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

IntelliSense.io is the leading Industrial AI company enabling the Industrial world to make better and reliable decisions through the use of trusted and open AI solutions. The Industry we focus on is Mining and our solutions are making mining operations efficient, sustainable, and safe. Our real-time decision-making platform brains.app and a portfolio of process optimization applications covering the entire mining value chain resulting in accelerated value delivery, reduced energy & water consumption, minimized waste & reduced process variability.

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 optimizing its own behavior but also working together with the other applications to optimize overall pit to port productivity.

The IntelliSense.io Academy is an e-learning platform offering learning opportunities in “Industry 4.0 and AI’ technologies to brains.app users through a series of training programs.

The educational programs are built around the brains.app and provide certification for three different skill levels:
Level 1 (L1) Beginner
Level 2 (L2) Advanced

Level 3 (L3) Expert

Users of different backgrounds can either specialize in their target product or broaden their knowledge:
brains.app User and Administrator cover the platform 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

Reconciliation

User Story:

When I am required to do end of month reconciliation.

I want to add my claim values in an easy-to-use format and generate end-of-month reports.

So I can receive reconciled values for the given time period and have a better interpretation of results quickly and effectively.

User type: Operator
Application: Reconciliation

Certification: User L2

Solution:

  1. Navigate to the ‘Reconciliation’ screen.
  2. Click on the ‘New Job’ and follow the subsequent steps.
  3. Fill in the process data such as tonnage, grade, volume density, etc.
  4. Click on the ‘Process Job’ and download the report.
  5. The Reconciliation Report shows the deviations of the reconciled values from the claim values and can be done for a monthly period as a quick analysis of production figures.

Hints and Tips:

  1. Know more about the plant performance status with dashboards, sharing insight into the performance of different sections such as the scrubber and rougher spirals of the plant.
  2. Try comparing Intellisense.io reconciliation against your existing spreadsheet.

brains.app Platform

User Story:

When my network security requirements prevent the use of the brains.app cloud-based optimization models.

I want to have a deployment configuration of the application on my local server.

So I can run sophisticated optimization inside the OT environment.

User type: General Manager
Application: brains.app

Certification: User L3

Solution:

  1. Contact IntelliSense.io.
  2. Select the appropriate optimization model.
  3. Provide historical data to train/calibrate/verify the optimization model.
  4. Select integration solution for Data Ingestion and Control Interfaces.
  5. Select calibration and update strategies for the optimization model.
  6. Deploy and commission pre-configured brains.app lite solution on the OT network.

Hints and Tips:

  1. brains.app lite can be configured to be accessed from any computer on the local network (not only locally on deployment server).
  2. Check Input / Output tags for each asset using the toggle at the top of the screen.
  3. Check the number of tags at the bottom of the list where page navigation is available as well.
  4. Hybrid deployments combine the benefits of optimization model calibration and validation in the cloud and secure local deployment.

Digital Stockpile

User Story:

When the material is reclaimed from a stockpile and fed to a crusher.

I want to see the origins and key properties of the material.

So I can understand the content in each stockpile, the recovery, and the concentrate they produce to optimize decision making.

User type: Geo Metallurgist

Application: Digital Stockpile

Certification: Stockpile L1

Solution:

  1. Navigate to the ‘Reclaiming to Crushers’ dashboard.
  2. The line graphs display the amount of metal contribution from each stockpile and grade of concentrate from their processing.
  3. Refer to the categorical data to understand the throughput going to the plant, such as:
    • Tonnage per hour
    • Recovery
    • Concentrate grade
  4. Visualize and compare the metal recovery per stockpile over a chosen period of time.

Hints and Tips:

  1. Use this information with the data related to recovery and concentrate grade, to make reclaiming strategies.
  2. Export the Reclaiming Report dashboard to get a summarized view of the reclaimed material and use it for the end of month reconciliation.

3. Widgets act differently in different time modes. In live mode, the current data point is shown, but in historic mode, the average is shown.

Digital Stockpile

User Story:

When I create and maintain stockpiles.

I want to have a 3D Block model that reflects the shape and material properties of a truck dump stockpile.

So I can use it to plan my reclaim and blending strategy.

User type: Geologist

Application: Digital Stockpile

Certification: Stockpile L1

Solution:

  1. Navigate to the desired stockpile in the ‘Search and Asset Hierarchy’ screen. Click on the ‘Info’ icon to access the Asset details screens.
  2. Navigate to the Files tab and download one of the CSV files.
  3. These files are periodically generated and uploaded here by the stockpile model service.
  4. Refer to the first three columns in the file that represent the x,y,z centroid coordinates of your 3d block model and the rest as the material properties that are tracked.

Hints and Tips:

  1. Import the 3D Block model file data to any mine planning/geomodeling software for analysis and mine planning purposes.
  2. Keep track of all the notable changes made to the Asset in the Asset Logs.

Grinding Circuit Optimization

User Story:

When the SAG mill is underperforming.

I want to see what the real-time ball charge of the mill is.

So I can add balls at the right time, to maintain the desired ball charge, and thereby optimize mill performance.

User type: Metallurgist

Application: Grinding

Certification: Grinding L1

Solution:

  1. Navigate to the ‘SAG Mill Ball Charge’ dashboard.
  2. Select the LIVE mode in the time picker.
  3. Observe the Line graph to ensure the ball charge remains within the desired range.
  4. See the bar chart to know about the current ball size distribution.
  5. Adjust the current ball addition schedule as required to achieve the desired ball size distribution.
  6. Record the ball addition via the Data Input Widget.
  7. See the total volume taken up by balls.

Hints and Tips:

  1. Add a line graph with recorded ball additions to see how it impacts the ball charge and mill performance.
  2. With the Dynamic Mill Charge virtual sensors and the Ball Charge information on the same dashboard, see how the Ball Charge has an impact on the Mill’s grinding performance.
  3. The ball size distribution can also be plotted using a line widget to see the trend over time.

Grinding Circuit Optimization

User Story:

When the SAG mill feeds material changes.

I want to be alerted when this would potentially cause a mill overload.

So I can take corrective action proactively to keep the Grinding circuit stable.

User type: Operator

Application: Grinding

Certification: Grinding L1

Solutions:

  1. Navigate to the ‘SAG Mill Overload Monitoring’ dashboard.
  2. Monitor the alert widget for predictions that the Mill will breach this limit, along with the current mill performance.
  3. When a mill overload is predicted, the Alert widget turns red.
  4. Follow the in-house procedures to reduce the mill weight.
  5. Keep an eye on the variables you have made changes to and the overload probability, to ensure that you have successfully averted a mill overload event.

Hints and Tips:

  1. Update the Mill Overload threshold you would not want your mill to breach, with the Data Input Widget.
  2. Have a look at the Load-Power scatter plot to see whether the mill is operating in a formal overload region (power decreases as mill weight increases and vice versa).

Heap Leach Optimization

User Story:

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

I want to compare and evaluate Ore’s Moisture content in the past.

So I can define a strategy for reclaiming modules to maximize throughput and equipment utilization.

User type: Mine Engineer

Application: Heap Leach

Certification: Heap Leach L1

Solution:

  1. Navigate to the ‘New Project’ screen.
  2. Configure a project with the asset and metrics, to see residual moisture influence to reclaim difficulty.
  3. Compare the material influence on residual moisture content, and the associated reclaim difficulty for the given time period.
  4. If these variables are outside the desired limits, implement the required process adjustments.

Hints and Tips:

  1. Navigate to Reclaim difficulty dashboards to see predictions, probabilities, and material influence to reclaim difficulty.
  2. Project metrics can be compared against two things - another period in time and an overall target.
  3. Export the Module Difficulty Prediction report, to relate the moisture content to the reclaim rate.

Flotation Optimization

User Story:

When the Flotation circuit is not performing as I want it to.

I want to see the individual cell/ column recoveries.

So I can know which cells/ columns to make adjustments to improve the overall grade and recovery.

User type: Metallurgist

Application: Flotation

Certification: Flotation L1

Solution:

  1. Navigate to the ‘Cleaners Performance’ dashboard.
  2. Monitor each bank’s/column’s Gas Hold-up and Recovery virtual sensors.
  3. Refer to box plots to see performance statistics over a chosen period of time.
  4. If these are outside of the acceptable bounds, modify the control system to bring the flotation section back to the desired performance.

Hints and Tips:

  1. Parallel flotation banks/columns are normally desired to have similar performance. Hence abnormal behavior can be flagged when one bank/column performs differently from the others.
  2. For a single flotation bank with cells in series, it is desired to have a certain profile. The Box plot gives one the ability to monitor the recovery profile, and respond if the bank deviates from a desirable profile.
  3. Flotation Application also outputs virtual sensors for Mass Pull and Mean Bubble Diameter. These can be monitored in real-time to provide a holistic view of how each part of the flotation circuit performs.

Thickener Circuit Optimization

User Story:

When the Thickener circuit is not operating the way I want it to.

I want to be able to configure a Value Driver to set my priorities for the Thickener Optimizer.

So I can receive control setpoints from the Optimizer that will achieve my objectives and keep the Thickener circuit at maximum potential.

User type: Metallurgist

Application: Thickener

Certification: Thickener L1

Solution:

  1. Navigate to the Thickener ‘Optimizer Configuration’ screen.
  2. Adjust the Reward weights and the variable limits as desired to reflect the desired Thickener Value Driver.
  3. Update the current Scenario (set of tuning parameters) to save the changes.
  4. Navigate to the ‘Operator’ Screen to see how the control variable recommendations respond to the changes you have submitted.

Hints and Tips:

  1. Only Admin Users can access this screen to add or edit the actual Rewards that are shown in the Optimizer Configuration section.
  2. Speak to us for more information on how you can start doing this yourself.
  3. Once saved the resultant recommendations are instantly applied to the operator screen, so no verbal communication is required with the operator.

IntelliSense.io Academy

User Story:

When I have recently subscribed to brains.app.

I want to learn about the application and its feature.

So I can start utilizing the application and optimize the processes faster.

User type: All Users

Application: All Apps

Solution:

  1. Access the IntelliSense.io Academy at https://academy.intellisense.io.
  2. Login with your valid credentials.
  3. Enroll in your preferred brains.app courses and get certified.

Hints and Tips:

  1. Browse through the Course Catalogue to find out more about the new and interesting Product training.
  2. Share your IntelliSense.io Certificates with your colleagues and employer on Linked In.
  3. Visit the IntelliSense.io Help Center to learn more about the brains.app features, its usability, OaaS applications, and Release Notes including a description of new additions, enhancement, and corrections.
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