Simulation Helps Increase Production

Client: Mount Isa Mines

Modelling Copper Production

Metallurgists from Mount Isa Mines and operations research specialists from CSIRO collaborated on a simulation that helps decision making in copper production. The simulation is frequently used for planning production.

Mount Isa Mines Ltd is among the world’s top producers of lead, silver, copper and zinc. In a competitive market for copper, the company wanted to reduce the unit cost of production by increasing the throughput of its current copper production facility.

CSIRO designed an animated simulation model to allow Mount Isa Mines to evaluate different options for increasing the throughput in its copper production aisle. With copper prices of the order of $3000 a tonne, even small improvements in efficiency of the production process are valuable.

The model incorporates detailed operating procedures for the primary smelters, the anode furnaces, and the phasing of converter cycle times. It also includes the logic needed to control the operation of the two overhead cranes that operate on the aisle. These cranes are the main materials handling devices in the facility.

Scheduled maintenance is incorporated into the model as are unplanned breakdowns in the processes and shutdown of the plant because of environmental effects.

An animated simulation model allows engineers to investigate different operating scenarios. Animation was used to show the operation of the copper production aisle, and also to demonstrate different options for operating the aisle to management.

The model draws on CSIRO skills in simulation modelling and statistics and was validated with the help of Mount Isa Mines metallurgists. It can be run on a notebook computer.

What If?

An animated simulation model allows engineers to investigate different operating scenarios.

The model was linked to an Excel spreadsheet to provide a familiar software interface for staff to use when entering data for different operating scenarios and to analyse the results from these scenarios.

Since its delivery in 1995, Mount Isa Mines has used the simulation over 600 times, mainly for planning purposes. CSIRO makes modifications to the simulation as needed. The simulation model has been expanded twice to allow for changes to the copper production facility unforeseen at the time of the original development.

While the simulation model was tailor-made for Mount Isa Mines’ requirements, there are generic components in the software systems and the mathematical principles used can be applied to other industrial processes. Similar techniques have been used by CSIRO to model the operations of a coal terminal in Queensland and a WA salt production facility.

Client Feedback

The SIMAN model of the copper smelter aisle has been used extensively for comparing options for expanding the aisle throughput, and identifying bottlenecks. Over 600 runs have been completed. This is the first model of the aisle with which we feel confident of extrapolating aisle performance.

James Edwards, Acting Process Development Manager, Mount Isa Mines

Further Information

See the pdf document entitled Simulation Helps Increase Production, or contact David Sier

Page last updated September 08, 2004 01:02 PM by Mark Horn.