01 / Blending
Train-to-vessel blending
Decide which grades from which mines are combined for each vessel so the cargo meets its contractual quality requirements.
Customer case study · Coal · Port
Port Blending and Day-of-Operations Scheduling Software
BlendOpt is a configurable optimisation platform for mining value chains. Configured for port blending and day-of-operations scheduling, it tracks what is arriving by train, what is sitting on each port stockpile and what each vessel needs, then works out the blend that meets the contract quality at the highest value.
Customer resultSouth African coal exporter
Powered by BlendOpt
Outcome
Over 30% more blend value
An increase in the value of some vessel blends, with the blends still meeting the contractual requirements.
Predicted qualityWithin 0.6% of COA
Data updatesDaily, live
Used asDay-of-ops system
Coal · train to vesselCase study below
What BlendOpt optimises
What BlendOpt optimises in port blending and vessel loading
Daily data from the mines, the laboratory and the terminal keeps the plan in line with conditions on the ground, so the schedule is still useful at the end of the day it was made.
02 / Stockpiles
Port stockpile tracking
Monitor stockpile levels and qualities such as ash, volatile matter, sulphur, moisture and NCV using regularly updated data from the terminal.
03 / Quality risk
Tipping quality validation
Show new tippings to each stockpile and flag any tipping outside grade specifications as a quality risk.
04 / Optimisation
Optimised blend development
Replace trial-and-error blend development with optimisation, including grades that would not normally be considered in a manual blend.
05 / Day of operations
Day-of-operations updates
Update the plan with daily train arrival status, laboratory results, inventory reconciliation, vessel berthing and vessel ETA.
06 / Data
Data integration and dashboards
Connect the operation’s data sources through a configurable ETL pipeline and give non-technical users live dashboards of port operations.
Customer results
Port blending and scheduling results
Results BlendOpt customers have measured in blend value, product quality and revenue across their coal value chains.
Over 30%
increase in the value of some blends for a South African coal exporter, while still meeting contract requirements
Read the case study below →
35% → <5%
coal quality specification violations across a five-year plan
Coal quality consistency case study →
+$24M / yr
forecast revenue from new stockpile definitions and a moderate capacity change
Stockpile optimisation case study →
The whole value chain
Port blending in the context of the whole value chain
What can be loaded onto a vessel depends on what was mined, how it was processed and which trains reached the port.
BlendOpt takes what each mine supplies as an input and models stockpiles, logistics and sales contracts together, so a blend decision at the port is valued by its effect on the whole operation. See how this works for coal blending, multi-mine optimisation, stockpile optimisation and integrated mine planning and scheduling.
Train to vesselToday’s plan, today’s data.
BlendOpt model
- Minesmultiple grades
- Railtrain arrivals
- Portstockpiles & lab
- Vesselsberthing & ETA
- Contractsquality specs
Optimisation objective
Highest-value blend, within contract
Each vessel is loaded to its contract quality at the best available value, using the day’s train, laboratory, inventory and vessel data.
Customer case study · Coal
Case study
Day-of-operations port blending
Over 30% more value from some vessel blends
A multi-mine South African coal exporter used BlendOpt as its day-of-operations system to track port inventory and optimise the blending of coal onto vessels.
- 30%+value of some blends
- 0.6%predicted quality vs vessel COA
- Dailylive data updates
Before BlendOpt
See the value unlocked →
Trial-and-error blends
Blends were developed manually, so high discount grades that could add value were not normally considered.
Full case study
PDF
Download the case studyPort blending and day-of-operations scheduling (PDF)
The challenge, solution and value unlocked for a South African coal exporter’s port operations, as a PDF.
Highlights
- Quality within 0.6% of vessel COA
- Blend value up by over 30%
- Off-spec tippings flagged as a quality risk
- A single source of truth for port operations
01
The challenge
A multi-mine coal exporter in South Africa needed a “Day of Operations” system to track port inventory and optimise the delivery of coal onto vessels. Making informed and accurate decisions required daily live data updates of train arrival status, coal quality lab results, inventory reconciliation, vessel berthing and vessel ETA.
Coal transport consisted of railing multiple grades from each of several mines, with tracking and management of coal qualities including ash, volatile matter, sulphur, moisture and NCV.
02
The solution
Using BlendOpt, the client was able to monitor stockpile levels and qualities using regularly updated data from the coal terminal, with the predicted qualities falling within 0.6% of the vessel COA.
The port management team could view new tippings to the stockpiles, with validation showing when tipping qualities were outside grade specifications and therefore presented a quality risk. BlendOpt’s built-in optimisation module also removed the need for trial-and-error blend development.
BlendOpt’s highly configurable ETL pipeline GUI was used to rapidly configure and integrate the client’s data sources within the application.
03
The value unlocked
By selecting high discount grades to add to the blend, which would not normally be considered during manual blend development, BlendOpt found a solution that let the client increase the value of some of its blends by over 30%, with the blends still meeting the contractual requirements.
BlendOpt brought transparency and confidence to daily decisions with a significant impact on the client’s cash flow, while data integration and live dashboards allowed non-technical users to rely on BlendOpt as a single source of truth for viewing and understanding the client’s port operations.
FAQ
Port blending and day-of-operations scheduling FAQ
How BlendOpt tracks port inventory and optimises the blend loaded onto each vessel.
What is day-of-operations scheduling at a port?
Day-of-operations scheduling is the short-term planning of what coal or ore is stacked, blended and loaded at the port, updated as the day’s information arrives. It uses train arrival status, laboratory quality results, inventory reconciliation, vessel berthing and vessel ETA to keep the plan current. The aim is to load each vessel to its contract specification at the best available value.
How does BlendOpt increase the value of a vessel blend?
BlendOpt searches every feasible combination of available grades rather than relying on trial and error. In one case study it selected high discount grades that would not normally be considered during manual blend development. The coal exporter increased the value of some of its blends by over 30%, with the blends still meeting the contractual requirements.
How accurate are BlendOpt’s predicted stockpile qualities?
In the South African coal export case study, BlendOpt tracked stockpile levels and qualities using regularly updated data from the coal terminal. The predicted qualities fell within 0.6% of the vessel certificate of analysis (COA). That level of accuracy gave the port team confidence to rely on the predicted qualities when making daily blending decisions.
What data does BlendOpt need for train-to-vessel blending?
Typical inputs are train arrival status, coal quality laboratory results, stockpile inventory, vessel berthing and vessel ETA, along with the contract quality requirements for each vessel. BlendOpt’s configurable ETL pipeline GUI is used to connect and configure these data sources within the application. Qualities tracked can include ash, volatile matter, sulphur, moisture and NCV.
Who uses BlendOpt at the port?
Port management teams use BlendOpt to see new tippings to stockpiles and to be warned when a tipping is outside grade specifications. Live dashboards let non-technical users rely on BlendOpt as a single source of truth for viewing and understanding port operations. Planners use the optimisation module to develop blends that meet contract requirements.