Circuito AI vs IntelliSense.io: Mining AI Compared
Circuito AI vs IntelliSense.io for mineral processing: architecture, control modes, data sovereignty, and deployment models compared.
TL;DR
Circuito AI writes setpoints directly to the DCS in closed-loop mode, deployed 100% on-premise. IntelliSense.io advises operators through physics-informed digital twins via cloud-based SaaS, with broader mine-to-plant scope. Both are credible platforms with real deployments. The choice depends on whether your operation needs autonomous closed-loop control with on-site data sovereignty, or broader advisory coverage across the full value chain.
Introduction
Circuito AI and IntelliSense.io both focus on mineral processing optimization. Both have published results and real deployments. But they represent fundamentally different approaches — and understanding those differences matters when you are evaluating platforms for your operation.
Architecture and Technology
IntelliSense.io uses what they call “objective-driven AI” — a combination of physics-informed digital twins and machine learning. Their platform, brains.app, incorporates first-principles flotation kinetic models alongside data-driven ML. This approach has the advantage of being interpretable: process engineers can understand why the system recommends what it does, because the underlying physics models are transparent.
Circuito AI is built on reinforcement learning and neural networks from the ground up. Rather than encoding physics rules, the system learns optimal control strategies directly from operational data. Models continuously retrain on fresh plant data — adapting to ore blend changes, liner wear, and seasonal variations without manual recalibration. The platform was purpose-built for mineral processing, not adapted from another industry.
The practical difference: IntelliSense.io’s physics-informed approach provides interpretability and works well for advisory recommendations. Circuito AI’s reinforcement learning approach is optimized for real-time autonomous control, where the AI must make thousands of decisions per shift without human intervention.
Control Mode: Advisory vs Closed-Loop
This is the single most important difference between the two platforms.
IntelliSense.io operates in advisory and co-pilot mode. The platform analyzes process data, generates recommendations, and presents them to operators for approval. They are developing AI agents for autonomous execution, but the core deployment model relies on operator response — the system recommends, humans act.
Circuito AI operates in closed-loop mode, writing setpoints directly to the DCS. The AI makes control interventions every 10 seconds, managing up to 46 control actions per flotation line simultaneously. This is 120 times faster than manual operator response.
Why this matters: advisory systems depend on operator availability and response time. During night shifts, shift changes, or periods of high workload, recommendations go unacted upon for minutes or hours. Closed-loop systems execute continuously, regardless of staffing. The question is simple: what happens at your plant when your best process engineers are not on shift?
Data Sovereignty and Deployment
IntelliSense.io deploys via a cloud-edge hybrid model (brains.app in the cloud, brains.edge on-site). This SaaS approach means some portion of your operational data leaves the plant for processing in external infrastructure.
Circuito AI deploys 100% on-premise. All data processing, model training, and control execution happens within the plant network. No process data leaves the site. Remote access is strictly regulated and authorized.
For LATAM mining operations, this distinction carries real weight. Many sites operate in remote locations with limited or unreliable internet connectivity. Data sovereignty regulations vary across Latin American jurisdictions. And for operations processing high-value ores, the sensitivity of process data — grade, recovery rates, throughput figures — makes data governance a board-level concern, not just an IT consideration.
Process Coverage
IntelliSense.io offers broader coverage across the mine-to-plant value chain. Their platform extends beyond the concentrator to include stockpile 3D modeling, ore blending optimization, and geometallurgical integration. They report $12M in value at an Australian gold mine from mine-to-plant integration. This breadth is a genuine strength for operations looking to optimize the full value chain from pit to concentrate.
Circuito AI focuses on concentrator optimization — crushing, grinding, and flotation circuits. The platform does not currently extend upstream into mine planning or ore blending. However, this narrower focus allows deeper optimization within the concentrator. Circuito AI’s cross-process optimization treats crushing, grinding, and flotation as one integrated system rather than three separate circuits, preventing the common problem where local gains in one circuit create losses downstream.
The tradeoff is clear: IntelliSense.io offers breadth across the value chain; Circuito AI offers depth within the concentrator.
Published Results
Grinding
| Metric | IntelliSense.io | Circuito AI |
|---|---|---|
| Throughput increase | ~1% | +2.6% (ball mills), +1.4% (SAG/AG) |
| Reported value | ~$1.3M/year | Not disclosed separately |
Flotation
| Metric | IntelliSense.io | Circuito AI |
|---|---|---|
| Recovery improvement | 1–3% metal recovery | ~1% additional recovery improvement |
| Reported value | ~$5.5M/month at 120+ cell copper operation | Not disclosed separately |
IntelliSense.io publishes more specific dollar-value figures. Their $5.5M/month flotation result at a large South American copper operation is substantial and well-documented. Circuito AI’s published grinding results (+2.6% throughput at Norilsk Nickel) are strong, and their flotation optimization delivers approximately 1% additional recovery — a meaningful gain at scale given the nonlinear economics of concentrate production.
Both platforms use different result verification methodologies. Circuito AI employs a rigorous A/B testing approach — alternating AI-optimized and manual-baseline operation under identical ore conditions to statistically isolate the system’s contribution. IntelliSense.io reports results from live deployments with before-and-after comparisons.
Named References
IntelliSense.io claims 9 of the top 20 global miners as clients, with Evolution Mining (Cowal Gold) as a named reference and a large South American copper operation (unnamed). They won the 2025 Mining Technology Excellence Award and the 2024 InvestMETS ‘Best Scale-Up’ award.
Circuito AI references Norilsk Nickel (one of the world’s largest nickel producers) and Russian Copper Company — both complex, large-scale operations. They have over 20,000 combined production hours across deployments.
LATAM Presence
IntelliSense.io has an established LATAM presence with offices in Santiago, Chile and active deployments across Chile, Brazil, and Peru. For LATAM operations, this means local support, familiarity with regional regulatory environments, and existing relationships with regional miners.
Circuito AI is entering the LATAM market through Circuito AI, the exclusive regional partner for all of Latin America. While Circuito AI does not yet have LATAM deployments, the dedicated partner structure means focused attention on the region rather than LATAM being one market among many.
Pricing and Commercial Model
IntelliSense.io offers a “No CapEx” SaaS model — an annual subscription that includes license, implementation, managed service, and support with no upfront cost. They report a typical 10x value return on subscription fees. This model lowers the barrier to entry significantly.
Circuito AI uses a traditional license model — a paid site assessment, followed by integration and a platform license. This is a larger upfront commitment but eliminates ongoing subscription fees and keeps all infrastructure on-site. Pricing scales with plant capacity and is available on request.
The right model depends on how your operation allocates capital. SaaS keeps spending in OpEx with lower initial commitment. Licensing means outright ownership, predictable long-term costs, and complete on-site control.
Who Each Platform Is Best For
IntelliSense.io may be the better fit for operations that:
- Want mine-to-plant optimization scope beyond the concentrator
- Prefer an advisory/co-pilot model where operators retain direct control
- Are comfortable with cloud-based data processing
- Want to start with minimal upfront capital investment (SaaS model)
- Value physics-informed, interpretable AI models
Circuito AI may be the better fit for operations that:
- Need autonomous closed-loop control that executes without operator intervention
- Require 100% on-premise data sovereignty with no cloud dependency
- Want deep concentrator optimization (crushing, grinding, flotation as one system)
- Prefer AI that continuously adapts to ore variability via reinforcement learning
- Want A/B verified results with statistical rigor
Summary Comparison
| Dimension | IntelliSense.io | Circuito AI |
|---|---|---|
| Founded | 2017 | ~2018 |
| Mining focus | 100% | 100% |
| Core technology | Physics-informed digital twins + ML | Reinforcement learning + neural networks |
| Control mode | Advisory / Co-pilot | Closed-loop (writes to DCS) |
| Control frequency | Not disclosed | Every 10 seconds |
| Deployment | Cloud + edge (SaaS) | 100% on-premise |
| Data location | Cloud processing | On-site only |
| Process scope | Mine-to-plant | Concentrator (crushing, grinding, flotation) |
| Grinding results | ~1% throughput | +2.6% throughput (ball mills) |
| Flotation results | 1–3% recovery | ~1% additional recovery |
| Named mining clients | 9 of top 20 miners | Norilsk Nickel, Russian Copper Company |
| LATAM presence | Offices in Chile; deployments in Chile, Brazil, Peru | Entering via Circuito AI |
| Pricing model | No CapEx SaaS subscription | License + integration |
| DCS agnostic | Yes | Yes |
| Result verification | Before/after comparison | A/B testing methodology |
The Bottom Line
Circuito AI and IntelliSense.io represent two genuinely different philosophies for mining AI optimization. IntelliSense.io brings broader scope, an established LATAM presence, and a lower-barrier commercial model. Circuito AI brings autonomous closed-loop control, on-premise data sovereignty, and AI that adapts in real time without human intervention.
The right choice depends on what your operation needs most. If you are evaluating both, request technical demonstrations focused on your specific circuits and ore conditions — and ask each vendor to explain exactly how their system handles the gap between a recommendation and an executed control action.
Learn more about why mining operations choose Circuito AI or get in touch to discuss your specific operation.