 10
in level two, 9
3D block model blocks in level
1 are mined
first
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Mining sequencing
 Minimum working space

For minimum working space, blocks


2,3,4 are mined before block 7 in
same bench
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Solutions for the model

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Case study

Ta Thiet cement limestone quarry layout, Vietnam (Google map – January 2017)

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Case study

Ta Thiet 3D block model input for short term scheduling of 6-month period
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Case study

1st month
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Case study

2nd month
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Case study

3rd month
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Case study

4th month
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Case study

5thmonth
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Case study

6th month
OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION
Contributions of the research
 Create a novel real-life short term production
scheduling model for cement quarries;
 Improve the quality of blending in cement
manufacturing operations (blending is fulfilled not
only at stockpiles but also at quarry benches);
 Utilize properly and efficiently limestone resource.

OPTIMISATION OF SHORT-TERM SCHEDULING FOR CEMENT LIMESTONE QUARRY PRODUCTION


Thank You