Dispatch para Mina Subterránea - Encuentro Minero IIMP

Introduction to the Mining Meeting

Welcome and Purpose

• The event is a mining meeting aimed at professionals in the mining sector, focusing on sharing experiences and exchanging opinions related to the industry.

• Acknowledgment of participants and sponsors for this edition of the meeting, including various companies involved in mining operations.

Speaker Introduction

• Jesús Guerra, General Superintendent of Mines at Sociedad Minera El Brocal, will present on "Dispatch for Underground Mining." His extensive background includes over 17 years in both open-pit and underground mining.

• Jesús holds degrees from Universidad Nacional de Ingeniería and an MBA from Universidad Católica, with experience in planning, operations, and continuous improvement across several notable companies.

Presentation Overview

Project Background

• The presentation focuses on a project that has transitioned from concept to reality within El Brocal's operations regarding underground dispatch systems. This system has been successfully implemented since 2022.

• An overview of the agenda is provided, highlighting key aspects of El Brocal as a company dedicated to extracting polymetallic minerals primarily copper. Operations are based in Colquijirca with both open-pit and underground mines currently active.

Current Operations

• The open-pit mine is currently paused due to pending environmental permits while the underground mine continues production focused mainly on copper extraction. Expansion efforts are underway for increased output using new tools presented during this session.

• El Brocal operates two concentrator plants with a combined capacity of 18,000 tons per day as part of their optimization strategy under Grupo Buenaventura's umbrella which manages multiple projects nationwide.

Implementation of Dispatch Systems

Transitioning Technology

• The discussion emphasizes how dispatch systems have been effectively utilized in open-pit mining for over 25 years; there’s an initiative to replicate this success within underground operations by addressing unique challenges such as communication and positioning technology specific to subterranean environments.

Implementation of a Mining Communication System

Overview of the System Implementation

• The mining sector is evolving, and the implementation of a new communication system at Minero Brocal consists of two main stages: establishing the system's software and hardware, along with an essential methodology developed since 2022.

Methodology and Strategy

• The methodology emphasizes that having a system alone does not guarantee success; effective use is crucial. This approach has been inspired by practices from Tajo, likening it to using Excel for various functions beyond basic calculations.

Infrastructure and Communication

• The communication infrastructure relies on fiber optics within the mine, featuring a main trunk line that connects approximately 50 access points (APs) throughout the operation to ensure dynamic Wi-Fi coverage.

Positioning Technology

• Surface positioning utilizes GPS technology for real-time location tracking. However, underground positioning requires additional equipment called "bicons" placed strategically to capture coordinates as vehicles pass through designated routes.

Operator Interaction and Data Management

• Each vehicle is equipped with screens connected to computers that allow operators to interact with control rooms. Operators can log their status, report delays, and communicate via chat or voice messages, minimizing radio usage.

• Information captured by operators feeds into a centralized database monitored by engineers in real-time. This setup allows for immediate corrections if discrepancies arise in reported data.

Real-Time Monitoring and Control Room Operations

• With over 80 pieces of equipment operational—50 currently integrated with this system—the control room plays a vital role in monitoring performance metrics such as trips made and delays encountered during operations.

• The control room's responsibility extends beyond data collection; it also involves managing information effectively to enhance operational efficiency. A graphical interface displays real-time equipment locations and production data.

Challenges and Continuous Improvement

• As data collection systems often yield inaccuracies initially, ongoing adjustments are necessary. The control room ensures accurate monitoring while adapting strategies based on daily operational feedback.

Control Methodology in Operations

Importance of Data Transformation

• An engineer transforms operational information into data for decision-making, creating strategic reports that can be reviewed at specific intervals.

• Effective operations rely on detailed control mechanisms, which can be daily, weekly, or even hourly to ensure timely and accurate decision-making.

Hourly Control Methodology

• A developed methodology allows for hourly reporting by a database engineer, providing insights into operations every hour.

• This real-time monitoring enables supervisors to react promptly to unplanned issues and adjust operations accordingly to recover lost production.

Communication and Information Accessibility

• Information is accessible via WhatsApp, allowing for near real-time updates; the goal is to report every half hour as an evolution of information management.

• The current hourly management system has proven effective, leading to continuous improvement through regular analysis.

Weekly Analysis and Improvement Plans

• Weekly meetings analyze statistics from the past week, identifying deviations and formulating action plans for improvements.

• Daily controls are complemented by more comprehensive weekly analyses aimed at medium-term sustainability in operations.

Integrated Control Center Objectives

• The integrated control center not only receives but also distributes information timely for informed operational decisions.

• Future developments aim to enhance this center with integrated systems controlling various aspects like ventilation automation and personnel management.

Operational Reporting Insights

Hourly Mining Control Report

• A detailed report tracks mining operations hour by hour, developed in collaboration with a technology provider.

• The report visually represents performance against mining plans; underperformance indicates areas needing attention while exceeding targets shows effective operation management.

Performance Metrics Visualization

• Graphical representations show tonnage produced each hour compared to planned figures; e.g., 350 tons produced against a target of 200 tons in the first hour.

Operational Delays Tracking

• Reports track delays due to maintenance or other factors affecting equipment readiness; understanding these delays helps improve scheduling efficiency.

Continuous Improvement Opportunities

Operational Challenges and Solutions in Mining

Equipment Availability and Maintenance Issues

• The operation faced delays due to a lack of dump trucks, with actual operations starting at 3:25 AM instead of the planned time.

• Maintenance issues caused significant downtime for equipment, with response times for repairs taking between one to one and a half hours. Immediate attention is now prioritized.

• Detailed tracking of each equipment's operational hours has been implemented, revealing specific planned and unplanned downtimes.

Performance Metrics and Goals

• The drilling teams have set an ambitious target of 1,000 meters per shift; however, they achieved 10,018 meters in practice.

• Various delays are monitored including equipment transfers and ventilation issues during blasting operations to enhance performance.

Tactical Reporting and Data Analysis

• A tactical reporting system has been recently implemented to monitor drilling equipment on an hourly basis.

• Weekly meetings analyze collected data using Pareto analysis to identify areas for improvement in operational efficiency.

Identifying Improvement Opportunities

• In July alone, there were 235 hours spent on transferring equipment between fronts; strategies are being developed to minimize these transfers.

• Initiatives such as creating inspection bays aim to reduce workshop transfers by improving maintenance processes.

System Flexibility and Customization

• The team tracks average start times for operations daily, aiming for continuous improvement despite various logistical challenges encountered.

• A flexible reporting system allows real-time data management regarding mineral extraction metrics like tonnage and truck capacity.

Future Production Goals

Production Goals and Operational Insights

Overview of Production Targets

• The goal is to reach 13,000 tons per day, which reflects both current achievements and future objectives.

• By 2024, drilling equipment and service tools will be integrated into operations, with plans for further enhancements by 2025 including telemetry systems.

Current Production Status

• Since 2022, production has fluctuated between 8,400 to over 11,000 tons due to operational challenges and social restrictions.

• Currently achieving between 11,700 and 11,900 tons daily with a target nearing 12,000 tons.

Operational Efficiency Improvements

• Increased operational efficiency from an average utilization rate of around 55% in January to peaks of over 73% in mid-year.

• Effective working hours have improved from approximately 5 hours to nearly 7 hours per shift through reduced downtime.

Project Initiatives for Optimization

• Plans are underway to optimize transport times within the mine by constructing a new dining facility.

• Aiming to reduce blasting delays from an average of 1.4 hours down to about 0.8 hours as part of ongoing efficiency projects.

Integrated Systems Development

• Transitioning towards an integrated control system that includes personnel entry management and automated collision avoidance systems.

• Implementing telemetry for real-time monitoring of equipment performance to identify issues promptly.

Conclusion on System Success

• The implementation of the DISP system at Unidad Miner Brocal has led to increased production without additional resources while reducing fixed costs.

• Real-time data access enhances decision-making capabilities regarding extraction processes and plant input management.

Future Communication Infrastructure Enhancements

• Plans include migrating communication systems entirely to fiber optics for better bandwidth as more data-intensive equipment is introduced in operations.

Q&A Session

Participant Engagement

Operational Strategies and Challenges in Mining

Cost Management and Production Efficiency

• The company currently pays $1 per ton for outsourced operations, which includes maintenance costs. There is a focus on increasing production while reducing fixed costs.

• Specific cost information related to the system cannot be disclosed due to confidentiality agreements with partner companies.

• Key tools for achieving production objectives include promptness in project initiation and enhancing extraction capabilities, with current efforts focused on drilling advancements.

Project Developments and Innovations

• Ongoing projects involve real-time monitoring of delays through equipment installation, aiming to improve operational efficiency.

• Current initiatives include controlling the entry of non-operational vehicles into the mine and automating ventilation systems, highlighting the importance of these upgrades.

Challenges in Mineral Processing

• A significant challenge faced by Brocal is the gradual decline in ore grades, necessitating increased production levels to maintain cash flow.

• Infrastructure improvements are underway alongside exploration plans to address declining ore grades while also focusing on cost reduction strategies.

Communication Systems Impact

• The implementation of fiber optic communication systems has been crucial for underground mining operations since mid-2022, significantly enhancing communication reliability.

• This technology serves as the backbone for effective communication within the mine, facilitating better operational coordination.

Decision-Making Enhancements

• The integrated control center has reduced equipment utilization time from 5.5 hours to 7 hours, indicating improved efficiency in decision-making processes.

• The system allows for quicker identification of operational issues such as ventilation failures or energy losses that previously took longer to diagnose without this technology.

Future Production Goals

• By 2026, there are plans to optimize plant capacity closer to its maximum potential of 18,000 tons per day despite anticipated declines in ore grades over coming years.

• Projects are also underway to monitor gas levels and ventilation more effectively within the mine using real-time data integration techniques.

Emerging Trends in Mining Operations

Implementing Dispatch Systems in Mining Operations

Overview of Dispatch System Implementation

• The speaker discusses the potential of dispatch tools to enhance operational efficiency and reduce costs, emphasizing their applicability across various mining processes.

• The speaker shares personal experience, noting that while they cannot speak for other mines, they have successfully adapted open-pit methodologies to underground operations at Brocal.

Challenges and Cultural Shifts

• Acknowledges the challenges faced by other mines but emphasizes Brocal's strategy focused on real-time control as a means to achieve operational goals.

• Highlights the primary challenge as a cultural shift among technical staff, where many fear loss of privacy due to increased monitoring through dispatch systems.

Training and Adaptation

• Initially faced resistance from operators; however, ongoing training has helped clarify the system's purpose and benefits, fostering acceptance over time.

• Emphasizes the importance of utilizing screens for data recording, with current usage at 60%, indicating room for improvement as cultural adaptation continues.

Collaboration with Technology Providers

• Discusses collaboration with MySens, which has provided flexible methodologies tailored to Brocal’s needs while maintaining oversight under their control.

• Stresses that technological advancement must go hand-in-hand with cultural change management for successful implementation.

Evidence of Success and Future Directions

• Shares tangible results since 2022 that demonstrate the effectiveness of new technologies in improving productivity at Brocal.

• Expresses confidence in continuing investment in technology and innovation based on positive outcomes observed thus far.

Final Thoughts and Recommendations

• Encourages others not to succumb to uncertainty when initiating similar projects; proactive decision-making is crucial for success.

• Reflects on Peru's high standards in mining compared to other countries like Chile, asserting that there are ample opportunities for innovation within the industry.

Closing Remarks

• Thanks the audience and acknowledges the role of institutions like the Institute of Mining Engineers in supporting such discussions.