Verified Results Across Mining Operations
Every result below was measured through statistically significant A/B testing — comparing AI-optimized operation against manual baselines under the same ore conditions. These are real improvements delivered at operating mines including Nornickel, Pavlik Gold, and Russian Copper Company facilities.
14
Deployed Solutions
USD 100M+
Annual Value Delivered
+2.9%
Best Throughput Gain
+0.9%
Best Extraction Gain
5
Metals Optimized
Copper · Gold · Nickel · Iron Ore · Platinum
~95%
AI Uptime
Grinding & Mill Optimization
Real-time control of feed rates, water ratios, and classifier settings
+2.9%
Throughput Increase
Grinding Circuit — Bystrinski GOK
Full grinding circuit optimization at Bystrinski GOK (Nornickel). The system manages mill feed rates, water ratios, and classifier settings. Part of a 3-year cross-process deployment that reduced manual operator interventions by 96% — from 122 to just 4 per shift.
Gold • Copper • Iron Ore
+1.5%
Throughput Increase
SAG Mill — Kola MMC
Semi-autogenous grinding mill optimization at Kola MMC (Nornickel). The AI system maintains optimal mill load and throughput while preventing mechanical limit exceedances across the copper-nickel operation.
Copper • Nickel
+1.3%
Throughput Increase
SAG Mill — Pavlik Gold
SAG mill autopilot at Pavlik Gold (ZIF-1). The system controls individual feeder speeds, mill RPM, and water flow — achieving +1.2% throughput in summer and +1.3% in winter, with a 30% reduction in mill overload time through predictive anti-overload control.
Gold
+0.9%
Throughput Increase
SAG Mill Overload Prevention
Dedicated SAG mill overload prevention system. Predictive control reduces load before discharge issues arise and only recovers throughput when fill levels are safe — preventing chain overloads that cause extended downtime.
Gold • Copper • Iron Ore
+0.5%
Throughput Increase
Feeder Optimization
AI-driven feeder speed optimization calculating maximum possible processing capacity each moment. The system assigns individual feeder setpoints in small steps every minute, maximizing feed while maintaining circuit stability.
Gold • Copper • Iron Ore
+0.35%
Extraction Rate Increase
Classification Optimization
Hydrocyclone classification optimization controlling water feed and the number of open cyclones. AI increases target class yield by 0.6 percentage points, improving downstream flotation feed quality.
Gold • Copper • Iron Ore
+2.4%
Throughput Increase
Iron Ore Grinding
Grinding circuit optimization at an iron ore processing plant. The AI system manages the complete grinding loop to maximize throughput while maintaining target particle size distribution for pelletizing.
Iron Ore
Flotation Optimization
AI-controlled reagent dosing, airflow, and froth management
+0.65%
Extraction Rate Increase
Flotation — Bystrinski GOK
Flotation optimization at Bystrinski GOK (Nornickel) as part of a cross-process deployment. The system reduced feed density variations by 30% and integrates with a proprietary computer vision froth sensor monitoring bubble size, dynamics, and stability.
Copper • Gold • Iron Ore
+0.9%
Extraction Rate Increase
Nickel Flotation — Kola MMC
Flotation optimization at Kola MMC (Nornickel) across 40+ cells in 3 plant sections with 300+ sensors. Achieved +0.9 percentage point increase in Ni recovery — equivalent to USD 3 million annual economic effect. Cleaner-scavenger standard deviation reduced by 35%.
Nickel
Cross-Process Optimization
End-to-end optimization spanning grinding and flotation circuits
+0.78%
Extraction Rate Increase
Copper Flotation — Tominski GOK
Full flotation autopilot at Tominski GOK (Russian Copper Company). Achieved +0.78% extraction increase, +0.59% throughput increase (+3,114 additional tons during pilot), -8% SAG mill energy consumption, -35% concentrate quality variability, and -96% manual interventions (from 122 to 4 per shift). A/B tests ongoing for 5 months confirming sustained results.
Copper
Crushing
Ore flow stabilization and variability reduction
+2.6%
Throughput Increase
Crushing Circuit
Full crushing circuit optimization managing ore volumes, bunker levels, and granularity in real time. Ensures consistent material flow and size distribution to downstream grinding and flotation.
Platinum
Measurable Variance Reduction
Real-time AI control keeps processes within tight operational bands
The chart shows real-time AI control in action — the blue line represents the AI-calculated optimal setpoint tracking the actual process variable (black line). Under AI control, the process stays within tight operational bands, dramatically reducing variability compared to manual operation. This translates directly into higher recovery, lower energy use, and more consistent product quality.
How We Verify Results
Every implementation includes a statistically significant A/B test. We alternate between AI-optimized and manual-baseline operation under identical ore conditions, then measure the delta in throughput or recovery. Results are verified jointly by our team and the client's process engineers before being reported. Typical payback period: 3 to 6 months after results are achieved.
Results achieved at Nornickel (Kola MMC, Bystrinski GOK), Pavlik Gold, and Russian Copper Company (Tominski GOK) facilities. All verified through independent A/B testing.
Proven in the World's Most Demanding Mines
Circuito AI's results were achieved at Nornickel, Pavlik Gold, and Russian Copper Company — processing the same minerals, with the same equipment, using the same circuit configurations found across Latin America.
Identical Minerals
Copper, gold, nickel, iron ore. The minerals Circuito AI optimizes in Russia are the same minerals driving Latin America's mining economy. Ore processing physics don't change by geography — the same flotation chemistry and grinding kinetics apply at any concentrator worldwide.
Same Equipment Vendors
Circuito AI integrates with ABB, Siemens, Honeywell, FLSmidth, Schneider Electric, and Metso — the same DCS platforms and equipment manufacturers that LATAM mines already run. No new hardware. No new infrastructure.
Universal Circuit Configurations
SAG mills, ball mills, multi-stage flotation banks, crushing circuits — these are industry-standard worldwide. The control strategies proven at a copper-nickel concentrator in the Russian Arctic work on the same circuit architecture at 3,000+ meters in the Andes.
Extreme Conditions, Higher Bar
Russian mining operations run in Arctic temperatures, remote locations, and constrained power grids. Circuito AI delivers measurable results under conditions that would stress any system. LATAM operations benefit from that engineering margin.
What Could These Results Mean for Your Operation?
Use our ROI calculator to estimate the annual profit impact based on your plant's specific parameters.
Frequently Asked Questions
What results has Circuito AI achieved at operating mines?
Circuito AI has delivered up to +2.9% throughput increase in grinding, +0.9% extraction rate increase in flotation, and +2.6% throughput increase in crushing across 14 deployed solutions at 7 plants. Annual economic value delivered exceeds USD 100 million.
How are AI optimization results verified?
Every result is measured through statistically significant A/B testing. We alternate between AI-optimized and manual-baseline operation under identical ore conditions, then measure the delta in throughput or recovery. Results are verified jointly by our team and the client's process engineers.
What is the typical ROI timeline for mining AI optimization?
Typical timeline to measurable results is 4 to 5 months from project start. Payback period is 3 to 6 months after results are achieved. The implementation includes data diagnostics, platform deployment, and A/B validated pilot tests.
Start With a Free Assessment
We'll analyze your plant data and show you where AI can move the needle — no commitment, no contract. If the numbers make sense, we run a pilot on one circuit before you scale.