Simon Collins, TSG Consulting, Good Models are More Than Screen Deep: The Case of Newmont Mining’s...

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Simon Collins delivered the presentation at 2014 Bulk Materials Handling Conference. The 11th annual Bulk Materials Handling Conference is an expert led forum focusing on the engineering behind the latest expansions and upgrades of bulk materials facilities. This conference will evaluate the latest engineering feats that are creating record levels of throughput whilst minimising downtime. For more information about the event, please visit: http://www.informa.com.au/bulkmaterials14

Transcript of Simon Collins, TSG Consulting, Good Models are More Than Screen Deep: The Case of Newmont Mining’s...

  • Good models are more than screen deep Newmont Boddington Gold Case Study Bulk Materials Handling 2014 conference 01-05 30th April 2014
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning 1 CAPEX Optimsation 2 Plant commissioning performance evaluation 3 Operating & maintenance optimisation Three recent & succesful NBG studies Developing confidence in the NBG DES model Site knowledge NBG Model integrity TSG Cross functional study team System response System insights Iterative learning Introduction Page 2 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning TSG and NBG | study timeline The following represents the different studies that have been conducted over the past 14 years at the start date of the study. Page 3 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx Timeline 2000 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Preliminary study carried out to evaluate initial flow sheet. Plant only model Model updated to represent new flow sheet Model expanded to include mining to undertake trucking evaluation Mine interface study Contribution to financial modeling Model update and additional scenario analysis Expanded works study Optimization study Mine plant interface study with revised equipment and operating strategy Bottleneck analysis, upgrade options and variability evaluation Operations modeling
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning Model animations Page 4 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning Detailed truck and shovel model implemented during the latest studies Enabled understanding of crusher utilisation and variability in supply of material proper understanding of coarse ore stockpile sizing and the impact on system productivity NBG mining operation | animation Page 5 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning NBG mining operation | animation Page 6 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning Process model was updated from previous work major capital options testing required the largest model updates Significant effort to insert detailed bin level controls, up-to-date failure data, smart screen splits, conveyor capacity limits NBG processing plant | animation Page 7 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning NBG processing plant | animation Page 8 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning Summary of results Page 9 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning CAPEX Optimisation | summary Option 1: Minor CAPEX process improvement options Option 2: Large CAPEX possibilities allowing higher mill production rates Iterative process to arrive at a final set of cases increasing levels of system response insights and new improvement ideas Page 10 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx Process improvements capital options at varying mill rate assumptions
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning Plant commissioning performance evaluation | summary Detailed mining model development enabled rehandle approaches to be tested Confirmation and optimisation of truck and shovel strategies supplying the processing facility Page 11 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx Mining truck and shovels optimisation Effect of equipment upgrades with and without an operating mine
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning Operating & maintenance optimisation | summary Testing of maintenance strategies to minimise system disturbances and maximise production More than 15 maintenance schedules tested Minor upgrade timing effects Page 12 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx Planned maintenance scenarios testing Timing of equipment upgrades
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning NBG expertise Significant expansion project management and site management experience. This is a key element to a successful study outcome Data extraction and preparation: NBG team members excelled during this phase of the project and enabled model validation Documentation trail for internal critique Understanding of the decision making processes whether they be automated or manual decisions. One team member had significant control engineering experience on site Understanding how the supply chain should respond to change. Very knowledgeable team members with substantial operations experience. This enabled detailed validation work TSG expertise TSG has conducted more than 500 supply chain studies in almost 3 decades and is the companys core business. Successful studies require a high level of attention to detail for both modelling and reporting of pertinent insights Optimal input of data into the DES model and highlighting areas where data quality is key to a successful outcome Data and logic document implemented for the model Iterative and collaborative work with the NBG team to ensure model functionality and model output tools were accurately reflecting the real system Assisting with the development and implementation of sensitivity cases . Displaying meaningful outputs to allow system level assessment DES model performance | developing confidence Collaborative effort to arrive at a quality study outcome Page 13 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning NBG assigned significant resourcing to validate model against known plant performance Detailed checking of sensitivity case model outputs built confidence in expansion option case results DES model performance | example outputs Page 14 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx System component KPIs Annual production Equipment states Average equipment rates or truck cycle times Equipment output time series & distributions Conveyor rate limit 3, 2, 1 & 0 units offlineMajor planned outage No feed to conveyor 03 Average ball mill performance for a 1-year model run
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning System response testing System productivity with increasing mill rates (see right) System productivity with increasing truck numbers System productivity with increasing COS size Highlight point at which upgrades are no longer cost effective For the system as defined Other model changes could shift the point of cost effectiveness Combinations of upgrades are often effective Use of detailed outputs to assess where bottleneck predominates then propose changes to equipment upgrades or control strategies DES model performance | system response System response evaluation provides another layer of confidence that model is performing as expected Good models are more than screen deep Page 15 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx 32 33 34 35 36 37 38 Mean Mill Rate - 300 Mean Mill Rate - 200 Mean Mill Rate - 100 Mean Mill Rate Mean Mill Rate + 100 Mean Mill Rate + 200 Mean Mill Rate + 300 Mean Mill Rate + 400 Mean Mill Rate + 500 Mill Rate Sensitivity Mtpa Expected diminishing system return from increasing mill rate
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning -1 -0.5 0 0.5 1 -1 0 1 33 34 35 36 37 38 Throughput(Mtpa) DES modelling a powerful tool to understand supply chains NBG and TSG efforts resulted in a robust supply chain model Provides confidence for capital upgrade decision making Directly supplies financial analysis (IRR determination) Study process generates improvement ideas Facilitates a system level understanding Can highlight shortfalls in data collection systems Can highlight areas where higher system level control strategies can be improved Conclusions | Good models are more than screen deep Page 16 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx Design of Experiments: efficient system response understanding
  • 2012 TSG Consulting All Rights Reserved Simulation | Optimisation | Strategic Planning Questions The end Page 17 INT-MKT-PRE-BMH2014ConferencePresentation-01-05.pptx
  • 2012 TSG Consulting All Right