Improve Overall Cu Recovery by 1% ($38M)

Major Copper Mine in Chile

A case study demonstrating how Flotation real-time monitoring and optimization enhanced metal recovery by 1%, a value of $38M

Stockpile Optimization App snippet 3

Customer Challenge

Low Columnar Cells Performance

A complex flotation circuit consisting of over 100 cells, encompassing rougher and second cleaner stages, faced challenges of instability stemming from significant variability in ore feed.

The absence of per-cell process visibility and control contributed to diminished recovery rates.

How We Helped

Real-time Virtual Sensors per Column Cell

We incorporated real-time Hydrodynamic and Kinetic Virtual Sensors (VS) for each cell.

Optimizer tool for Air Flow and Froth Depth recommended setpoints.

Additionally, we carefully configured a comprehensive Control and Alerts panel tailored to site-specific needs.

The Outcome

 Improved Circuit Overall Recovery by 1%

New virtual Hydrodynamic and Kinetic sensors across 125 flotation cells, providing optimizer-guided suggestions for air flow and froth depth adjustments. 

Potentially yield a 1%recovery boost, translating to annual gains of $38M USD, while also facilitating swift identification of underperforming cells.

Enhanced visibility allowed quicker operational response, minimizing downtime and unplanned shutdowns.

Discover how Flotation Optimization can be applied to your operation

Mine to Market: Value Chain Optimization

The Stockpile & Inventory Optimization Application is one of a suite of real-time decision-making applications that uses AI to optimize each process; from mine to market.

Our Material Handling model connects these applications to drive even greater efficiency.

Our process optimization apps can be deployed on a specific process bottleneck or expanded across the entire value chain. They are powered by our Industrial AI Decision Intelligence Platform,

Stockpile and Inventory Optimization

Stockpile & Inventory Optimization

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