IJSMRVol 19 No 3
IJSMRVol 19 No 3
net/publication/233153708
Cutoff grade optimization algorithm with stockpiling option for open pit
mining operations of two economic minerals
CITATIONS READS
43 1,247
1 author:
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
Stochastic Simultaneous Optimization of Mining Complexes - Mineral Value Chains View project
Enhancing Value through Grade Engineering - a heuristic method for optimal production scheduling of mining operations View project
All content following this page was uploaded by Mohammad Waqar Ali Asad on 30 December 2013.
M. W. A. ASAD*
Lane’s theory of cutoff grade optimization maximizes the Net Present Value
(NPV) of an open pit mining operation with a declining effect as the deposit
moves toward exhaustion. This declining effect of NPV defines dynamic cutoff
grades, i.e. higher cutoff grades in the early years of mine life and lower cutoff
grades in the later years. This phenomenon allows the creation of stockpiles with
material between the lowest (breakeven) and optimum cutoff grades for
processing during later years, when it becomes economical. As an extension to
Lane’s original theory of cutoff grades in deposits of two economic minerals, the
management, i.e. supplies of material from the mine to the stockpile and from
the stockpile to the processing plant, is addressed through the development of a
cutoff grade optimization algorithm with option to stockpile. The benefits of the
methodology are elaborated in a hypothetical case study.
1. Introduction
Cutoff grade is defined as the grade, which discriminates between ore and waste (Dagdelen 1992).
The material in the deposit with grade higher than cutoff grade is ore, which is sent to the
processing plant; the material below the cutoff grade is sent to the waste dump (Dagdelen 1992,
1993). However, it is critical that the material classified as waste today could become economical
to be processed in future.
Cutoff grade optimization theory supports the ultimate objective of a mining operation through
maximizing the Net Present Value (NPV) (Dagdalen 1992). However, the NPV declines as the
material is mined, processed and refined year by year (Lane 1964, 1984, 1988, Dagdelen and
Mohammad 1997, Mohammad 1997). Since, the definition of cutoff grade in a given year is
dependent upon NPV, it also declines (i.e. cutoff grades are dynamic rather than static or
constant) throughout the life of the mine (Mohammad 2002, 2003). This inherent nature of cutoff
grade optimization theory leads to the provision of stockpiles of low-grade ore, i.e. material below
*Email: mwaasad@nwfpuet.edu.pk
International Journal of Surface Mining, Reclamation and Environment
ISSN 1389-5265 print/ISSN 1744-5000 online Ó 2005 Taylor & Francis
http://www.tandf.co.uk/journals
DOI: 10.1080/13895260500258661
Cutoff grade optimization algorithm 177
optimum cutoff grade in the early years of mine life is processed later on when it becomes
economical (Lane 1988). This further enhances the NPV of a mining operation.
The management of stockpiles of low-grade ore is possible using the following two options
(Mohammad 1997, Mohammad and Khan 2004).
1. The stockpile is utilized parallel to the mining operation. This means that material is sent to
the processing plant either from the mine or stockpile. This decision is based on the overall
profitability of the operation.
2. The stockpile is utilized after the mine is exhausted. This simplifies the decision making,
since the stockpile acts as an additional pushback, where all available material is
economical to process. However, the high-grade material in the stockpile is utilized earlier
than the low-grade material.
In this study, the ease of operation for the second case becomes a reason of choice for the de-
velopment of the cutoff grade optimization algorithm with a stockpiling option for deposits of two
economic minerals. The case study of a hypothetical copper – gold deposit is presented, where the
effect of introducing a stockpiling option in mine planning is demonstrated with an increase in NPV.
2. Methodology
Cutoff grade optimization model considers an ideal open pit mining operation, consisting of mining,
processing and refining stages (Lane 1964). The refining stage is further divided into two refineries in
the deposits of two economic minerals with an additional refinery for the second mineral (Lane 1984).
The following notations are defined (Lane 1984, Mohammad 1997) for a better understanding
of the steps of algorithm.
X
N
Pi
Max NPV ¼ ð1Þ
i¼1 ð1 þ dÞi
Subject to:
Qm M ð2Þ
Qc C ð3Þ
Qr1 R1 ð4Þ
Qr2 R2 ð5Þ
here
The cutoff grade of both mineral 1 and mineral 2 dictates the quantity mined, processed and
refined in a given period i and, accordingly, the profit becomes dependent upon the definition of
cutoff grade. Therefore, the solution of the problem lies in the determination of optimum cutoff
grades in a given period, which ultimately maximizes the objective function.
The grade–tonnage distribution is two-dimensional for the case of deposits of two economic
minerals (Lane 1984, Mohammad 1997, 2003), as shown in figure 1. Instead of a curve, the
distribution is a surface and may be represented by a series of contours. The cutoff is a boundary
between the ore and the waste, and therefore it is a line. The simplest way to specify a cutoff line is
by means of its intercepts, g1 and g2, on the grade axes. The value g1 is actually the cutoff grade for
mineral 1 in the absence of mineral 2 and g2 is the cutoff grade for mineral 2 in the absence of
mineral 1. Therefore, the problem of determining an optimum cutoff policy for a deposit of two
economic minerals is in fact the determination of the sequence of pairs of values for the cutoff
intercepts g1 and g2 that maximize the NPV of operation (Lane 1984, Mohammad 1997, 2003).
Assume that the grade tonnage distribution of the deposit consists of K individual grade
categories or increments of mineral 1, which is presented as:
g1 ð1Þ; g1 ð2Þ ; g1 ð2Þ; g1 ð3Þ ; . . . ; g1 ðK 1Þ; g1 ðKÞ
Therefore the deposit consists of M individual grade categories or increments of mineral 2 for
each grade category or increment of mineral 1, which is presented as:
g2 ð1Þ; g2 ð2Þ ; g2 ð2Þ; g2 ð3Þ ; . . . ; g2 ðM 1Þ; g2 ðMÞ
Consequently, for each grade category of mineral 1 and M grade categories of mineral 2, there
exist t tons of material.
In general, if grade category [g1 (k), g1(k + 1)] of mineral 1 is represented as k*, and the lower
grade in k*, g1(k) is considered as cutoff grade of mineral 1. Accordingly, if grade category [g2 (m),
g2(m + 1)] mineral 2 corresponding to k* is represented as m*, and the lower grade in m*, g2(m) is
considered as cutoff grade of mineral 2.
This leads to the following four calculations.
1. Ore tons, i.e. tons above cutoff grade of mineral 1 and mineral 2, represented as To:
X
K X
M
To ðk ; m Þ ¼ tðk;mÞ ð7Þ
k¼k m¼m
2. Waste tons, i.e. tons below cutoff grades of mineral 1 and mineral 2, represented as Tw:
kX X
1 m 1
Tw ðk ; m Þ ¼ tðk;mÞ ð8Þ
k¼1 m¼1
180 M. W. A. Asad
Now,
Qc ¼ C; if To > C
ð11Þ
Qc ¼ To ; otherwise
Similarly,
Tw
Qm ¼ Qc 1 þ ð12Þ
To
Qr1 ¼ Qc gavg1 y1 ð13Þ
Qr2 ¼ Qc gavg2 y2 ð14Þ
If it takes time T to mine the next Qm of material, then the profit realized from Qm at the end of
time T can be achieved by substituting equations (13) and (14) into equation (6):
ðS1 r1 Þgavg1 y1 þ ðS2 r2 Þgavg2 y2 c Qc
P¼ ð15Þ
mQm fT
However, the objective function is to maximize the NPV of future profits. Assuming that V is
the maximum possible present value of future profits at time zero and W is the maximum possible
present value of future profits (pT+1 to pN) to be obtained from reserves after mining next Qm of
material, i.e. in time T, then the scenario can be presented as shown in figure 2.
Knowing the discount rate d:
pTþ1 pN
W¼ þ þ ð16Þ
ð1 þ d ÞTþ1 ð1 þ d ÞN
PþW
V¼ ð17Þ
ð1 þ d ÞT
Figure 2.
Cutoff grade optimization algorithm 181
The difference of V and W represented as v is actually the increase in present value achieved by
mining the next Qm of material. Since T is short interval of time, equation (17) can be written as:
v ¼ ðV WÞ ¼ P dVT ð18Þ
Substituting equation (15) into equation (18) yields the basic present value expression, which is
used for calculation of optimum cutoff grades:
2
3
ðS1 r1 Þgavg1 y1 þ ðS2 r2 Þgavg2 y2 c Qc
v¼4 5 ð19Þ
mQm ð f þ dVÞT
The time T is defined by the limiting capacity of any of four stages of the mining operation,
which introduces four cases depending upon the actual constraining capacity. Therefore, it
changes as follows depending upon whether mining, milling, refinery of mineral 1 or refinery of
mineral 2 is limiting the operation, respectively:
Qm
T¼ ð20Þ
M
Qc
T¼ ð21Þ
C
Qc gavg1 y1
T¼ ð22Þ
R1
Qc gavg2 y2
T¼ ð23Þ
R2
2
3
ðS1 r1 Þgavg1 y1 þ ðS2 r2 Þgavg2 y2 c Qc
6 7
vm ¼ 4 h i 5 ð24Þ
f þ dV
m þ M Qm
2 28
9 33
< ðS1 r1 Þgavg1 y1 þ ðS2 r2 Þgavg2 y2 =
64 Q 57
6 ; c 7
vc ¼ 6 : c þ fþdV 7 ð25Þ
4 C 5
½mQm
228 9 3 3
< S1 r1 f þ dV gavg1 y1 =
R
vr1 ¼ 44 1
Q 5 ½mQm 5 ð26Þ
:
; c
þ ðS2 r2 Þgavg2 y2 c
228
9 3 3
< ðS1 r1 Þgavg1 y1 =
vr2 ¼ 44 Q 5 ½mQm 5 ð27Þ
: þ S2 r2 f þ dV gavg2 y2 c ; c
R2
182 M. W. A. Asad
Now, for any values of g1 and g2, it is possible to calculate vm, vc, vr1 and vr2. The minimum of
these four values is always associated with the constraining capacity. Hence, the objective function
is maximized as:
1. the tons of waste below the breakeven cutoff grade will never be economical and hence sent
to the waste dump;
2. the tons of waste between the breakeven cutoff grade and the optimum cutoff grade become
the intermediate grade material and hence sent to the stockpile.
Note that the grade categories of stockpile are arranged according to the original grade categories
of the deposit between the breakeven and the optimum cutoff grades of mineral 1 and 2 as
mentioned in section 2.2.
This creation of stockpiles continues throughout the life of a mine. Once the mine is exhausted,
the material from the stockpile is processed in the same fashion as the material from the mine. The
value of material is assessed based on the material handling cost incurred during the loading and
transportation of stockpiled material rather than the mining cost. This material handling cost is
usually 45% of the mining cost, which is composed of 40% corresponding to material handling
and 5% to supervision (Schellman 1989).
Tw ðg1 ; g2 Þ
Qm ¼ Qc 1 þ ð30Þ
To ðg1 ; g2 Þ
9. If j is equal to 1, then:
(a) compute the life of deposit N based on the limiting capacity among mine, mill,
refinery 1 and refinery 2;
(b) compute the annual profit for the life of mine using modified equation (15):
2( ) 3
ðS1 r1 Þgavg1 ðg1 ; g2 Þy1 þ
6 Qc 7
P¼6
4 ðS2 r2 Þgavg2 ðg1 ; g2 Þy2 c 7
5
mQm f T ð33Þ
Where T ¼ 1; if N >¼ 1
T ¼ N; otherwise
(c) determine NPV by discounting profits at a discount rate d for the time N. The
following relationship is based on the assumption that uniform profit will be achieved
from years 1 to N.
h i
P ð1 þ d ÞN 1
NPV ¼ ð34Þ
dð1 þ d ÞN
(d) compare this NPV with the previous V (step 5). If the computed NPV is not
converged (within some tolerance, say + $500,000 of V), go to step 5, otherwise, go
to step 10.
10. Create the stockpile grade categories and accumulate the reserves available in each
category, as discussed in section 2.3.
184 M. W. A. Asad
11. Adjust the grade tonnage curve of the deposit by subtracting ore tons, i.e. Qc from the
grade distribution intervals above optimum cutoff grades g1 and g2 and the waste tons
(Qm 7 Qc) from the intervals below optimum cutoff grade g1 and g2 proportionate
amounts such that the distribution is not changed.
12. Check if the deposit is completely depleted, then go to step 4. If not, then go to step 3.
13. Start processing the stockpile material using steps 3 to 13. However, equation (33) is
modified as:
2( ) 3
ðS1 r1 Þgavg1 ðg1 ; g2 Þy1 þ
6 Qc 7
P¼4 ðS2 r2 Þgavg2 ðg1 ; g2 Þy2 c 5 ð35Þ
sh Qm f T
Gold (oz/ton)
Copper (%) 0.00 – 0.02 0.02 – 0.03 0.03 – 0.04 0.04 – 0.05 4 0.05
0.00 – 0.25 963 250 834 670 987 650 824 870 977 640
0.25 – 0.35 782 450 928 780 887 780 954 480 853 760
0.35 – 0.45 954 760 919 830 692 870 673 780 839 860
0.45 – 0.55 827 380 739 390 842 670 689 290 658 540
0.55 – 0.65 853 890 794 790 947 870 824 890 875 780
0.65 – 0.75 682 760 823 760 983 480 974 590 773 830
0.75 – 0.85 754 870 859 940 991 650 873 480 930 580
0.85 – 0.95 747 780 759 570 693 390 962 380 878 470
4 0.95 927 470 797 780 892 480 989 870 627 780
Cutoff Grade
Qm Qc Qr1 Qr2 Profit NPV
Year Copper (%) Gold (oz/ton) (ton) (ton) (ton) (ton) ($) ($)
1 0.250 0.028 3 490 000 2 000 000 12 830 79 350 35 660 000 192 670 000
2 0.250 0.027 3 380 000 2 000 000 12 830 78 180 35 380 000 185 920 000
3 0.250 0.027 3 380 000 2 000 000 12 830 78 180 35 380 000 178 430 000
4 0.250 0.026 3 270 000 2 000 000 12 820 77 030 35 100 000 169 810 000
5 0.194 0.026 3 180 000 2 000 000 12 560 77 080 34 850 000 160 180 000
6 0.194 0.024 3 080 000 2 000 000 12 550 75 940 34 560 000 149 360 000
7 0.167 0.023 2 950 000 2 000 000 12 410 74 850 34 130 000 137 210 000
8 0.167 0.022 2 860 000 2 000 000 12 400 73 740 33 840 000 123 660 000
9 0.167 0.020 2 700 000 2 000 000 12 390 71 560 33 250 000 108 370 000
10 0.125 0.018 2 590 000 2 000 000 12 190 70 780 32 800 000 91 370 000
11 0.104 0.017 2 520 000 2 000 000 12 080 69 960 32 440 000 72 280 000
12 0.063 0.016 2 430 000 2 000 000 11 870 69 420 32 020 000 50 680 000
13 0.042 0.011 2 220 000 1 940 000 11 390 64 960 30 210 000 26 270 000
186 M. W. A. Asad
Cutoff Grade
Qm Qc Qr1 Qr2 Profit NPV
Year Copper (%) Gold (oz/ton) (ton) (ton) (ton) (ton) ($) ($)
1 0.250 0.028 3 490 000 2 000 000 12 830 79 350 35 660 000 200 190 000
2 0.250 0.027 3 380 000 2 000 000 12 830 78 180 35 380 000 194 570 000
3 0.250 0.027 3 380 000 2 000 000 12 830 78 180 35 380 000 188 370 000
4 0.250 0.026 3 270 000 2 000 000 12 820 77 030 35 100 000 181 250 000
5 0.194 0.026 3 180 000 2 000 000 12 560 77 080 34 850 000 173 340 000
6 0.194 0.024 3 080 000 2 000 000 12 550 75 940 34 560 000 164 490 000
7 0.167 0.023 2 950 000 2 000 000 12 410 74 850 34 130 000 154 600 000
8 0.167 0.022 2 860 000 2 000 000 12 400 73 740 33 840 000 134 660 000
9 0.167 0.020 2 700 000 2 000 000 12 390 71 560 33 250 000 131 370 000
10 0.125 0.018 2 590 000 2 000 000 12 190 70 780 32 800 000 117 830 000
11 0.104 0.017 2 520 000 2 000 000 12 080 69 960 32 440 000 102 710 000
12 0.063 0.016 2 430 000 2 000 000 11 870 69 420 32 020 000 85 670 000
13 0.042 0.011 2 220 000 1 940 000 11 390 64 960 30 210 000 66 510 000
14 0.230 0.010 2 000 000 2 000 000 14 950 30 460 24 840 000 46 280 000
15 0.183 0.010 2 000 000 2 000 000 14 080 30 460 23 440 000 28 380 000
16 0.042 0.010 1 610 000 1 610 000 5 820 25 900 10 580 000 9 200 000
5. Conclusions
The provision of stockpiles is a strategic decision, which solely depends upon the existing
conditions of a given mining operation. The technique developed in this study is applicable to
metallic ore deposits, because it considers long-term stockpiles (e.g. in the case study the life of the
stockpile is almost equal to the mine life). Hence, an important consideration to take into account
is that the material may deteriorate during long exposure to the environment. Some leaching may
occur, with consequent loss of mineral. Oxidation may create difficulties in the treatment plant and
cause poor recoveries.
However, it is a well-established fact that stockpiles provide an additional flexibility to
management in decision-making with respect to ore processing in the processing plant. The impact
of this decision is also demonstrated in the case study through enhancement of the NPV and life of
the mining operation.
References
Ataei, M. and Osanloo, M., Using a combination of genetic algorithm and grid search method to determine optimum cutoff
grades of multiple metal deposits, Int. J. Surf. Mining Reclama. Environ., 2004, 18, 60–78.
Dagdelen, K., Cutoff grade optimization, in Proceedings of the 23rd International Symposium on Application of Computers
and Operations Research in Minerals Industries, 1992, pp. 157–165.
Dagdelen, K., An NPV optimization algorithm for open pit mine design, in Proceedings of the 24th International Symposium
on Application of Computers and Operations Research in Minerals Industries, 1993, pp. 257–263.
Dagdelen, K. and Mohammad, W.A., Multi-mineral cutoff grade optimization with option to stockpile, in SME Annual
Meeting, 1997, Preprint # 97186.
Lane, K.F., Choosing the optimum cutoff grade. Colorado Sch. Mines Quart., 1964, 59, 811–829.
Lane, K.F., Cutoff grades for two minerals, in Proceedings of the 18th International Symposium on Application of Computers
and Operations Research in Minerals Industries, 1984, pp. 485–492.
Lane, K.F., The Economic Definition of Ore, Cutoff Grade in Theory and Practice, 1988 (Mining Journal Books: London).
Cutoff grade optimization algorithm 187
Mohammad, W.A., Multi-mineral cutoff grade optimization with option to stockpile. MSc thesis, Colorado School of
Mines, 1997.
Mohammad, W.A., Development of generalized cutoff grade optimization algorithm for open pit mining operations J. Eng.
Appl. Sci., 2002, 21, 119–127.
Mohammad, W.A., Generalized cutoff grades optimization algorithm in two minerals case. J. Eng. Appl. Sci., 2003, 22,
81–87.
Mohammad, W.A. and Khan, M.N., Management of open pit mining operations with ore stockpiles. J. Eng. Appl. Sci.,
2004, 23, 51–56.
Schellman, M.G., Determination of an optimum cutoff grade policy considering the stockpile alternative. MSc thesis 1,
Colorado School of Mines, 1989.