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To cite this article: Angelina Anani, Kwame Awuah-Offei & Joseph Hirschi (2016): Application
of discrete event simulation in optimising coal mine room-and-pillar panel width: a case study,
Mining Technology, DOI: 10.1080/14749009.2016.1195035
(number of entries). Data from a real-life mine is used to validate the model in Arena®. An optimal panel
width is recommended based on simulation results.
Keywords: Discrete event simulation, Room-and-pillar mining, Panel width optimisation, Simulation analysis program, Monte Carlo simulation, Fleet
size optimisation, Coal mine, Productivity
panel width design as a possible dual objective optimisation of uncertainty on the performance indicator. Similarly, Petering
problem where we seek to maximise productivity and mini- (2009) investigated the optimal width of storage blocks in a
mise unit costs subject to all constraints. The approach is to terminal container and its effect on gross crane rate.
build a discrete event simulation (DES) model and use it to The advantage of DES lies in its ability to model complex
conduct experiments to estimate the productivity and unit systems with relative ease. DES allows for implementation of
costs at varying panel widths and operating conditions. As a new designs and methods without interfering with the real-life
case study, a coal mine is modelled as a DES using Arena® system. DES also helps answer the question of why certain
(Rockwell Automation Inc., Milwaukee, WI). phenomenon occur (Asplund and Jakobsson 2011). It has the
ability to capture random behaviour caused by a large number
of factors that impact the system, using the Monte-Carlo sim-
Discrete event simulation for panel ulation technique. This gives a sense of interactions between
width optimisation variables that make up such systems.
DES can be used to perform ‘bottleneck’ evaluations to
DES for engineering design
discover where work in process in a system is delayed and
DES is a computer-based approach that facilitates modelling, which variables affect this. Identifying problems and gaining
simulation and analysis of the behaviour of complex systems understanding into the importance of these variables increases
as a sequence of discrete events. DES software has been con- awareness of their importance relative to the performance of the
tinuously improved for the past four decades leading to more overall system. DES allows an analyst to vary the system oper-
advanced simulation languages (Nance 1995; Pegden et al. ating periods, cheaply and easily (Schriber 1977). On the other
1995; Rice et al. 2005). Simulation languages are symbols/ hand, even though DES provides a way to analyse and under-
codes recognised by computers or computer programs as stand the changing behaviour of the system, it only provides an
issued commands a programmer wishes to perform (Kiviat estimate of the model output. Building DES models can be costly
1969). Common simulation languages currently used for DES and time consuming. Therefore, it is used on an as-needed basis
include SIMAN (system modelling), GPSS and SLAM. This where benefits outweigh costs (Asplund and Jakobsson 2011).
work uses Arena®, which is based on the SIMAN language
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Case study
A case study of an actual coal mine is presented in this section
to illustrate the approach discussed in Section DES for panel
width design. The discussion here follows the general steps
of a typical simulation study (Kelton et al. 2003).
Problem formulation
The objective of the panel width optimisation study is to eval-
uate the impact of panel width on the unit cost and produc-
tivity of an underground R&P operation. A DES model with
variables that characterise the mining system was built using
1 Haulage unit dumping time Arena®. The model predicts unit mining costs and produc-
tivity at different panel widths. The DES model was validated
with shift production data obtained from a R&P coal mine
in southern Illinois, United States of America (USA). The
defined performance metric was that the relevant simulated
output should be within 15% of actual values from the mine.
coal per year from the Herrin No. 6 seam using R&P mining
methods with a panel recovery rate of 54%. Eight Joy Model
14CM27 CMs (two for each panel) cut and load coal at up to
40 tons per minute with a maximum cutting height of 11.2 feet.
2 Empty haulage unit travel speed Coal is hauled from CMs to feeder-breakers by 20-ton Joy
Model BH20 battery-powered haulage units. A feeder-breaker
is located at the centre of each production panel to transfer
mined coal from haulage units to conveyor belts. As the panel
advances, it is moved forward in three-crosscut increments
with each crosscut forming a row of in-line pillars across the
panel. The full width of the panel is mined in six-cross-cut
increments. The mine has experimented with different panel
widths and mining sequences. Currently, advancing base
widths of 11 and 13 entries before mining rooms is the most
common. Maximum and minimum panel widths are 21 and
11 entries, respectively. Each CM mines up to seven entries
on one side of a panel.
The objective of the simulation is to develop a valid DES
model that predicts unit mining costs and productivity and
3 Loaded haulage unit travel speed provides basic animation for verification. Input data used in
the model were obtained from time studies done at the mine as
described by histograms in Figs. 1–6. Raw data were analysed
to fit statistical distributions using the chi-squared goodness-
of-fit test as shown in Table 1. Input data include loading and
dumping times, payloads and battery change data, which are
sampled from the distribution. Model output includes produc-
tion per shift, tons per hour, total operating costs including
equipment costs and the calculated cost per ton for a given
panel width.
Mining Technology 2016 3
Anani et al. Application of discrete event simulation in optimising coal mine room-and-pillar panel width
non-consecutive shifts. During the first shift, 6.33 hours were as an input based on mining practices at the mine. Mining
spent making 11 cuts with the remaining time spent on con- faces in the 11- or 13-entry base width are mined using the
veyor belt and CM repairs. The second shift was spent entirely cut sequence shown in Fig. 8. Rooms are mined using the
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on production; however, data was collected for only the first cut sequence shown in Fig. 9. The experiment evaluates a
half of the shift during which seven cuts were completed. super-section mining system with two CMs (one on each side
For both shifts, coal was hauled by four haulage units with of the section). The conveyor belt is located in the centre
an average payload of 10,886 kg (12 tons). The production entry of the panel.
reported from the CM’s onboard monitoring system indicates The simulation output includes production data (e.g. load
that the mine produced 2.2M kg (2448 tons) of coal from 204 count and total production tonnage), duration of mining and
loads and 3.2M kg (3576) from 298 loads during the first shift percentage of time the CM spends loading haulers. Other
and second shift, respectively. outputs include total cost of mining and estimated unit costs
In the validation experiment, 150 replications were con- (Equation (2)). Results of simulation experiments are dis-
ducted to obtain estimates of load count and total coal pro- cussed in the Results and Discussion section.
duction, mining duration and other output. The number of
replications selected was such that the half-width1 of the min- nCM CCM + nH CH tr + CF
( )
ing duration (the most uncertain output) is less than 1% of the Unit costs($∕ton) = 2
Total production
estimated duration. The cut sequence used in the validation
experiment duplicated that used during the time-and-motion where nCM and nH are the number of CMs and haulage units,
study. Each replication stops when all specified cuts have been respectively; tr is the duration of the simulation run; CCM and
mined in the simulation. Results are discussed in the Results CH are hourly costs for CMs and haulage units, respectively;
and Discussion section. and CF is fixed costs, which include labour and equipment for
advancing belt and power systems.
Mining Technology 2016 5
Anani et al. Application of discrete event simulation in optimising coal mine room-and-pillar panel width
9 Room cut sequence for 11 entry advance with two additional rooms on each side
1.40
24.0 11 13 15 17 19 21 23
11 13 15 17 19 21 23
Number of entries
Number of entries
17 Unit costs
13 CM time spent loading (RHS)
10.45
Productivity (tph)
10.40 550
10.35
10.30 540
10.25
10.20 530
11 13 15 17 19 21 23
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16 Productivity
Effect of fixed costs
From Equation (2), if fixed costs are negligible, the unit costs
• Unit costs decrease with increasing number of entries
curve should be the inverse of the productivity relationship.
due to the effect of fixed costs.
However, Figs. 16 and 17 do not show this relationship
indicating that fixed costs significantly affect the unit cost
Effect of number of haulage units relationship. Figure 22 shows the sensitivity of the unit cost
relationship to fixed costs using results for the 11-entry system
Figures 18 and 19 show the sensitivity of productivity results with four haulage units (same as Fig. 17). Figure 22 shows
to the number of haulage units. It can be observed that with that the unit cost relationship will indeed show an optimal at
the addition of each haulage unit, productivity increases; 17 entries if fixed costs are less than or equal to $1000. Fixed
Mining Technology 2016 7
Anani et al. Application of discrete event simulation in optimising coal mine room-and-pillar panel width
3 Cars 4 Cars 5 Cars costs as low as $2000 more than compensate for any decline in
productivity due to under-resourced CMs. That is, with high
560 fixed costs (≥$2000), unit costs for mining larger panels will
be lower, even though productivity will be sub-optimal after
Productivity (tph)
550 the panel width exceeds the optimal panel width for produc-
tivity. From a cost perspective, larger panels are advantageous
540 because of fixed costs included in moving belt and power.
530
Conclusion
520 This research effort has successfully built a discrete event
13 15 17 19 21 23 simulation model that can be used to facilitate panel
Number of entries width design. The DES model is capable of evaluating
the effect of panel width (number of entries) on R&P
19 Effect of number of haulage units on productivity for mine productivity and unit costs. The DES model has
13-entry system
successfully been validated for the mine that cooperated
with this study. The validated model has been used to
evaluate the effect of panel width on productivity and unit
3 Cars 4 Cars 5 Cars
costs of the mine.
$3.60 Based on results of this work, the following general con-
clusions can be made:
Unit costs ($/ton)
$2.40
Acknowledgement
$2.00
13 15 17 19 21 23 This work was made possible with funding from the Illinois
Clean Coal Institute. The authors are grateful for the support
Number of entries
of Prairie State Generating Company, owners of the cooper-
21 Effect of number of haulage units on unit costs for
ating mine for their support during this research. The authors
13-entry system are also thankful to Ms Sisi Que and Mr Mark Boateng for
their assistance.
$- $500.00 Funding
$1,000.00 $2,000.00 This work was supported by Illinois clean coal institute
$1.65 [13/3B-1].
Unit cost ($/ton)
$1.60
$1.55 Notes
1. Half-width = tn−1,1−𝛼∕2 √s n, tn−1, 1−α/2 = critical values from
$1.50
11 13 15 17 19 21 t tables, n = number of replications, s = sample
No. of entries standard deviation.
2. InfoMine cost data is used in this paper to protect the
22 Effect of fixed costs on unit cost relationships mine’s confidential data.
Notes on contributors Harrison, J. and Sturgul, J. R. 1988. GPSS computer simulation of equipment
requirements for the iron duke mine, 2nd large open pit mining conference,
Angelina Anani is a postdoctoral fellow at the Missouri AusIMM, 133–136.
InfoMine. 2013. Mine and mill equipment costs, UG-10–UG-48, Spokane
University of Science and Technology. She holds a PhD Valley, InfoMine USA Inc.
and BSc degree in mining engineering from the Missouri Kelton, D. W., Sadowski, R. P. and Sturrock, D. T. 2003. Simulation with
University of Science and Technology. Her current research Arena, New York, McGraw-Hill.
interest includes modelling and optimisation of mining Kiviat, P. J. 1969. Digital computer simulation: computer programming
systems. languages, Santa Monica, CA, Rand Corporation, RM-5883-PR.
Kleijnen, J. P. C. 1998. Experimental design for sensitivity analysis,
Kwame Awuah-Offei is an associate professor of mining engi- optimization, and validation of simulation models, in Handbook of
neering at Missouri University of Science and Technology. simulation – principles, methodology, advances, applications, and practice,
His research interests revolve around applying modelling, (ed. J. Banks), 173–223, New York, Wiley.
simulation and optimisation to promote sustainable mining Loui, J. P. and Sheorey, P. R. 2002. Estimation of non-effective width for
different panel shapes in room and pillar extraction, International Journal
practices. He holds a PhD and BSc degrees in mining engi- of Rock Mechanics and Mining Sciences, 39, (1), 95–99.
neering. He is a registered professional engineer. McHaney, R. 1991. Computer simulation: a practical perspective, San Diego,
Joseph Hirschi is an assistant professor of mining engineering CA, Academic Press.
at Southern Illinois University Carbondale. His research inter- Michalakopoulos, T. N., Arvaniti, S. E. and Panagiotou, G. N. 2005. Simulation
ests are in mine and power plant optimisation; mining meth- of a continuous lignite excavation system, International symposium on
mine planning and Equipment selection (MPES 2005), Alberta, Canada,
ods; coal processing; and miner health, safety, and training. 1694–1706.
He holds a PhD, MSc, and BSc degrees in mining engineering Nance, R. E. 1995. Simulation programming languages: an abridged history,
and an MBA. He has been certified by the State of Illinois Proceedings, 27th Winter Simulation Conference, IEEE computer society,
as a First Class Miner, Mine Examiner, Mine Manager, and 1307–1313.
Pegden, C. D., Sadowski, R. P. and Shannon, R. E. 1995. Introduction to
Shot Firer. simulation using SIMAN, New York, McGraw-Hill.
Pereira, S. P., Costa, J. F. C. L., Salvadoretti, P. and Koppe, J. C. 2010.
Simulação de produção em mina subterrânea de carvão com uso
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Mining Technology 2016 9