How it works

One system, three layers.

Minealytics connects the signals already produced by a mining operation with practical control and planning tools. The result is a shared operational picture that can support people, automate defined responses and coordinate the plant around its constraints.

The architecture

From signal to action.

01

Sense

Cameras, historians, laboratory results, instruments and maintenance signals are brought together at the edge and in the plant data layer.

02

Act

Validated models, advanced process control and supervisory tools turn those signals into recommendations, targets or approved control actions.

03

Orchestrate

Plant-level intelligence weighs throughput, recovery, quality, energy, water, equipment condition and operating constraints together.

The controller lifecycle

Build it, prove it, run it, keep it current.

Minealytics treats autonomy as a lifecycle. A controller learns from the plant's operating record, is tested against unseen campaigns and the site's safety case, and is then connected to the running plant so real operating evidence can improve the next version.

Explore the workflow

Hover over the stages or reveal the control points

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How it works

A controller is learned from your plant, proven in simulation, then runs on the control system you already have.

operating data

BEFORE IT TOUCHES THE PLANT

LEARN

Learns your plant

Built from your own history and the regimes your best operators run.

  • Historian collection
  • Cleaning & mass-balance reconciliation
  • Operating-regime augmentation
  • Metallurgical analysis
VERIFY

Proven before it runs

Tested against a simulation of your circuit and against your safety case.

  • Digital-twin testing
  • Hold-out campaigns
  • Safety case & interlocks
  • Constraint encoding
DEPLOY

Runs on what you have

Sits on top of your existing control system, whoever built it.

  • Integration with DCS / PLC
  • Live performance monitoring
  • Retraining & updating

EVERY MINUTE IT RUNS

SENSE

Sees the material

Cameras and soft sensors measure size, froth and flow — not just tags.

  • Vision — froth, size, grizzly
  • Instruments — density, power
  • Acoustic — mill, crusher
  • Soft sensors where no gauge exists
DECIDE

Finds the constraint

Works out where the plant is limited and what to change to lift it.

  • Capacity & headroom per unit
  • ML understanding beside mass balance
  • Scenarios ranked by economics
  • One goal across every controller
ACT

Moves the setpoints

Adjusts in real time, alongside the control you already trust.

  • Setpoints, feeders, valves
  • Autonomous rock breaking
  • Chases the optimum as ore changes
  • Hands back on exception
YOUR CIRCUIT  ·  PIT TO PORT

Hover any stage to open it — or use the button to pin every stage open.

Build and verify

Build and verify the controller

Production targets and the safety case define what success looks like.

Plant data management brings in the historian record, cleans it, reconciles the mass balance and adds the operating regimes recorded by operators. It creates two datasets: one for training and one of hold-out campaigns reserved for a fair test.

Controller learning chooses a model, learns from the operating record, transfers useful knowledge from similar circuits and tunes its hyperparameters. The result is a trained controller.

Verification tests that controller in the digital twin against the hold-out campaigns. It checks performance against the safety case and interlocks, and confirms that the flowsheet constraints are respected.

If the results fall short, the performance gap report sends the work back to data preparation or learning. Once it passes, the controller is ready for deployment.

Run the plant

Run the plant

Cameras, instruments and acoustic sensors watch the circuit.

Analysis combines ML soft sensors and computer vision with mass-balance calculations and familiar KPIs to build a picture of the current state.

Planning uses neural APC and reinforcement learning alongside established MPC and PID strategies to choose a response.

Execution applies approved changes to setpoints, feeders or the rock breaker. The plant responds, and the cycle starts again.

Keep the system learning

The two loops stay connected

Deployment brings the verified controller into the running plant, where it works with the DCS/PLC already in place and is monitored in real time. Operational data then flows back into data management, so the next controller learns from what actually happened rather than from the last commissioning campaign.

Where it fits

Designed around the control system you already have.

Data sources

Historian tags, cameras, lab data, asset condition and operator context provide the evidence.

Edge and signal layer

Vision and soft-sensor services convert raw signals into events, measurements and forecasts near the process.

Control layer

APC, optimisation and supervisory applications provide targets or actions through approved interfaces.

Existing safety and control

The site PLC, DCS and safety instrumented systems remain the final authority, with existing interlocks and fallback behaviour preserved.

The operating loop

A decision is only useful when it can be measured.

01Sense the process
02Reason about state and constraints
03Plan a response
04Approve within the site boundary
05Direct through the approved interface
06Measure the outcome and learn

Every site starts with a defined operating boundary.

The deployment path can move from monitoring to advice, supervised control or closed-loop control as evidence, operator confidence and the site safety case allow.

See the deployment path