Case Study: Vale achieves optimized coal mining productivity with AnyLogic

Optimization and Simulation of Coal Mining Operations

Vale, the Brazilian mining company, needed to maximize productivity at its Moatize coal mines in Mozambique while dealing with complex operations, multiple mining fronts, varied coal types, and a large truck fleet. To test changes without disrupting live production, Vale worked with AnyLogic-based simulation support from Genoa to analyze its open-pit coal mining operations.

AnyLogic helped Genoa build a detailed simulation and optimization model of the mines, covering 8 mining fronts, 80 trucks, crushers, shift schedules, maintenance, and waste constraints. The solution optimized truck fleet size and routing to increase coal throughput, enabled scenario testing for equipment and shift policies, and gave Vale a scalable framework for future expansion, all without affecting real-world production.

Vale