Mining
Optimize throughput and reliability by seeing your entire operation clearly—before changes ever touch the field.
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 Studies
Connected Performance for Mining
Digital Twin Accelerates Start Up of Lithium Plant
Challenge
A major lithium processing operation faced the complex task of converting one of North America’s largest hard-rock lithium suppliers into a lithium hydroxide production facility — combining mine conversion, concentrator operations, and downstream chemical processing to meet Québec’s growing lithium demand.
The extraction process requires precise temperature control, residence times, and acid-to-mineral ratios and plant performance hinges on managing variability in feed grade, moisture, reagent quality, and energy integration. These dynamics created significant uncertainty for the commissioning, control strategy development, and operator training for their new facility. Lithium market volatility and prior project disruptions added further pressure to execute efficiently and safely.
Solution
Multi-Purpose Dynamic Simulation (MPDS) enabled them to build an understanding of the lithium extraction process and train on critical unit operations before the plant was built. Integrating simulation with their control system allowed them to test control strategies, conduct process automation studies, and successfully execute virtual commissioning and start up.
Rigorous custom models were designed for dryers, crystallizers, and filtration systems to accurately represent lithium process chemistry while simplified models we used for support systems like utilities. This helped them ensure accuracy in critical areas and keep their digital twin investment within budget.
Results
- Four DCS FAT events completed.
- 100+ alarm ranges corrected.
- Operator training on 10,000 simulated i/o points completed prior to startup.
- Process optimization in recycle management, purge strategies, and energy consumption.
100%
Investment recouped before startup
338%
ROI Year 1
100+
Alarm corrections prior to startup
$780k/yr
Savings via kiln optimization
3D Simulation for Mining Facilities
Faster, safer startups and ramp-up Identify issues early and rehearse critical scenarios off-line.
Striking Gold With
a Digital Twin
Challenge
A large greenfield mining project with one of the most complex plant designs ever executed was facing aggressive startup and production deadlines. Engineering responsibility was split between two EPC firms located more than 4,000 km apart, increasing the integration risks with their 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 that only allowed them to staff the facility with local personnel. Together, these headwinds created significant risk for commissioning, early operations, and for continuous performance.
Solution
A mixed-fidelity dynamic simulation environment, tailored to project scope and budget, was developed. The simulation covered 10 process areas and circuits that were directly integrated with the client’s Distributed Control System configuration.
Hosted remotely, this robust simulation allowed North America–based engineering, startup, and commissioning teams to begin training and testing months earlier than would have been possible onsite. The safe, offline 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
- Creation and refinement of operating procedures prior to startup
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-based training
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