Mining
AI for Mining Operations
From pit face to port — specialist AI agents that optimize every stage of your mining operation, from drilling and blasting to grinding and flotation.
In a published case study, Brainiall’s AI delivered 5–10% grinding throughput gains and ~3% energy reduction in mid-tier gold mining operations. A separate Canadian gold pilot documented +6% throughput on hard ore (Wi ≥ 14 kWh/t).
SoftwareOne/AWS case study · Brasil Mineral Magazine #441 (Jul 2024)Solutions for Mining
AI-powered optimization from pit face to port.
Grinding Optimization
Dynamically adjust SAG and ball mill parameters including feed rate, speed, and water addition to maximize throughput while maintaining target grind size. AI responds to ore hardness changes in seconds.
Flotation Control
Optimize reagent dosing, air flow, and froth depth across multi-stage flotation circuits. Maximize mineral recovery while minimizing dilution and reagent costs through continuous AI-driven adjustments.
Drilling & Blasting
AI coordinates drill rig positioning and blast hole patterns based on geological models and real-time MWD data. Optimize fragmentation to reduce oversize events by up to 35% and improve dig rates.
Predictive Maintenance
Detect equipment degradation weeks before failure across crushers, conveyors, mills, and pumps. AI analyzes vibration, temperature, and load patterns to schedule maintenance during planned shutdowns.
Energy Optimization
Reduce energy consumption across haul trucks, crushers, and grinding circuits through intelligent load balancing. Achieve 8-12% energy savings without compromising throughput targets.
Safety & Environmental
AI-driven hazard detection across pit walls, haul roads, and processing areas. Real-time alerts for slope instability, proximity violations, and environmental compliance with dust and water monitoring.
Pit-to-Plant Optimization Across the Entire Value Chain
Traditional mining operations suffer from siloed decision-making between pit planning, hauling, and processing. Brainiall integrates data from drill-and-blast, load-haul-dump, crushing, and grinding into a unified AI model that optimizes the entire value chain simultaneously. The system learns the relationship between blast fragmentation, truck cycle times, and crusher performance to deliver throughput improvements that individual optimizations cannot achieve.
Autonomous Drilling with Adaptive Blast Design
Brainiall AI coordinates drill rig positioning and blast hole patterns based on geological models, real-time MWD data, and downstream processing requirements. The system continuously refines blast designs to achieve target fragmentation, reducing oversize events by up to 35% and improving dig rates. Each blast becomes a learning opportunity that improves future performance.
Environmental Monitoring with Predictive Compliance
Mining operations face increasing scrutiny on dust emissions, water discharge, and noise levels. Brainiall continuously monitors environmental sensors across the mine site and predicts compliance risks hours before they materialize. The AI proactively adjusts operations to maintain regulatory compliance without manual intervention or production stoppages.
Supply Chain from Mine to Market
Brainiall AI extends beyond the mine fence to optimize logistics, stockpile management, and rail or port loading schedules. The system forecasts production volumes and quality, coordinates with downstream customers, and dynamically adjusts blending strategies to meet contract specifications, reducing demurrage costs by up to 25%.
Dedicated Process Pages
Deep-dive into AI Autopilot configurations for each mining process.
Grinding — AI-controlled SAG & ball mills
Real-time optimization of grinding circuits. AI Autopilot tunes feed rate, mill speed, water addition, and power draw to maximize throughput while holding the p80 target — across varying ore hardness and mineralogy.
Flotation — AI-driven recovery optimization
Continuous tuning of collector dosage, frother rate, pH, air flow, and froth depth across rougher / scavenger / cleaner circuits. AI balances recovery vs concentrate grade non-linearly, accounting for ore mineralogy and mill p80 upstream.
Leaching — AI for CIP/CIL and heap leach circuits
Predictive control of cyanide (or acid) dosage, dissolved oxygen, retention time, CCD thickener performance, and carbon loading. AI forecasts recovery drops from chemistry shifts and pre-adjusts before extraction falls.
Crushing — AI for primary, secondary and tertiary stages
AI Autopilot coordinates crusher feed, CSS (closed-side setting), gap, and circulating load across jaw, cone, and gyratory crushers — smoothing downstream p80 before grinding even starts.
Thickening & tailings management
AI-controlled thickener underflow density, flocculant dosing, rake torque, and bed depth — plus water recovery planning across the tailings circuit to protect dam integrity and cut fresh-water draw.
Blasting — AI-optimized blast design & fragmentation
AI Autopilot tunes hole pattern, stemming, powder factor and delay timing against geology and downstream processing targets. Better fragmentation means less oversize, faster dig rates and lower kWh/t at the primary crusher.
Drilling — AI-guided blasthole & exploration drilling
AI Autopilot tunes rotation, thrust and flushing air in real time to each rock domain, extends bit life, keeps holes within azimuth/dip tolerance, and feeds MWD/LWD data straight into the next blast design and ore-body model.
Conveyors — AI for belt health, loading and energy
Continuous monitoring of belt condition, idler health, tracking, and load distribution. AI flags splice degradation days ahead of failure, optimizes speed to load profile, and cuts idling time across multi-kilometer overland conveyors.
Integrates via standard industrial protocols
Connects to any DCS, SCADA, PLC or historian that speaks one of the protocols below — Siemens PCS 7, ABB 800xA, Schneider EcoStruxure, Honeywell Experion, Rockwell PlantPAx, Emerson DeltaV, AVEVA / OSIsoft PI, and others.
OPC UAModbus TCPMQTTOSIsoft PIREST / gRPCApache KafkaCSV / SFTP
Trusted partners & press
Public partnerships and publications that have validated our work.
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IEC 61508 SIS preserved
No hardware changes