Making Mining Operations Efficient, Sustainable and Safe through trusted and open Artificial Intelligence (AI) solutions.

Intellisense.io is uniquely positioned in the market through; its dual modelling approach combining machine learning and first principle models to create the Intellisense.io technology that includes the platform and the out-of-the-box optimization applications which have been proven by deployment at mining majors. This has allowed us to sign up a scale up distribution strategy with leading mining industry suppliers, enabling us to scale by focusing on our product and partnering with Industry giants for sales and marketing.

The Brains.app Platform is a real-time decision-making platform for the natural resource industry powered by Artificial Intelligence (AI) and Industrial Internet of Things (IIOT) technology.

Optimization as a Service (OaaS) Applications

Intellisense.io optimization applications are “out of the box” solutions for each process within the mine to market. They are initially deployed on customer identified processes until gradually expanded across the entire value chain. Once fully connected, each application is an autonomous actor optimising its own behaviour but also working together with the other applications to optimize overall pit to port productivity.

The IntelliSense.io Academy is an educational programme built around the brains.app. It offers users the opportunity to earn certification in ‘Industry 4.0 and AI’ technologies.

The IntelliSense.io Academy provides certification for three different levels skills: Level 1 (L1) Beginner
Level 2 (L2) Advanced

Level 3 (L3) Expert

Users of different backgrounds can either specialise in their target product or broaden their knowledge:
brains.app User and Administrator covers the platforms functions and features. brains.app Developer teaches potential collaborators how to develop their own custom applications.
brains.app Specialist is dedicated to each of our live applications.

User Story Index

User Stories

Grinding Circuit Optimization

User Story:

When: I am responsible for the overall operating cost of a grinding circuit.
I want to: Receive regular detailed financial reports.
So I can: Follow up with the main cost drivers and ensure optimal operation.

User type: General Manager
Application: Grinding

Certification: User L1

Solution:

  1. Navigate to the “New Report” section.
  2. Schedule the financial dashboard for the SAG mill.
  3. Set the report generation frequency to how often to receive the reports.
  4. Get notified through an email and access the reports to analyze the SAG mill cost changes.

Hints and Tips:

  1. A set of template reports are available, but can be completely customised on request to IntelliSense. io. These reports are listed in the “Run Report by Template”.
  2. Scheduled and template reports are stored in the “My Files” section for later.
  3. A link to the Scheduled and template reports can also be sent to the user’s email with the subscription.

brains.app Platform

User Story:

When: I am off site.

I want to: Be able to easily check on the process.

So I can: Continue to optimise the process and have one true picture of performance.

User type: All User

Application: brains.app

Certification: User L1

Solution:

  1. Open any browser on a laptop, tablet or smartphone.
  2. Enter the site specific web address.
  3. Enter your secure email and password.

Hints and Tips:

  1. Brains.app runs on any browser type.
  2. Brains.app runs on any screen resolution and size.
  3. Screens are fully reactive and can be manipulated (zoomed) to change the amount of content shown.
  4. The user type is displayed in the “My Profile” section. The “Search” screen is the new user default home screen.

brains.app Platform

User Story:

When: I am required to reconcile my metal and mass variables.

I want to: Be able to do so automatically on demand with minimal configuration.

So I can: Proactively monitor it in real time to maximise reporting accuracies.

User type: Geologist

Application: brains.app

Certification: User L2

Solution:

  1. Navigate to the asset/area from which reconciliation is required on the “Search” screen and select the “Info” icon under that assets row.
  2. Navigate to the “Files” tab of that asset.
  3. Reconciliation files can be downloaded to view in either .pdf or .xls format.

Hints and Tips:

  1. Reconciliation files are generated automatically but can also be requested on demand through the “Help” icon.
  2. NEW! The next release of brains.app digital plant contains a reconciliation configuration screen from which users can set up their own reconciliations.
  3. Try comparing Intellisense.io reconciliation against your existing spreadsheet.

Digital Stockpile

User Story:

When: A stockpile is being reclaimed.

I want to: Monitor its properties in real time.

So I can: Optimize my mine planning decisions to give the plant a consistent feed.

User type: Geologist

Application: Digital Stockpile

Certification: Digital Stockpile L1

Solution:

  1. Navigate to the ‘Stockpile Information’ dashboard.
  2. Multi unit line widgets give the user live stockpile content information.
  3. Stockpile properties examples:
    • Average grade of different types of copper over time.
    • Maximum ore hardness of the material dumped last week.
    • Average Fe content over time in material coming from a specific mine.
  4. The spatial heat map widget shows all the properties associated with the stockpile.
  5. Move the slider on the left to select the height at which you want to see a cross-sectional slice of the stockpile.

Hints and Tips:

  1. The legend on the right relates the colours to the property values.
  2. This is a quick way to see what is in a stockpile, without the need to export it in 3D block model format.

Heap Leach Optimization

User Story:

When: I have implemented an improvement project on the heap leaching process.

I want to: Compare the improved performance against the same properties in the past or against a target into the future.

So I can: Benchmark and optimise my irrigation strategy to maximise recovery.

User type: Mine Engineer

Application: Heap Leach

Certification: Heap Leach L1

Solution:

  1. Navigate to ‘New Projects’.
  2. Configure a project with the asset and metrics which make up the project goals.
  3. A visual showing the results of the goals.
  4. Compare the project metrics (e.g. metal concentration (g/l) and pH) against the bench marked time period with the current or at an overall target.

Hints and Tips:

  1. The goals can be set up in three ways; greater than, less than and equal to plus or minus a percentage.
  2. Comparing the standard deviations is a great way of bench-marking variance.
  3. Once a project is closed you can archive it for later use if needed.

Flotation Circuit Optimization

User Story:

When: I am operating an under-performing flotation circuit.

I want to: I want a hybrid deployment of a gas hold up virtual sensor.

So I can: Proactively monitor it in real time to maximise recovery with maximum up-time.

User type: Operator

Application: Flotation

Certification: Flotation L1

Solution:

  1. Navigate to the “Gas Holdup” dashboard which comes with the flotation application.
  2. Observe the real time gas holdup metrics (ratio).
  3. Observe the same variables sent to the OT (operational technology) network and are visualised in the control room alongside.

Hints and Tips:

  1. Hybrid deployments do not rely on the internet and so are more reliable.
  2. There is less change management in this case as the same physical screens can be used to on board users.
  3. The metrics can be used in existing control loops.
  4. The online version of brains.app can be used for much more powerful simulations such as running ”what if” scenarios for different control.

Grinding Circuit Optimization

User Story:

When: A grinding circuit has been under-performing.

I want to: Understand the current condition of the equipment (liner profile and ball charge).

So I can: Schedule maintenance shutdowns more accurately to maximise asset use and recommend upcoming ball additions to increase grind size consistency.

User type: Maintenance Engineer

Application: Grinding

Certification: Grinding L1

Solution:

  1. The equipment condition virtual sensors are attached to the “SAG Mill” digital asset.
  2. Select the “Liner Model” and/or “Ball Charge” dashboards provided with the subscription.
  3. The line graph depicts the height of the liner and lifter including uncertainty.
  4. The user can infer the remaining equipment lifetime.
  5. The ball charge model provides the ball charge (%), weight (t), size distribution (%) and the next expected ball addition.
  6. Follow the expected ball addition information to optimise performance.

Hints and Tips:

  1. To constantly calibrate the ball charge model outputs in real time, users can add the ball additions manually into the application to increase model accuracy.
  2. Record the data entries with the “Data Input” widget on the dashboard.

Thickener Circuit Optimization

User Story:

When: The feed material properties are about to change.

I want to: See its predicted impact on my process.

So I can: Proactively adjust the process to account for these changes.

User type: Metallurgist

Application: Thickener

Certification: Thickener L1

Solution:

  1. Navigate to the “Performance Screen”.
  2. Open the “Lithology” Tab.
  3. Select the asset of interest.
  4. The lithology types are listed in the legend.
  5. The “influence” this lithology has on this particular asset type is highlighted in a simple traffic light colour coding.

Hints and Tips:

  1. The traffic light system means that no previous knowledge of the material type is required.
  2. This is generated through the material transport model that links the block model to the rest of the circuit.
  3. Check other feed material properties available in the “Feed” drop-down (e.g. P80, flow rate, density).
  4. Use this tool in “Live” mode to see potential upcoming changes and communicate concerns back to geology or mining.

Grinding Circuit Optimization

User Story:

When: A grinding circuit is being pushed to its operational limit.

I want to: Be notified in real time of possible mill overload events and retrospectively simulate alternative control strategies.

So I can: Take preventative measures before overloads occur ensuring stability through making informed strategic decisions.

User type: Operator

Application: Grinding

Certification: Grinding L1

Solution:

  1. Navigate to the “Dashboards”.
  2. Select the SAG Mill - Overload Dashboard.
  3. Hover on the line graph for the overload probability to know how close an overload event is in %.
  4. The overload alert turns on when action is required (e.g. over 70% probability).
  5. The overload model provides you with information to estimate feed reductions to prevent overloads.
  6. The brains.vos provides the financial returns based on different control strategies.

Hints and Tips:

  1. Line graph widget types are the best source of raw data.
  2. Try adding a constant data type to the app, these can be used to set limits and are great for dynamic equations.

Pipeline Pumping Optimization

User Story:

When: Have a complex schedule based process.

I want to: Be provided a dynamic optimised schedule in real time with direct actions and times.

So I can: Optimise the process based on value based metrics (e.g. energy/maintenance).

User type: Maintenance Manager

Application: Pumping Pipeline

Certification: Pumping Pipeline L1

Solution:

  1. Navigate to the “Pump Performance Screen”.
  2. Open the “Optimise” tab. Select the Pump station.
  3. It displays the detailed statistics of that Pump station with the pumps running information over time.
  4. Hover on the graphical representation and observe the pump status in detail.
  5. The Performance Variables table compares the recorded/ live data with the actual observed data the output of the optimisation model.

Hints and Tips:

  1. Observe the line graph representation of the pump stations in the pipeline to get more insight.
  2. A smaller time resolution enables the metric table with the “Current”, “Optimise” and “Observed” performance variables.
  3. The action time recommendations indicate the next scheduled event when pumps need to be turned off or on.
  4. The observed column in the performance variable table is applicable only in the Historic time stamp.

Thickener Circuit Optimization

User Story:

When: Objectives and constraints change.

I want to: Update the value optimiser.

So I can: Ensure my recommendations are always maximising value.

User type: Control Engineer

Application: Thickener

Certification: Thickener L2

Solution:

  1. Navigate to the “Optimisation Admin” screen and enter the required limits/constraints and targets of the process.
  2. Preview changes before implementing them.
  3. The preview is visually represented in the graphs.
  4. The “Parallel Coordinate Graph” highlights the positive / negative impact each control variable option will have on the system.

Hints and Tips:

  1. Use this screen in historic mode to analyse where the “effort” could have been changed in different operational scenarios.
  2. Once saved the resultant recommendations will be instantly applied to the operator screen and so no verbal communication is required with the operator.
  3. The “Parallel Coordinate Graph” is one of the few methodologies for visualising what the optimiser is thinking ensuring transparency.

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