Leaching Optimization

Increase Process Visibility & Metal Recovery Using Scientific AI

IntelliSense.io’s Leaching Optimization application uses real-time Scientific AI to provide near real-time virtual sensors to improve visibility into heap leach material distribution, feed stream and in-tank content compositions. Metallurgists can promptly evaluate block models and process performance, enabling timely adjustments to achieve operational KPIs.

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Made for Your Mining Challenges

Lack of Visibility into Material Properties and Chemical Conditions 

Significant uncertainty regarding the distribution of ore types and material properties across heap pads results in inefficient irrigation strategies and high acid consumption.

Suboptimal metal recovery is attributed to the lack of real-time control over variables and chemical conditions inside tanks (pH and Redox).

The delayed availability of laboratory assay results poses a threat, and the frequent presence of gangue mineralogy often leads to ‘gelling’ events.

How It Helps

Enhance Efficiency with Real-time Monitoring

Scientific AI virtual sensors offer real-time visibility into the spatial distribution of ore properties within stacked material.

Enhance process visibility by tracking material and feed stream properties, including the physical and chemical compositions of solid and liquid streams.

Optimize reagent addition, configure setpoints, and establish alerts by monitoring in-tank density, viscosity, and carbon mass flow with real-time virtual sensors.

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What You Get

Improve Process Stability and Metal Recovery

Enhanced leaching kinetics by adapting your mine planning and blending strategies, resulting in OPEX savings on acid consumption and material handling.

Attain clear visibility into material tracking influence, including feed and upstream properties, and receive alerts on silica gel formation.

Explicit operational guidance to proactively implement changes/setpoints and uphold your desired grade and recovery, regardless of variability.

Leaching Optimization in Action

The IntelliSense.io Leaching Optimization application has been developed and refined over several years at multiple customer sites, creating an ‘out-of-the-box’ product that can be rapidly deployed to deliver value within weeks.

The IntelliSense.io team was capable to provide real-time tracking of ore characteristics for heap deposition which was used as an input for the irrigation strategies, allowing metallurgists to save 5-8% in the total acid addition.

Major Copper Mine



savings in acid consumption 


improvement in copper recovery

Discover how Leaching Optimization can be applied to your operation

Mine to Market: Value Chain Optimization

Powered and connected together by the brains.app platform, the Heap Leach Optimization Application is one of a suite of real-time decision-making applications that use Scientific 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 Scientific AI Decision Intelligence Platform, brains.app.

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