Use of the modular dispatch system

to control production operations

at the DOZ block cave mine
Rudy Prasetyo, Superintendent Cave Management, David C. Flint, Technical Expert – Cave Management,
Tarsisus B. Setyoko, Chief Dispatch EngineerP. T. Freeport Indonesia
Eddy Samosir, Project Engineer, Strategic Planning, Freeport McMoRan Inc.

Abstract
The Modular Mining Dispatch software and hardware systems have been installed at the DOZ Block Cave Mine to aid
production operations. The system is being utilized to implement the daily detailed production plan, prioritize the location
of production for each individual loader, collect actual drawpoint production data, provide real-time drawpoint status data
and to measure loader productivity. Discussion is provided as to how use of the system benefits each of these points.
This paper also describes the software and hardware configurations, as installed to control extraction and haulage operations of
the mine. The Intelimine Dispatch software logic has been customized for DOZ conditions and production control requirements.
The hardware system consists of a central computer, a micro-cell network and field computerswhich are installed on each mobile
equipment piece. Communication between the mobile equipment and the network micro-cells is by UHF radio transmissions.
Hubs manage the communications between the equipment and the system’s central computer, and monitor vehicle vital signs.
Dispatch operations are monitored by Dispatch Engineers from a central underground location.
Use of the Dispatch software has increased the reliability of production data and compliance to the production plan, and
allows for a higher degree of management of the block cave.

1 INTRODUCTION

The Deep Ore Zone (DOZ) block cave mine, operated by

P. T. Freeport Indonesia (PTFI), is located in the Ertsberg
District, West Papua Indonesia (Figure 1). Development of
the mine was initiated in 1997, production commenced in
2000 (Barber et. al, 2000), and currently produces at 40,000
tonnes per day.
DOZ is the third level of block caving to exploit the copper-
gold Ertsberg East Skarn System (EESS). The Gunung
Bijih Timur mine (GBT) exploited upper levels of the deposit
(Owen, 1992), from which 68.7 million tonnes at a grade of
1.93 % copper was extracted. The Intermediate Ore Zone
(IOZ) mine produced from the deposit between the 3456
meter and 3706 elevations, with 43 million tonnes of ore on
an average grade of 1.21 % copper and 0.43 g/t gold
extracted.
Figure 1: Ertsberg Mining District Location Map.
The Intellimine Dispatch system, of Modular Mining Inc.,
has been installed at DOZ to control block cave extraction
and haulage operations.
herringbone layout, are spaced at 18 meters along the
panel drifts (Barber, et. al. 2001) (Figure 2). Currently,
2 THE DOZ BLOCK CAVE MINE DOZ produces from 240 drawpoints, accessed from 15
panel drifts.
The DOZ mine exploits the Ertsberg East Skarn System The undercut level is developed 20 meters above the
(EESS) deposit between the 3470 and 3120 meter (base of extraction level. The advanced undercut method is utilized
the IOZ mine) elevations. Draw column heights are 350 for caving. Caving has been completed for the eastern
meters where below the IOZ, and a maximum of 500 meters portion of the mine, and will be initiated for the western
elsewhere. The DOZ block cave mineable zone extends portion in the 4th quarter of 2004.
approximately 900 meters along strike and varies between Block cave ore is delivered from drawpoints to orepasses
200 to 350 meters wide. The mine is an advanced undercut, by load-haul-dump (LHD) equipment. A four (4)-meter
mechanized block cave, utilizing truck haulage and a diameter orepass is located in the center of each panel drift,
gyratory crusher. as ground conditions allow (Barber et. al, 2001). In addition,
The extraction level has been developed at the 3120 three (3) orepasses, two (2) fitted with rock breakers, have
meter elevation. Panel drifts are oriented perpendicular been constructed along the extraction level fringe. All
to the strike of the deposit and are developed on a orepasses bottom at truck-loading chutes at the haulage
spacing of 30 meters. Drawpoints, developed with the level.

696 Santiago Chile, 22-25 August 2004 Massmin 2004

 Figure 2: Eastern DOZ Extraction Level Showing Dispatch Hardware Installations

Figure 3: DOZ Haulage Level Showing Dispatch Hardware Installations

The haulage level is located at the 3076 meter elevation.
Truck haulage is through a limited access, one-way traffic,
racetrack-type loop system between the orepass loading
chutes and the crusher (Figure 3). The haul trucks dump
directly, at one (1) of three (3) dump positions, into the
Fuller-Taylor 1,372 x 1,956mm gyratory crusher (Barber et.
al., 2001).
The production equipment fleet is comprised of
Elphinstone LHDs, and Elphinstone and Toro haul trucks.
Typically, 15 production loaders and six (6) haul trucks at
active at any time.
3 DOZ DISPATCH SYSTEM
DOZ employs the Intellimine Dispatch software system of
Modular Mining. Intellimine is a large scale, computer based
mine management system that allows PTFI to monitor and
control production loaders, trucks and secondary sizing drills.

Massmin 2004 Santiago Chile, 22-25 August 2004 697

 Figure 4: Schematic of the DOZ Dispatch hardware network
The hardware system consists of a central computer, a
network of micro-cells, equipment field computer systems
(FCS) and fixed radio frequency (RF) tags. Communication
between the FCS and the micro-cell network and the RF
tags is by UHF radio transmissions. Hubs manage
communication between the equipment and the central
computer system. Dispatch operations are monitored by
Dispatchers, from a central underground location (Figure 4).
3.1 Computer System
The Intelimine (version 5.1) Dispatch software operates
on two (2) Sun Ultra30 workstations, running on the Solaris
2.7 operating system. These servers, one as a backup, are
situated six kilometers from the mine. Fiber-optic cable links
the server to the mine Dispatch hardware network.
Dispatchers monitor operations on two (2) emulator
monitors located in the mine.
The Intelimine software has been highly modified to suit
the block cave environment and the DOZ mine
configuration. It has also been customized to include
communications in the Indonesian language.
3.2 Master Hub
Two (2) master hubs manage and distribute
communications between the mine equipment and the
central computer. The master hub reads the data packages
sent from the server and routes each to the correct micro-
cell loop. Likewise, the hub organizes data generated from
the field computers and forwards it to the central computer.
The master hubs are connected to the micro-cell networks
and the PTFI network by fiber-optic cable.
3.3 Micro-cell Radio Network
The micro-cell radio network consists of a series of low-
power radio modems that run on a simplex radio channel
operating at 451 MHz.
As information is received from the system (via the master
hub), the micro-cells read the data packages to determine
the intended recipient of the communication. If for
equipment with which a particular micro-cell is in radio
contact, the data package is translated to radio frequency
and relayed to the accompanying antenna. The antenna
then transmits the radio message to the equipment FCS.
698 Santiago Chile, 22-25 August 2004
For data packages transmitted by the equipment, the
process works in reverse.
Micro-cells, with dipole antennae, have been installed at
strategic locations throughout the extraction and haulage
levels (Figures 2 and 3). The micro-cells are internally
connected by token-ring cable, and networked to the master
hub by fiber-optic cable.
3.4 Field Computer System
A field computer system has been installed on each
mobile production equipment piece. The FCS receives and
displays instructions from the central computer system and
also accepts input from the equipment operator.
The FCS is comprised of a:
• UHF data radio (inside the hub) and antenna, to transmit
and receive signals.
• Hub, which manages communication between the micro-
cells and RF tags.
• Touch-screen graphics console (GOIC).
• Tag reader, integral to the hub, and antenna, to
communicate with the RF tags.
The function of the FCS hub, like that of the master hub,
is to manage and distribute data between the equipment
FCS components and the micro-cells. The hub is
comprised of a processor, interface card, data radio and tag-
reader. The interface card translates data between the
digital and radio format. The tag-reader, and associated
antenna, transmits radio signals that interrogate fixed tags
to determine location. The data radio communicates radio
signals with the micro-cells.
The GOIC is a 640 x 480, VGA compatible, touch-
sensitive screen that displays instructions from the central
computer and allows for the operator to transmit data to the
central computer and messages to the Dispatcher. The unit
is sealed, has no moving parts, and is physically robust. It
can be easily configured for truck LHD, or auxiliary
equipment operation, and can display messages in either
text or icon mode.
3.5 RF Tags
Passive radio frequency tags have been installed at
drawpoints, orepass collars, orepass chutes and at each of
Massmin 2004
the three crusher dump positions. These tags have been
programmed with a unique identification that is cross-
referenced to the physical map location. The RF tags are
read by tag readers, which are a component of the FCS, to
determine location in the mine.
Tags installed at drawpoints are covered by rubber to
protect from secondary blast damage.
The performance of the RF tags is fundamental to
determining the specific location of production, so tag
integrity is monitored by the Dispatch Engineers on a
regular basis.
3.6 Extraction Level Network
Three micro-cell loops, connected to the master hub by
fiber-optic, have been installed at the DOZ extraction level.
Micro-cells are located along the north and south perimeter
of the level. A dipole antenna, connected to the micro-cells,
has been installed at the north and south of each panel drift
(Figure 2). Passive RF tags have been installed at each
drawpoint and orepass collar.
3.7 Truck Haulage Level Network
A network of twelve (12) strategically located micro-cells
with antennae, also connected to the master hub by fiber-
optic cable, has been installed though out the truck haulage
level. Passive RF tags have been installed at each loading
chute and crusher dump point (Figure 3).
4 DISPATCH CONTROL OF PRODUCTION
The DOZ Dispatch system is utilized to communicate the
production plan to the equipment operators and to collect
data on the details of actual production.
A production control system was chosen for DOZ due to
challenges experienced at the GBT and IOZ mines, where
production plans and actual performance data were
transferred between engineering and operations by paper
copy. The integrity of some of this information was suspect,
and therefore resulted in inaccurate reporting of daily mine
tonnage and grade, and calculation of remaining drawpoint
reserves. The quality of long-term production planning and
overall cave management suffered, accordingly.
4.1 LHD Dispatching
At the beginning of a production shift, the Dispatcher
uploads the detailed production plan generated by the Cave
Management System (CMS) production planning tool
(Samosir et. al., 2004). This plan includes the number of
desired buckets of production for each drawpoint, plus the
order of production priority for drawpoints within a panel.
The LHD operator travels to the desired panel and logs-in
on the GOIC to the Dispatch system. Based on the pre-
determined order of production for that particular panel, the
central computer directs the LHD to produce from the initial
drawpoint. The operator either accepts this order or actively
logs-in to an alternate drawpoint. The operator then
commences production from that drawpoint. When at the
drawpoint, the tag-reader component of the FCS
interrogates the RF tag installed at the drawpoint to
determine the drawpoint identification. The operator also
pushes the "load" icon on the GOIC. The LHD’s FCS then
relays the RF tag and the LHD’s FCS identification numbers
to the central computer via the micro-cell radio network. This
informs the system that the LHD has produced a load from
the specific drawpoint.
The system then directs the loader to the assigned
orepass for tipping. En route, the LHD passes beneath other
RF tags (known as call points) strategically located in the
tunnel which inform the system of the LHD’s progress.
At the orepass, the FCS reads the RF tag to determine
the tip location. Once the load is tipped, the operator
Massmin 2004 Santiago Chile, 22-25 August 2004
pushes the "dump" icon on the GOIC to register the load to
the orepass. The system records the dump and then
automatically directs the LHD to the point of next
production. If an LHD is late to complete the next expected
action, such as "arriving at the assigned rock breaker," the
system alerts the dispatcher by an exception message.
The Intelimine software has been customized to calculate
the height of material in the orepass, based on LHD bucket
factors. When the "dump" button is pushed, the orepass
material level is recalculated.
The LHD operator then returns to the drawpoint and
continues to produce according to the draw order. Once the
planned number of buckets has been produced from the
initial drawpoint, the LHD is automatically dispatched to the
next priority drawpoint.
As a drawpoint becomes unavailable for production, the
LHD operator has the capability to change the status of the
drawpoint within the database. The system will then
dispatch the loader to the next priority drawpoint.
If the operator desires to produce from a drawpoint out of
sequence, he may do so by actively selecting the particular
drawpoint off the GOIC icons list. The FCS tag reader
continues to communicate with the RF tags installed at the
drawpoints to confirm the production location.
Should the operator key-in a drawpoint that is in conflict
with the drawpoint RF tag, an exception report is
automatically submitted to the operator and Dispatcher by
the central computer.
Once the available draw order for a panel has been
completed, the LHD operator sends a message to the
Dispatcher for further instructions.
The customized system has codes for various classes of
equipment delay. The operator actively selects the
appropriate category off the icon list on the GOIC. The
central computer and Dispatcher are thereby notified of the
current operating condition for the equipment.
At the end of shift, the Dispatcher makes whatever
manual adjustments to the recorded data that are
necessary.
Once daily, Dispatch production information is
downloaded to the central production-planning database.
This information is then utilized within CMS to calculate
daily production, draw order compliance, and remaining
drawpoint reserves, and to analyze potential sources of
induced stress in the production area. The production
strategy for the subsequent day and the balance of the
month is then re-established based on analysis of this daily
information.
On a monthly basis, the Dispatch data is utilized to
analyze LHD equipment and manpower efficiency and
productivity.
4.2 Truck Dispatching
Trucks at the DOZ haulage level are generally
automatically dispatched to orepass chutes according to
rules established by the Dispatch Engineer. These rules
consider the following:
• Distance between the truck and an available loading
point.
• Dispatching of other trucks.
• Orepass material inventory.
• Time since the loading point has last produced.
The Dispatcher is able to also actively direct trucks to
particular loading points, as operational conditions dictate.
At the beginning of a shift, the truck operator logs-in to the
Dispatch system and the central computer automatically
directs the truck to the initial chute for loading. When the
truck arrives at the chute, the FCS reads the tag installed at
the chute and the operator pushes the "arrive at LP" icon.
Once the truck is loaded, the operator pushes the "load"
699
icon on the GOIC. The system then registers the equipment
as loaded, and directs the truck to travel to the crusher. The
material inventory in the orepass is also adjusted for the
load, based on the factor for that truck type. At the crusher,
the FCS reads the tag for the particular crusher dump point
and the operator pushes the "arrive at crusher" icon on the
GOIC. Once dumping has been completed, the truck
operator pushes the "dump" icon on the GOIC. At this point,
the system records the load as dumped and adds the
tonnage to the shift total. The central computer then
dispatches the truck to a chute for the next load.
Dispatchers have the capability to classify as a chute as
"Down" or on "Standby", based on operational conditions,
and thereby remove the unit from the dispatching logic.
A utility screen has been created which provides orepass
information to the dispatcher for:
• Tonnes remaining,
• Last time it was drawn from,
• Dispatch priority level,
• Truck identification number, if one is currently assigned to
it; plus the expected arrival time,
• Status of the loading chute.

6 DISPATCHER MONITOR AND CONTROL

Dispatchers monitor and control DOZ production
activities, on each shift, from emulator monitors in a control
room located within the mine. The Intellimine software Figure 6: Dispatch Utility Screen
system has been customized to provide a number of real-
time informational screens that allow the Dispatchers to
determine critical operating parameters and to interact with and the current draw compliance.
equipment operators. A daily summary report is automatically generated by
The Transaction Screen displays real-time tonnage Dispatch and emailed to DOZ Management. The email
summaries (last hour, this hour, shift-to-date) for extraction, includes data, by shift, for production tonnage; equipment
orepass inventory and haulage to the crusher. operating hours, delay hours, availability and utilization, and
The Exception Screen displays messages generated from orepass material inventory. An hourly summary of the same
the central computer for operator actions that are information, plus cycle time data (Figure 7), may be
unexpected (Figure 5). Examples include: 1) locking-in to accessed from the Report Utility Screen.
a drawpoint that is different than the drawpoint tag
identification, 2) producing from a drawpoint above the draw
plan, 3) loss of radio contact with the micro-cell network, and
4) equipment operating without the operator actively
logging-in to the system. The Exception Screen demands
that the Dispatcher either "accept" or "reject" these operator
actions. If "rejected", the central computer automatically
sends a message to the equipment FCS to request remedial
action from the operator.

Figure 7: Truck Cycle Time Report

5 CONCLUSION

Use of the Dispatch system provides many benefits to

Figure 5: Exception Screen
A range of equipment status information is displayed on
the Dispatch Utility Screen. The utility also provides a
means for the Dispatcher to send text messages to the
equipment field computer system (Figure 6).
The Draw Card Screen provides the Dispatcher real-time
information on the drawpoint production plan, drawpoint
status and buckets of ore produced shift-to-date. The
screen also tabulates the percent drawn for each drawpoint
controlling production activities at the DOZ Block Cave
Mine.
For extraction, the system provides an effective means: 1) to
communicate the details of the production plan to the
equipment operators, 2) to collect accurate actual production
data, 3) to calculate compliance to the production plan, 4) to
summarize daily actual production for transfer to other
production planning tools, 5) to identify circumstances when
equipment operators produce in an unexpected fashion, and 6)
for the loader operator to effectively communicate with the
Dispatcher. All these benefits allow for precise compliance of
actual production to the long-term plan and aids PTFI to
effectively manage the DOZ cave.

700 Santiago Chile, 22-25 August 2004 Massmin 2004

 The Intelimine system allows haulage operations to be
conducted and optimized with only minor active input from
the Dispatchers or supervisors. Custom features of the
system also provide real-time information on the material
inventory in each orepass.
Use of the system, in general, provides a continuous
monitor of all production activity. Information stored to the
database provides the basis for calculating equipment
productivity and efficiency. Since allocation of equipment to
a particular task is automated, supervision is able to instead
focus on resolving mine issues.
ACKNOWLEDGEMENTS
The authors are grateful to all their colleagues working at
the DOZ Mine. Also, the authors acknowledge the
permission given by P. T. Freeport Indonesia to publish this
paper.
Massmin 2004 Santiago Chile, 22-25 August 2004
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• Barber, J., Ganesia, B., and Casten, T., 2001, Developing
the DOZ Mine at PT Freeport Indonesia, Mining
Engineering, vol. 35, no. 11, pp. 19-24.
• Owen, T., 1992, Ertsberg East Mine Freeport Indonesia
Inc. Papua Indonesia, SME Mining Engineering
Handbook, vol. 2, p. 1830-1835.
• Samosir, E., Brannon, C., and Diering, T., Implementation
of Cave Management System (CMS) Tools at the
Freeport DOZ Mine, Proceedings from MassMin 2004, in
press.
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