As the mining industry faces increasing pressure to improve efficiency, reduce variability, and meet ambitious sustainability goals, the demand for smarter, connected decision-making has never been greater.
At IntelliSense.io, we believe the answer lies in end-to-end optimization of the mining value chain—powered by AI-driven solutions that deliver real-time insights and measurable value.
Last week, at the GMG Brisbane Forum, we showcased how this vision is becoming a reality through our collaboration with Cowal Gold Operations (Evolution Mining). We presented results from the implementation of Scientific AI to optimize gold recovery by bridging the gap between mine and plant.
This success highlights the growing impact of our AI Recovery Optimization Solution—designed to unlock powerful synergies between upstream and downstream operations. Here’s a closer look at how this integrated approach is reshaping gold recovery—and what it means for the future of mining
Connecting Mine and Plant: AI Recovery Optimization Case for Gold
A major gold operation in Australia was facing a familiar yet critical challenge: limited visibility into the properties of stockpiled material. This lack of insight led to poor blending, inconsistent plant feed, and recovery losses—particularly when silver-rich ores introduced toxicity, impacting process stability and increasing reagent consumption.
To address this, IntelliSense.io deployed four integrated AI-powered applications across the mine and plant. The result was a fully connected system that linked stockpile movements, crushed ore piles (COS), and downstream processes such as flotation and leaching—establishing a seamless mine-to-plant optimization loop.
By leveraging real-time data on material feed and stream characteristics, operators can now dynamically adjust blending strategies and plant setpoints—even at the cell level—based on live system feedback. This enables consistent performance, higher recovery, and reduced operational risk.
Real Results: Early Benefits Observed
The AI Recovery Optimization Solution is already delivering measurable value across operations. By integrating unit operations and enhancing communication between mine and plant, the system is unlocking new levels of performance.
Together, these capabilities are enhancing process visibility, maximizing metal recovery, and improving overall plant efficiency—driving performance gains across the mining value chain. Initial projections estimate AUD $10M in value across the mine-to-plant process.
You can dive deeper into results with these case studies:
- Selective Mining Strategy: Leveraging 3D block model dynamics to increase gold production by $1.6M
- Contaminant Detection: Real-time alerts identifying foreign material in crushed stockpiles, saving over $200K in losses
Most importantly, this approach shifts operations from isolated process management to a cohesive, end-to-end optimization strategy—driving alignment, efficiency, and value across the entire value chain.
Do you want to know how this would be applied to your operations?
