Mining
Optimize throughput and reliability by seeing your entire operation clearly—before changes ever touch the field.
Big Picture
Visibility That Drives Throughput and Safety
Mining operations depend on tightly interconnected systems—from comminution and flotation to pumping, dewatering, and material handling. Variability in ore quality, operating conditions, and equipment performance leaves little room for error. Onyx 360 gives mining teams engineering-driven insight into how these systems behave, helping you optimize throughput, reduce bottlenecks, and improve safety before changes ever touch the field.
Case Study
Connected Performance for Mining
Striking Gold With The Digital Twin
Challenge
A large greenfield mining project faced aggressive startup and production deadlines combined with one of the most complex plant designs ever executed for the customer. Engineering responsibility was split between two EPC firms located more than 4,000 km apart, increasing integration risk across process and automation systems. The plant’s remote location in the Dominican Republic made it nearly impossible to recruit operators with relevant experience, yet the customer had government commitments to staff the facility with local personnel. These factors created significant risk for commissioning, early operations, and long-term performance.
Solution
Developed a mixed-fidelity dynamic simulation environment tailored to project scope and budget, modeling 10 critical process areas and circuits and integrating them directly with the Distributed Control System configuration. The simulator was hosted remotely, allowing North America–based engineering, startup, and commissioning teams to begin training and testing months earlier than would have been possible onsite. This off-line environment enabled:
- Comprehensive testing of sequence controls
- Development of automatic sequencing strategies
- Discovery and correction of functional logic issues, circular interlocks, and incorrect alarm limits
- Early HMI usability improvements
- Offline creation and refinement of operating procedures
This approach aligned engineering, operations, and commissioning stakeholders long before first ore.
Results
- >100X ROI from reduced automation and process commissioning time
- Identification and elimination of critical configuration issues before startup
- Fully tested and verified sequence controls and automation strategies
- Operating procedures developed and trained off-line well ahead of commissioning
- Local operators trained earlier and more effectively despite remote project location
Together, these improvements dramatically reduced startup risk and strengthened operational readiness for one of the most challenging mining projects in the region.
10
circuits modeled and integrated with DCS
Early remote training for
North America–based teams
Robust procedure development before first ore
100X
simulator ROI
Major reduction in commissioning time and rework
3D Simulation for Mining Facilities
Enable safe, immersive training for underground and surface operations, validate equipment access and maintenance workflows, plan expansions, and visualize complex environments to improve coordination and hazard awareness.
Benefits
What Mining Teams Gain
Higher Throughput & Recovery
Optimize circuits and material handling to improve output and consistency.
Reduced Unplanned Downtime
Predict bottlenecks, wear conditions, and process upsets before they happen.
Improved Worker Safety
Train teams virtually for critical procedures and hazardous scenarios.
More Stable, Reliable Operations
Understand how changes affect upstream and downstream processes.
Energy & Resource Efficiency
Reduce energy consumption and optimize water, reagent, and material use.
Faster Ramp-Up for New Assets
Model expansions, retrofits, and new equipment with confidence.
Stronger Operational Discipline
Standardize processes across shifts and sites.
Better Planning & Coordination
Align engineering, operations, and maintenance with a shared visual understanding.
Use Cases
Where Connected Performance Delivers Impact
- Crushing, grinding, and comminution circuit optimization
- Slurry transport and pumping behavior analysis
- Flotation modeling and reagent optimization
- Dewatering and tailings process evaluation
- Startup, shutdown, and emergency procedure training
- Facility layout changes and equipment access planning
- Digital twins for continuous process monitoring