AI Co-Pilot for Optimized Coal Operations

Challenge

Coal blending directly impacts a mining site's profitability, influencing:

• Total output and operational throughput.
• Product quality and stability.
• Process flexibility and adaptability.
• Final market value of coal products.

Given these critical factors, the client required a sophisticated and precise solution to optimize coal blending and associated operational processes.
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Solution

The Mahusai team developed an intelligent AI Co-Pilot leveraging advanced AI capabilities, including:

• Core Blending Optimization: A dynamic AI-driven blending engine that continuously evaluates coal stockpile properties, recommending optimal coal mixes to achieve targeted product grades.
• Real-Time Data Integration: Real-time ingestion and analysis of data streams, including coal quality indices, market prices, vessel locations, port conditions, and weather forecasts.
• Sales & Supply Optimization: AI-powered recommendations aligning sales strategy with dynamic blend suggestions, optimized scheduling, and prioritization to maximize revenue and minimize demurrage.
• Streamlined Data Management: Automated certificate uploading and intuitive reporting tools that eliminate manual data entry, enhancing data traceability and simplifying reporting.
• Forecasting & Planning Tools: Predictive analytics enabling proactive decision-making by forecasting stockpile volumes, vessel schedules, and anticipating demand surges or potential overstock scenarios.
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Technology

• Frontend: React Native
• Backend Framework: Django REST
• Cloud Infrastructure: AWS
• Optimization Algorithms: Nonlinear Programming (NLP) & Mixed-Integer Nonlinear Programming (MINLP)
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Results

Following deployment, the AI-driven coal optimization solution dramatically improved the client's operations:

• Significantly increased operational efficiency and coal product quality consistency.
• Enhanced profitability through dynamic, real-time decision-making.
• Reduced operational risks by transitioning from reactive to proactive management.