From the bottom to the transshipment point. An example of the integration of GEOVIA Surpac and the automated dispatch system of the State Customs Committee
What do enterprises produce? Gold, iron ore, coal, diamonds? Not!
Every company makes money. This is the goal of every enterprise. If the extracted ton of gold or iron ore does not bring you income or, worse, your costs are higher than the profit from the sale of products, what is the value of this ore for the enterprise?
Each ton of ore should bring maximum income or bear minimum costs in conditions of safe production and observance of production technology. Those. the distribution of rock mass movement over time should lead the enterprise to the goal. In order to achieve the goal, it is necessary to create a good plan that will simulate the production process with the maximum achievement of volume-quality indicators. Each plan must be provided with accurate, accurate and current data. Especially when it comes to short-term or operational planning.
What data does mining planning provide? This is surveying and geological information, design data and production and technical information (for example, from ERP systems).
All these processes carry a huge amount of graphical, digital and textual information, such as a cloud of laser scanning points, a surveying database, operational bottom-hole surveying, a geological block model, test data from blasting wells, changing contacts in blasted rock mass, production indicators and their changes, changes in the dynamics of equipment operation, etc. The data stream is constant and infinite. And most of the information depends on each other. We must not forget that all this data is the primary source, the information with which the creation of the plan begins.
Therefore, to create the optimal plan, you must be able to obtain the most accurate data. The correctness of the source information exponentially affects the final goal.
If one of the sources carries data with low accuracy or incorrect information, then the entire process chain will be erroneous and distant from the goal. Therefore, you must have resources that allow you to qualitatively prepare data and work with them.
If we talk about short-term planning, it is important that this data is not only accurate, but also relevant. You must be able to receive information at any time in order to respond to changes and quickly edit the production scenario. Accordingly, we need such systems and equipment that will improve the efficiency of the processes for obtaining and processing information. Lidar scanners allow you to quickly obtain data with high accuracy, rock sampling technologies give a picture of the position of the ore body in the array, positioning systems track the position and condition of the equipment in real time, and GEOVIA Surpac design and planning systems and GEOVIA MineSched work projects and are tools. To achieve the goals as quickly as possible, the systems must be connected in a single productive chain. Imagine: you get data from different systems and sources, but they are available to you only upon request, in addition, this data is transferred to you by a specialist who can change the content at any time.This leads not only to a decrease in the speed of data acquisition, but also to a loss of accuracy or reliability at one of the stages of data transmission. Therefore, data must be centralized, stored on one platform, in one digital ecosystem and be available at any time. In addition, it is important to ensure the collaboration of all departments, versioning, integrity and data security. The 3DEXPEREINCE platform is up to the challenge.
Information obtained from various sources - electronic systems, GGIS (GEOVIA Surpac) systems, ERP systems, automated mining planning systems ( GEOVIA MineSched ), mining management systems (for example, VIST Group) - has a different data format.
This raises the question of systems integration. Often, all decisions in the chain of mining planning and design can be more or less integrated with each other.
But the intensity of the data flow, the number of their types, and variability are such that a person is not able to convert from one system to another in a relatively quick time. Whether a geologist or a planning engineer, a specialist should not spend time importing and exporting files from one system to another, he should create value and move the enterprise to the goal. Therefore, the integration process is important to automate, configure in such a way that the number of manipulations on data processing is minimized.
Without automation, the process looks something like this. After the survey, the surveyor connects the scanner to the PC, extracts the survey file, converts the data to the appropriate format, opens the file in the GGIS system, creates a surface, performs the necessary manipulations to calculate volumes and generate reports, saves a new version of the surface file on a network resource. To update the block model, he finds an updated survey file, downloads it and the corresponding block model, uses the survey file as a new limiter, performs manipulations to calculate volume-quality indicators and generate reports.
In the presence of operational data, for example, from dispatch systems, the geologist unloads data from such a system, imports coordinates into the GGIS, forms a new file of limiters. If the network resource has the actual sampling data from the laboratory, it gets through to it through a string of folders and loads them, updates the block model, creates certificates, saves work files, converts the data to the format necessary for the dispatch system and loads them into this system. It is important not to forget about creating an archive copy of all files.
The automated process of data processing and integration with surveying and geological support for mining using GEOVIA Surpac is as follows. The survey is ready, the surveyor connects the instrument to the PC, opens GEOVIA Surpac, starts the function of importing and processing the survey data, selects from the list what needs to be obtained as a result.
The system generates graphic and tabular data, updates the working file on the network resource and saves the previous version of the file. The geologist launches the update functions of the block model according to the current surveying data and/or data from dispatch systems.
All data is loaded from a network resource/platform, the macro converts and imports the necessary data, the geologist only needs to select the appropriate settings. After checking with the appropriate functions, the result is saved and exported to other systems.
Such a process was implemented in the surveying and geological services at the Kachkanarsky GOK of the EVRAZ company.
EVRAZ KGOK is one of the five largest mining enterprises in Russia. The plant is located 140 km from EVRAZ NTMK, in the Sverdlovsk region. EVRAZ KGOK is developing the Gusevogorsk deposit of titanomagnetite iron ores containing vanadium impurities. The vanadium content allows smelting high-strength alloy steel grades.The production capacity of the plant is about 55 million tons of iron ore per year. The main consumer of EVRAZ KGOK products is EVRAZ NTMK.
Currently, EVRAZ KGOK extracts ore from four quarries with its further processing in crushing, processing, sintering and sintering workshops. The final product (sinter and pellets) is loaded into railway wagons and sent to consumers, including abroad.
In 2018, EVRAZ KGOK produced more than 58.5 million tons of ore, produced 3.5 million tons of sinter, 6.5 million tons of pellets, and about 2.5 million tons of crushed stone.
Ore mining is carried out in four quarries: Main, Western, Northern, as well as Southern deposit. BelAZ trucks deliver ore from lower horizons, and the rock mass is transported to the crushing plant by rail. Quarries use powerful 130-ton dump trucks, modern NP-1 locomotives, excavators with a bucket capacity of 12 cubic meters.
The average iron content in the ore is 15.6%, and the vanadium content is 0.13%.
The technology for producing iron ore at EVRAZ KGOK is as follows: drilling - blasting - excavation - transportation to the processing site and overburden to dumps. ( Source ).
In 2019, an automated dispatching system VIST Group was introduced at Kachkanarsky GOK. The implementation of this solution allowed to increase the production control of mining equipment, ore movement from faces to transshipment points, as well as to quickly obtain data on volume-quality indicators in the faces and at transshipment points. Bilateral integration of the VIST and GEOVIA Surpac ASD systems was carried out, which made it possible to use the obtained data (equipment position, bottom face mining, rock mass balance at transshipment points, quality distribution at transshipment points, etc.) for operational planning and design of mining operations, as well as control the production process at the level of line manager and excavator driver.
Thanks to the development of the leading geologist S.M. Nekrasov and the chief surveyor A.V. Without money, experts of the surveying and geological departments using GEOVA Surpac tools automated most of the processes for processing surveying data, designing, creating printed documentation, creating geological block models, updating geological and surveying information on a network resource. Now, specialists do not need to perform repetitive processes daily, whether it is uploading/downloading a survey from/to the device, searching for the necessary data for everyday work in a huge number of folders. The GEOVIA Surpac macros do this for them. It is important to note that these data are available to all involved specialists from different departments. For example, in order to open the last survey of a quarry, an updated block model, a block of explosive reconnaissance, communications, etc., a planning specialist does not need to look for this in a large number of surveying and geological files. All he needs for this is to open the corresponding menu in GEOVA Surpac and select the data that needs to be loaded into the working window.
Automation tools made it easy to integrate GEOVIA Surpac and ASD VIST Group and make this process as simple and fast as possible.
By selecting the appropriate menu in the GEOVIA Surpac panel, the geologist obtains operational data on block mining or data for a specific date and time from VIST ASD. This data is used to analyze the current situation and update the block model.
After updating the block model and ore/overburden contacts in GEOVIA Surpac, the geologist loads this information with the click of a button into the VIST ASD system, after which the data is available to all users in both systems.
By combining the capabilities of mining transportation equipment positioning tools in the VIST Group ASD system and GEOVIA Surpac tools, the processes of controlling rock mass movement from the bottom to the transshipment point, placing rock mass in the sectors of transshipment points, controlling the balance of rock mass arrival/departure by sector and maintaining mobile residues were set up for the period of operational filling.
For this, in GEOVIA Surpac, block models of transshipment points were created and a methodology for filling them was developed. At the request of the geologist, the process of adding rock mass to a virtual transfer point in a block model (BM), as well as shipping from it, can be carried out both entirely over the past period and online. Having set the BM to be filled with an indication of the end time, the macro program itself makes a request (at a certain time interval) to retrieve data on excavators digging, and also extracts information on the movement and unloading of vehicles at a transshipment point.
Thus, at the end of the macro program, current information is generated on the state of the warehouse, the presence of rock mass for a given period of time in three-dimensional graphical form, and a summary table of the results of the operational change. This made it possible to quickly monitor the movement of ore, the balance and distribution of rock mass in the sectors of transshipment points, as well as present this information graphically in both systems and provide quick, free and safe access to information for all employees. In particular, according to the leading geologist S.N. Nekrasov, such a process has improved the accuracy of planning shipment in quality from transshipment points to rail.
He also notes that if earlier it was possible only to assume that it was brought to transshipment points and to represent only the average value of quality by sectors, today indicators are known for each individual sector of the sector.
To quickly analyze all sectors of transfer points and generate a tabular report, a macro was written in GEOVIA Surpac, which displays and saves graphic information in the specified format. In this case, there is no need to open the block model of each sector, apply constraints, color the block model by attributes, manually generate tabular reporting. All this is done with the click of a button.
You can learn more about the integration process and the results of the integration at Kachkanarsky GOK from the webinar “A new approach to automation of planning, drilling and blasting and quality management in the enterprise "by link
Obtaining the necessary up-to-date data at any time, easy and quick access to up-to-date information, possession of tools that allow you to exchange and manage this data in various systems and interact with units opens the way to more and more opportunities to create a digital double of your enterprise, which allows you to create more realistic scenarios of your mining plan and respond quickly to emerging changes during production.
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