Integrated tactical continuous production planning of two blending systems sharing supply sources: the case of a phosphate supply chain

Abstract

This paper deals with a problem of tactical planning of production activities. It considers the case of the world's largest phosphate production site, with several mines, several washing plants, and a drying plant, with transport of merchantable phosphate ores (MOs) by rail or pipeline. The tightening of product quality requirements by customers prevents from continuing to plan its production with the current rules. Currently, the plants are managed quite independently, source ores (SOs) are pre-assigned to the MOs for blending, and the MO production routings in the washing plants are predetermined. We propose a model that ensures flexibility in the production of MOs through the choice of dynamic blends and routings. Our approach goes beyond any pre-allocation of resources and aims at synchronising the flows of the washing plants. This specific problem of blending production and planning has not been addressed in the literature. Still, it is widely encountered in many mining industries and offers perspectives for the application of the approach proposed. Numerous tests show that this model ensures the quality constraints related to the composition of several chemical components, with a generalised use of the most economical routings while ensuring horizontal and vertical alignment of decisions.