Case Study:
Blend Mix Optimisation
Case Study:
Blend Mix
Optimisation
Client Challenge
A major copper producer in North America had its smelter as the critical bottleneck.
The challenge faced is that the throughput rate of the smelter is predominantly driven by the copper to Sulphur ratio of the feed, which changed depending on the mining schedule.
Purchasing external concentrate favored the copper to Sulphur ratio (increasing throughput), however such ore is more costly than ore sourced internally.
Given the non-linear complexity of the plant, what is the ideal mix?
The Solution
- Using a value stream model, an optimisation algorithm was developed and implemented that would take a daily view of the supply of concentrate from various sources, and determine an optimal configuration for the mills and the smelter.
- Trading off grind quality versus speed as well as the cost of purchased concentrate versus the quality of feed to the smelter, the algorithm determined a plan that would maximise profit.
Solution Value
- Test runs of the algorithm indicated that up to $70m in incremental annual operating profit can be realised by suitable configuration of the processing chain.
- The model is now in use on a regular basis for daily / weekly production planning purposes.