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International Journal of Surface Mining and Reclamation

ISSN: 1389-5265 (Print) 1744-5000 (Online) Journal homepage: https://www.tandfonline.com/loi/nsme19

Optimal blending of mine production using goal

programming and interactive graphics systems

E.K.C. Chanda & Kadri Dagdelen

To cite this article: E.K.C. Chanda & Kadri Dagdelen (1995) Optimal blending of mine
production using goal programming and interactive graphics systems, International Journal of
Surface Mining and Reclamation, 9:4, 203-208, DOI: 10.1080/09208119508964748

To link to this article: https://doi.org/10.1080/09208119508964748

Published online: 31 May 2007.

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International Journal of Surface Milling. Reclamation and Environment 9 (J995):20j·208 203

Optimal blending of mine production using goal programming

and interactive graphics systems

E.K.C.Chanda
Zambia Consolidated Copper Mines Limited. Nkana Division, Kitwe, Zambia
Kadri Dagdelen
Colorado School of Mines. Mining Department, Golden; CO 80401, USA

ABSTRACT: Although production scheduling in the mining context, is primarily concerned with the
sequence of removal of the mining blocks, there is an inherent task of blending the run-of-mine
materials before concentration. The objective is to mine in such a way that the resulting mix
meets the quality and quantity specifications of the processing plant or the customer. The
blending problem becomes even more important with regard to short/medium term mine planning,
where the planner is concerned with reducing grade fluctuations in the run-of-mine material and
how much to mine in order to satisfy demands in tonnage and composition. For instance, in the
case of coal, economic and environmental considerations may dictate stringent limits on ash,
sulphur, and BTU content. Blending of ores is also beneficial for a number of reasons: it can
improve the efficiency of the processing plant, it minimises the need for selective mining
hence, reducing mining costs and increasing mine production, it extends the ore reserve base
and it contributes to the grade control process.
Since blending requires that the resulting mix of different ores be of a certain quality and
quanti ty, realization of this requirement should be among the primary goals of any mine
production planning system. Classical linear programming has been widely used in modelling
production/blending problems in the mining industry. However, the classical LP formulation of
the blending problem suffers from the fact that only one objective function is permitted at a
time. In recent years CAD systems have been established as standard mine planning tools. In
these, too, blending is achieved via trial-and-error and so the optimum solution is not
guaranteed.
This paper describes a linear goal programming model of the blending problem in short term mine
planning. An example application of the model to a coal mine is presented. The capabilities of
this model are discussed in comparison to those pertaining to an interactive graphics based
system, in terms of minimizing the deviation from set targets for tonnage and given quality
parameters. Improvements in the quali ty of the planning resul ts can be realised through a
combination of these two techniques.

1 INTRODUCTION accomplish some degree of blending (Goergen

1980, Smith 1985).
~he general aim of mine 'production planning Understandably, simulation and heuristic
1.S to generate a plan to guide mining of methods were the first computer based
selected parts of the ore body that will techniques to be applied to blending. in mine
ensure delivery of the budgeted tonnes and planning for coal shipments [Fraser 1973].
grade of the mineral raw material to the mill Recent simulation based blending algorithms
in the period under consideration. Specifics are reported by [Bruno, etc 1986, Gershon
vary depending on whether the plan .involves 1986, Ciesielski 1988]. Many blending models
long, medium or short term planning. wi th based on linear programming have .been
regard to short term production scheduling, reported in literature (Johnson 1969, Baafi
an obvious and most frequently used 1983, Fytas and· Calder 1986). Most CAD
production goal is to supply ore of uniform systems often use blending as a planning
grade and tonnage based on plant requirements goal. In this case blending is done by
.so as to ensure its operating efficiency. In selecting ore increments (on a graphics
order to supply ore of uniform quality to the screen) which contribute to the achievement
processing plant, it is necessary to blend of the desired grade. This is basically
are of different quality from various parts trial-and error.
of a mine or from different mines. This
ensures a uniform feed which is important Formulation of the blending problem as a
from the operating stand point, since any classical linear programming model is limited
changes (in terms of grade and tonnage) are by the fact that only one objective function
usually accompanied by an increase in total may be formulated at a time, when in fact the
operating cost. blending/production problem is multi-
Blending techniques vary from mine to mine objective. The special case of LP known as
but the goal is the same, namely to deliver Goal Programming offers an improved model
ore of required quality and tonnage to the. because it' embraces an economic objective
mill or customer. Some mines resort to use of function and a function to minimise the sum
blending beds or bins. Today few mines employ of deviations for individual quality
this technique because of high operating parameters as well as tonnage from set
costs and capacity limitations. Judicious use targets. Another technique that can be used
of loaders, shovels or wheel excavations can to model this problem description is

e 1995A.A. Balkema,P.O. Box 1675.3000 BR Rotterdam,Netherlands

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204
Quadratic Programming (Ignizio 1976), but
this technique requires more computational
effort. The isolation of the blending problem
is to allow for effective mathematical
formulation although mine production
scheduling embraces many other aspects.
However, the blending' module can be
integrated wi th any mine scheduking and in
this study a procedure for enhancing the
effectiveness of short term planning by
combining interactive graphics wi th linear
programming is discussed.
2 ORE BLENDING AND MINE PRODUCTION SCHEDULING
Blending can be defined as a methodical
systematic process of combining a variety of
materials into uniform mass. The individual
materials to be blended can be widely
variable. After blending, however, the ideal
product must be uniform and homogenous.
Blending is thus an integral part of mine
scheduling whereby it is desired to deliver
mineral raw material to the customer or
concentrator at the specified quality and
quantity. This is a must for mines with a
high degree of grade variability
(inhomogeneous), especially for commodities
where product quali ty is important such as
coal, bauxit~, iron ore, gold etc. In
general, it is assumed that there are many
sources of the mineral raw material f r'om
which to mine for blending . Next is a set of
quality specifications that the blend must
satisfy. For example, for a polymetallic
mine, this could be copper, lead, zinc and
gold. In case of phosphate ore, this is
percent P20S' For coal the ash and sulphur
content are cricical blending parameters.
Blending in mine production planning may be
dictated by any or all the following factors:
- Design of the mill: usually designed to
handle a certain quali ty of through-put to
operate economically. Less tonnage leads to
under utilisation, and unnecessarily high
grades result in product los~es.
- Environmental factors: law may specify the
minimum/maximum quali ty of mineral raw
material to be processed in order to reduce
emissions, energy losses, etc.
- If the schedule is tailored to suit a plant
belonging to another business entity (e. g.
coal for power plant, limestone for cement
plant, or iron are for steel mill), there is
often a direct and well defined penalty for
deviating from the specified uniformity of
the material in the contract.
- Market requirement: should the ore be sold
directly to customers, it has to meet certain
specifications.
The above problem description contains all
of the concerns one would have in making
blends. The basis for any blending model is
accurate information about the material to be
blended (ore blocks, dumps, etc). InfQrmation
about quality can be obtained by sampling and
applying suitable estimation techniques, e.g·
geostatistics. With regard to ore quality,
the following objectives should be considered
in short term production scheduling.
- Prediction of next periodls ore quality and
reliability of such predictions.
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- Determination of anticipated fluctuations
in the daily ore quality around the estimated
monthly grade.
- Determination of exact locations of ore and
waste zones to be mined in the period, and at
what rates so as to satisfy demands in
tonnage and composition.
- Minimisation of deviations from stipulated
quality of run-of-mine ore to ensure
efficient plant operation.
The first two objectives can be achieved
by using Geostatistics (Kim 1987). The rest
can be ensured by proper blending of ore and
this can be effectively tackled during
production scheduling. This minimises the
need for selective mining, hence reducing
mining costs and increasing mine production.
Also the reserve base is expanded as the ore
below cut off is not regarded as waste, but
can be mined and blended with high grade
material. Careful planning of unit operations
(drilling and blasting, loading and
transport) can accomplish some degree of
blending, hence contributing to quality
control. Whatever technique of blending used
at a mi.ne, it is necessary to model the
situation mathematically in order to ensure
optimal blending. In the next section
formulation of the mathematical model for the
blending problem will be give.
3 FORMULATION OF A MATHEMATICAL MODEL
The most successful area of application for
linear programming (LP) in the mining
industry has been production/blending
problems. Cement production presents a
classic blending problem where a number of
ingredients must be mixed according to a
given recipe. There are several variations of
the blending problem formulation using linear
progranuning as reported by (Gershon 1986,
Gunn and Rutherford 1990). A classical LP
formulation of the blending problem has only
one objective function subject to grade and
other constraints. Also, the optimal solution
is not based on grade and tonnage targets,
but on the value of the objective function.
In this case, it is sufficient to have the
grade and tonnage of the blended ore within
the specified upper and lower limi ts. In
practice, however, the goal is to achieve the
target grade of blended run-of-mine are.
Hence, the limits,for these parameters become
tighter, zeroing in on specific values. To
correctly model this si tuation a goal
programming formulation will now be
presented. This is not a new technique and
has been used in the mining industry (Chanda
1990) .
In this formation, only quality and
quantity requirements of the
blending/scheduling problem will be
considered. The strategy employed is to
achieve the target grade and tonnage of the
blended ore via the minimisation of the sum
of absolute deviations of the individual
quali ty parameters and tonnage from their
call values. Minimisation of these deviations
thus becomes an additional goal of production
planning. Ideally, these absolute deviations
should be minimised to zero, but this may not
possible due to other factors. Nevertheless,
the optimal solution will reduce these
deviations to their lowest possible levels.
Hence, in th~ goal programming formulation,
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205

additional variables (so called deviational = Grade of parameter k in ore from block
variables) and deviational constraints have j
to be introduced (Charnes and Cooper 1961). = Required grade of parameter kin blended
Following is a goal programming model of the ore
blending problem. Maximum allowable production in the
period
Minimum allowable production in the
A. Objective function: period
= Upper bound for parameter k
= Lower bound for parameter k
n I = Available ore for mining from block j
EX
j-1
j • Cj - E
1e-1
Wk '" Pk -
(1)
In the above formulation of the blending
problem there are two criteria of
·optimization in the objective function,
namely, the maximization of an economic
Pk positive deviation for parameter k criterion and the minimization of the sum of
Nk,
Wk
= Weighting
Negative deviation for parameter k
factor for parameter k
absolute deviations of grade and tonnage from
their target values.Theoretically, minimizing
Cj = Economic value per tonne of are
associated with block j
the sum of deviation, i.e., EWk*N k + Wk*Pk is
equivalent to maximising the function EX j -
Xj = Tonnage of ore to be mined from block j EWk*N k + Wk*Nk • The reader is referred to
Charnes and Cooper (1961), Lee (1972) for the
background theory. The planner assigns to the
B. Deviation constraints: deviational variables weighting factors Wit
depending on the desired goal achievement for
the respective parameter. If all the
weighting factors are zero, the problem
+ (2) reduces to classical linear programming.
However, in order to minimise the said
deviations, the WklS have to be non-zero. In
the optimal solution either one or both the
deviational variables (N)c and Pk ) has to be
zero. The deviational variables are part of
n
the optimal solution and can be used to
E (G j k - Gmk ) -Xj + N k - Pic =a I k = 1, 2 .. , I determine the economic consequences for not
j-1
meeting the specifications of the blend since
(3) there is often a direct and well defined
penalty for deviating from these
specifications.
C. Upper and lower limit constraints

4 COMPUTER PROGRAM
n
EX
J-1
j ==' Tu (4) The computer program to solve the linear
system of equations (1) through (8) is based
on"the simplex method of linear programming
n (Charnes and Cooper 1961). The programs was
EX
j-1
j ~ T1 (5) written in Fortran 77 and implemented on
Personal Computer (Chanda 1993). Figure 1
shows the program logic and flow diagram for
interactive short/medium term mine
n (6) scheduling.
E (G jk - Guk ) .Xj:S a, for k=l, ••• I
The program incorporates assembler language
]-1
subroutines to facilitate better user
interface under the Fortran environment. The
n
(7)
information about the mineral resource is
E (G j k - G1k ) .Xj~O I for k=l, 2, ... I stored in a database. A series of menu
options ensures that the mine planner takes
j-1
control of the blending/scheduling process.
At the beginning of a planning session, the
engineer is presented with three options, i.e
D. Production control quit, modify an existing plan or generate a
new plan. When generating a new plan, one is
(8)
prompted for a new data file name which is
automatically saved as a unique input data
file for that project. Next the user is
prompted for number of operating shifts per
E. Non-negativity day and to indicate whether the problem.is a
minimization or maximization one. Quality and
quantity parameters are edited via a menu
that highlights the maximum, minimum, target
values and weighting factors for tonnage.and
Where quali ty parameters. Each time changes are
made in blending parameters, the simplex
Nt Negative deviation of tonnage from mine algorithm can be called to calculate the.new
call optimal solution. There are also options to
Pf positive deviation of tonnage 'from mine edit data base, force some ore sources out of
call consideration, and correct the optimal
TII\ Required production (mine call) solution manually.
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206
- - - ENGINEEDR----PERSONAL COMPUTE I'cr~No S'.I101l J I~crnl>cr 9)
l::nd 011 Ii Aflnl '14
Dural"'" III pcnncl. U~I

Are. 10 Op.tlld) M.qlldl 5(%1 BTlJ(%) A(%) COIl(M\JJI)

20
H
J~
41"
)f>R
410
1600
ZOO(J
1.250
I. SOlI
I.)OCJ
23.000
]]900
BOO
')00
,.
j(j

4S
20(()
1700 l.SOU
17400 ')00 5'
1700 JI.JOO 1000 62
4' CJ 600 Uoo 21,)00 I.CJOCJ 211
S9 17011 1700 1.100 199(1(1 I90CJ 61
S7 17,} 1100 <lAOO U.SOO 60100 69

t 1000 9110
• Devillioa:
1.1"
·OS3
1'.000
-4000
7,7n
-an
63.0'

TO'.&I fCIICf'tCl IMfore: TONL&"-

Sillfur
BnJ
.. 9&U~ \1)
1.26)4 (%)
26.2912 (%)
dirt: 9'76~~
1.26)9 1%)
26 ~4)6 (%)
(I)

Alii 1.916S t%) .9JSJ (%)

BJeDlha.Il p&r'mleQ ProcIueIIOll SWI~ BTU Alii

Uppa hmit 1400 t US % 2900% 10.00%

T.flci v.lue aooo I 1..2'% 2300% I.JC)%
Ln,'e,l;m;1 7600 t US% 1900% 6.00%
Weipt;a. (ICIOf 10 IllUA 1000.00 mllll .00 l'Gll.It .00 maJl

Unit coa ""ilhoul pcllollly(lcl) 63.(17 au....

lIml ud WIlli J'C1I&h~ltel) 6).61 mull

Figure 2: Output format from the GOPLAN

algorithm; weighting factor for sulpher =1000

P~Nu I: Slalt " ... IIMccml>cr en

End OIl: 6 ArnJ 94
o.ar.lIOD D1rniod' III da~'1

Figure 1: Interactive mine scheduling with /Uea ID Ope (lid) ·Mll.llld) S(%) BTUt%) A(%l C-<MUIl)
the goal programming based computer model. 410 .10 1.2j(J
20 23.000 1.500 50
24 )6' 1600 1.500 lJ.900 '.SOO '71
H 20W 1000 I.)ClO IHOO 7.jOO

The algorithm automatically sets up the .,

.S 1'00
0
1700
600
1.500
1500
21.)00
21.)00
1.000 "
61
'.000 211
simplex tableau using the input information S9
n
1'100
17$2
1700
1100
1.100
(1.100
19,900
13.500
'.900
6400
6t
6'
about quality parameter, number of equality,
less and greater or equal to constraints. By I 1000 91110

manipulating the weighting factors Wk , the •

[)cvlatlon:
1.19'
-.un
19.000
~.OOO
un
-,'"
6).0'

planner can smooth out the conflicting goals

among the grades of different quality 913:100 ( I )

.-
ToUl! I t...",u be(llrt: TOaAl'~ .(u:r: 9162S600 (I)
1.263. (%)
parameters, e . g., it may be necesSary to Sl1lflll
BTU 26.2911 (%)
1.26)9 (%)
26.).)6 <")
optimize the blend with respect to one or two Ash 1.91U C"" '.9HI (\to)
quality parameter out of say, the given four Bleadlllf rer.mU:fI ~~ Su1ler BTU AAb
under consideration. This means that some Upper limn 14001 US% 2900%
quality parameters may be allowed to deviate T.,.et \'lllI&' aooo t I.2S% H.oo%
1(/00 '"
I.~%

considerably from their target values than to_IIIm,t

lIIeipl1nll (ICIOf
'600 I
IOmIIIl
US".
100.00 muIt
19,00 %
00 II»'l
6.00%
00 IIllIh
others. However, the sum of absolute
deviations of all parameters should be UUlI coli .. ,lII"ut rmahy(ics) 6)07 1'.. 11I
minimized. Un,1 coJi Willi JlClI&lty(leI} 6)50 ruuIl

Figure 2 shows the typical output format

of the algorithm. The solution shows the
values of Xj in tonnes from the given mining
locations which will result in minimum sum of
deviations of the tonnage of coal and grades
of ash, sulphur, and BTU from their mine
call. As presented in Fig. 2, the optimal
solution is 8000 tonnes of coal per day with
average ash, sulphur and BTU content at
7.344%, 1.197% and 19.000% respectively. This
solution deviates from the set target by -
0.656%, -0.10%, -0.321% in terms of ash,
sulphur and BTU grades respectively. By
changing the weighting factor for tonnage,
new optimal solution as shown in Figure'3 is
generated.
The system also keeps track of the reserves
in the mine model and depletes the reverse
base according to the optimal mining plan.
The optimal tonnage to be mined in a given
period is subtracted from the current reserve
base to give the quantity and quality
reserves that would remain after that period.'
The system also calculates the penalties that
would be incurred when the quality
specifications of the supply contract are not
Figure 3: Output format from the GOPLAN
algorithm, weighting for sulpher BOO.OO =
met. For example, the supply contract might
demand that the sulphur content in the coal
delivered must be 1.25% otherwise a penalty
will be levied for every unit deviation above
this target. In the programs the penal ties
are treated as mining costs and are added to
the normal mining cost. Premiums are treated
as negative penalties in the context of the
program. As shown in Figure 4 the mining cost
per tonne of' coal varies with increasing
weighting factors for sulphur.
Weights for ash, sulphur and tonnage were
held ~onstant for these. runs. The mining cost
without penalty is 63.07 mu/t. The unit
mining cost increases with increasing
weighting factor but levels off at 63.76 mu/t
when the weight exceeds a value of 1500. The
goal programming algorithm indicates the
range of penalties that will affect overall
mining economics.
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".
~
".
!. n •
..•
•
ie 63 2
i• "
6H
62& ,'-"'===-"'''-'=====:;: :=='"' ''''''
'" "'" "'" "'"
Figure 4 : Speci fi c mlning cos t as a fu nction
o f weght ing f act or f or s ulphur with weighting
f a c t ors f or ash , BTU and tonnage being
constant
In t eg r a t ed mine plan ni ng a nd des i gn systems
g ive the planner a fe e l o f what he is d oing
by displ aying t he port i on o f t he orebody l i n
p lan o r sec tion ) in a window on t he graphics
screen . Dur i ng s hor t tern mine scheduling,
t he pl anner use s a l ocator de vice t o de fi ne
inte rac t ively on t he s c r een mining vo Iumea ,
usual ly i n the f o rm o f 2-di mens iona l polygons
a nd ob tai ns r esul t s i n stan t l y on another
window on t he s ame screen. The polygon cou ld
corre s po nd to blasts on open p i t be nch o r
underg r ound s topes . By ed iti ng t he base
des ign . the plann er can quickly try di f fe rent
mining plans and get ore and wa s t e tonnages
to mee t speci fic period targets .
Meds ys tem f rom Mi nt ec. Inc . is a good
example of commerc ia l mining sof tware used by
many companies for mi ne planning . For t he
purpos e o f t his s t udy on ly t he module on
sh or t t erm mine scheduling is o f i nt er es t .
The int era ct ive Gr aphics planner in the
Med s ys t em is driven by a program which us es
the 3D or gridded seam model of the deposi t
as one of t he basic inputs . The prog ram acts
as a sophis t icated ca lcu l a tor . one can de s ign
va r i ous mining i ncrements (po l ygona l
out lines ) and i ns tan tly obtain grade an d
t onnage i nformati on on the ma ter ial cont a i ned
wi thin t he polygon . These feat ures make the
system ideal fo r shor t t e rm mine planni ng
where t he p l anne r n.eds a h i gh deg ree of
f l exi bi l i t y i n the design of cuts and blast s
i n open pi t mini ng .
I f you have one face f rom which t o mine ,
it may be eas ier to generate the requi red
tonnage and gr ade for a gi ven period . wi t h
more production face s t hough , i t may take
seve ral tr i al designs before a plan that is
c l os e to t he se t t argets is generated .
Li kely . the result ing mix of or e will not
meet t he quality spec i f ications of t he r un -
of-mine ore . The amount of dev i a tions from
t he peri od t a rgets may be reduced by r ep eated
t rials but sti ll optimal ity cann ot be
gua ranteed . As menti oned ea r li er, the l inear
prog rams are JUS t abstrac t models of reali t y .
On the other hand , In t er ac tive Graphics based
p lann ing emu late s the rea lity by means ' of
screen representation of t he or ebody or pa rts
of i t . The engineer can see t he l ocat i on of
the areas where min ing wi ll t a ke place and
change in t opogr aphy . To make use o f both
t ec hniques . i . e . . inter a c tive gr ap hics and
l inear op t i mi za tion . t he eng ineer ca n r un the
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207
goa l progr amming algorithm. f i rst . This will
indicat e the op timal solut i on i n terms of
where t o mine and a t wha t r at e i n orde r to
meet demand i n t onnage and grad e of dif f erent
quali t y pa rameters in the r un- of·mi ne ore .
Usi ng thi s solution as a basis . he can then
us e the int erac t i ve graphics to gen erate the
op t imal t onn age s by de fi ning pol ygonal shapes
on t he sc r ee n and ob tain ing the t onnage
contained wi t h i n each pol ygon represent ing a
mi ni ng a rea . This procedu r e i s not only
f aster but l e ads t o genera t ion o f op t i ma l or
near optima l schedu les , us i ng interact ive
graphics .
5 I NTERACTI VE GRAPHICS BASED MI NE PLANNING
Wh il e linear programmi ng optim1:res the
production plan. it ach ieves this by
man ipula ting input va l ues f or the algorithm
an d does not anything about the posi tions of
t he mi n i ng areas (b l ocks ) . nor indeed abou t
mining its elf . Inte ractive Graphics p l anning
ove r comes thi s draw back bv di sDlay ing the
a rea of inte res t on t he screen. s howing its
l oca t i on wi t h i n the mi ne coordinat e s y s t em
and other foatu res associa ted with it .
6 CONCLUSION
Blending i s an impor tant aspec t o f mine
planni ng especially as limits on product
qua lity become more st r i ngen t f or ec onomic ,
environmental . or ot her r easons . t he blending
problem in mine pr oduc t i on planning has been
f ormul a t ed as a goa l programming model and
so lved using the s implex algorithm . Goal
Pr ogramming off ers an i mproved model compar ed
to c lass ica l li near programmi ng because of
the formula t i on of a secondary ob jective
f unct ion to minimize the sum of absolute
de viations of qua lity parameter s and t onnage
f r om set t arge t s . Dev iat iona l var i abl es a re
used t o ca lculate penalties (or premiums )
i ncurred f or not meeting the contractual
quali ty spec if i ca t ions. Goa l progr4lllllling
al l ows f or vi olat i on of c ertai n co ns t r a i nt s
i n orde r to meet p r ac t i cal requi rements o f
mi ne pr oduction sched Ul i ng .
I ntegrat i ve graphics based sys tems for
mine p lanning display mi ni ng enti t ies on t he
s cr een an d t hus he lp t he en gineer t o
visualiz e the geomet r ica l i mpl i cat i ons of hi s
designs . Also t hese systems have t he
capabil ity t o comput e volumes of excava ti ons
i n r oc k . Howeve r . explici t optimization of
schedules i s l ack i ng i n these s ystems . By
combining the goa l progr4lllllling model with
i nter active gr aphi cs op t imal or near optima l
mine p l an s can be ge nera ted . Resea r ch is
continuing into the possibilities o f
i nteg ra ting ma t hema t i c a l programmi ng models
i nt o t he graphics based mine planning
s ystems .
ACKNOWLEDGEMENTS.
The authors would l i ke to t ha nk the Amer ican
Counci l f or Int erna t i ona l Exchange of
Scholars (CIES) f or financia l assistance
under t he Ful bright Senio r Researeh Scholar
Program and the Col orado Schoo l of Mines f or
comput i ng faci lities . Mr . S . Schuster of TU
Berlin is acknO\frlledge d for some assembler
l an guage r out i ne s used in t he computer
program .
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