AI Optimization for Every Stage of Mineral Processing
Circuito AI delivers AI solutions engineered to optimize your concentrator circuits in real time — from crushing through grinding to flotation — with measurable, verifiable results.
Flotation Optimization
Our flotation optimization solution monitors 283 input parameters per flotation line simultaneously, using machine vision and AI models that learn the non-linear relationships among process variables. The system manages 46 control actions — adjusting reagent dosing, airflow, and froth levels — making interventions every 10 seconds compared to a human operator's rate of once every 20 minutes.
- Continuous optimization of reagent dosing and airflow across all flotation cells
- AI control interventions every 10 seconds vs. manual adjustments every 20 minutes
- Proven results across copper, gold, iron ore, and nickel operations
Copper • Gold • Iron Ore • Nickel
Up to +0.9%
Up to +0.9% extraction rate
Grinding Optimization
The grinding optimization solution acts as an intelligent autopilot for mill operators. It manages feed rates, water ratios, and classifier settings in real time — with the AI model automatically retraining on fresh operational data to adapt to ore type changes and mill lining wear. The system reduces process variability by up to 50% while improving energy efficiency by up to 8%.
- Real-time prediction and compensation for fluctuating ore properties
- Reduces process variability by up to 50% and energy consumption by up to 8%
- Maintains optimal throughput without exceeding mechanical or safety limits
Gold • Copper • Iron Ore • Nickel
Up to +2.9%
Up to +2.9% throughput
Crushing Optimization
The crushing optimization solution stabilizes the entire crushing circuit by managing ore volumes, bunker levels, and granularity in real time. It ensures consistent material flow and size distribution to downstream grinding and flotation processes — preventing bottlenecks and throughput losses.
- Automated management of ore volumes and granularity across the crushing circuit
- Consistent material flow and size distribution to downstream processes
- Eliminates bottlenecks caused by uneven feed or oversized material
Platinum • Copper • Gold
Up to +2.6%
Up to +2.6% throughput
Cross-Process Optimization
The complete picture — not just individual circuits
Most optimization solutions focus on a single unit operation. Circuito AI connects crushing, grinding, and flotation into a unified optimization strategy — preventing local gains in one circuit from hurting performance downstream. At Bystrinski GOK, cross-process optimization has been running for 3 years, reducing manual operator interventions by 96% (from 122 to just 4 per shift).
- Unified strategy across crushing, grinding, and flotation
- Prevents local optimizations from degrading downstream performance
- Incremental adoption — start with one circuit, expand as results prove out
How It Works
A proven implementation path from evaluation to results
Data Diagnostics
We analyze your technical data to assess data quality, identify priority optimization projects, recommend any sensor upgrades, and evaluate the potential economic effect — before any commitment.
Platform Deployment
Full on-premise installation with your existing infrastructure. We develop the approved solution concept, adapt it to your specific process, and prepare the test methodology. All data stays at your site.
Industrial Pilot Tests
1 to 2 months of supervised operation in your live production environment. A/B testing validates performance against manual baselines under identical ore conditions.
Operation & Support
24/7 AI-optimized operation with 3 levels of SLA support. Typical timeline to measurable results: 4–5 months from project start. Payback period: 3–6 months from go-live.
Proven Results
Every 10 sec
AI Control Frequency
Up to 50%
Process Variability Reduction
3–6 months
Typical Payback Period
14
Deployed Solutions
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.