PROCESS CONTROL
Metrics Monitoring and their insights also drive analytics , optimisation , and strategic decisionmaking .”
Courier analysers deliver elemental composition insights from slurry and solution streams . PSI analysers provide particle size distribution data from grinding circuits . This information feeds directly into the Metrics Monitoring platform , where it combines with sensor outputs and operational KPIs for comprehensive analytics . Metrics Monitoring consolidates data into a user-friendly dashboard , offering a high-level overview of plant performance . Operators can monitor trends , identify correlations , and quickly detect deviations in areas such as recovery efficiency and grinding stability .
With real-time inputs from analysers , Metrics Monitoring applies predictive analytics to identify inefficiencies or potential equipment failures . Root cause analysis to resolve bottlenecks in processes like grinding and flotation . This enables proactive adjustments , reducing downtime and maximising efficiency . Historical data from the analysers allows benchmarking against industry standards or past performance . Long-term trend analysis allows measurement of the impact of operational changes over time .
Venegas adds : “ The platform generates realtime alerts for deviations in particle size or elemental composition , offering automated recommendations to guide operators in corrective actions . Aggregated insights help management teams and engineers identify opportunities for improvements in throughput , energy efficiency , and plant expansions , as well as aligning operations with sustainability initiatives .”
Sustainability monitoring data from the analysers also supports resource efficiency such as water , energy , and reagents , and tracks progress toward ESG goals , facilitating transparent stakeholder reporting .
Venegas concludes that by integrating realtime process data with the analytics capabilities of Metrics Monitoring , Metso ’ s analysers empower mining operations to achieve enhanced efficiency , smarter decision-making , and alignment with sustainability objectives - all critical in today ’ s competitive and resourceconscious industry .
Moving on to the digital ecosystem , what is the distinction between Metrics Monitoring and Geminex ? “ Metso ’ s Metrics Monitoring and Geminex platforms are cornerstones of its digital ecosystem , designed to enhance mining operations . While they serve distinct purposes , their integration offers powerful synergies for achieving operational efficiency and sustainability .”
Metso Metrics Monitoring is a performance monitoring platform that focuses on real-time data from equipment and processes to drive operational efficiency and reliability . Core features include condition monitoring and tracking equipment health using IoT sensors and predictive algorithms . Process visualisation comes from centralised dashboards that display parameters like throughput , energy use , and downtime . Machine learning forecasts equipment failures for predictive maintenance , optimising maintenance schedules . Reporting Tools enable trend analysis and stakeholder reporting . Overall , Venegas says it is ideal for day-to-day operational decisions to maximise uptime , reduce costs , and ensure smooth operations .
Metso Geminex is focused on simulation and strategic optimisation . Venegas : “ Geminex is a digital twin platform that simulates mining processes to optimise long-term strategies , sustainability , and plant performance . It models entire process flows , from ore extraction to final product . Plus it tests ‘ what-if ’ scenarios to optimise recovery rates , throughput , or energy efficiency . Sustainability-wise it evaluates resource usage , emissions , and ESG impacts of operational changes . And it can simulate plant expansions or new designs before implementation .” Geminex is ideal for strategic planning and long-term optimisation and supports sustainability initiatives by modeling greener process changes .
While Metrics Monitoring focuses on the present and Geminex looks to the future , Venegas says they work together seamlessly . Metrics Monitoring feeds equipment and process data into Geminex to enhance digital twin accuracy . This creates a feedback loop , as insights from Geminex simulations such as recommended adjustments to grinding circuits - can be implemented in real operations and tracked via Metrics Monitoring . Predictive and strategic synergy comes from Metrics Monitoring driving real-time decisions , while Geminex informs forecasting and long-term planning , enabling a continuous improvement cycle . And they bring shared sustainability goals in that Metrics Monitoring tracks real-time resource efficiency and emissions while Geminex models the impact of future changes , driving greener innovations .
Venegas : “ The key distinction is that Metrics Monitoring is focused on what ’ s happening now in terms of real-time performance and equipment health . Geminex addresses what could happen in terms of simulation , optimisation , and strategic foresight .”
Together , Metso Metrics Monitoring and Geminex empower mining operators with a holistic approach , combining real-time insights with the foresight of simulation and planning .
This synergy enhances efficiency , drives sustainability , and ensures operations remain competitive in an evolving industry .
Finally , IM also asked Metso about algorithms and AI in mineral process plant control . Venegas : “ AI is already making inroads in mineral process plant control and is poised to revolutionise the industry by enabling greater adaptability , predictive capabilities , and automation . While traditional algorithms remain important for straightforward and predictable processes , AI enables a leap forward , especially in complex , data-rich environments . He adds : “ As data infrastructures improve and trust in AI grows , the mining industry is likely to see fully autonomous , AI-driven operations become the norm , driving efficiency , sustainability , and profitability .”
Despite all these state of the art advanced technologies like AI and ML beginning to revolutionise mineral processing , Metso points out that they are still tools that require expert human oversight to function effectively . Experts interpret results with an understanding of context , guide the customisation and application of technologies , and ensure alignment with broader operational goals . “ In short , while technology enables automation and optimisation , human expertise remains indispensable for ensuring accuracy , reliability , and meaningful insights in mineral processing operations .”
Emerson – from the ground to the cloud
During MINExpo 2024 , IM sat down with Mike Gordon , Emerson Strategic Business Unit Director – Knife Gate Valves to discuss the uniquely broad role Emerson plays in today ’ s mineral processing industry . Emerson is one of the few companies in the mineral processing arena that starts all the way back at the field level with field devices and goes right the way through to cloud-based monitoring and maintenance . On the ground this covers a vast array of instruments and analysers to sense all the different parameters – as well as the final control elements , including different types of valves including control and isolation valves .
Gordon states : “ Then we have the next level – including PLCs and edge controllers , and above that the DCS and everything that comes with that . Now , with Emerson also having a controlling ownership share of AspenTech , our offering goes all the way up to the cloud , including cloudbased analytics for predictive maintenance and other purposes . So Emerson brings just about everything that is in a concentrator plant from primary crushing onwards from an automation solutions perspective – so our advantage is in the breadth of our offering , but also our worldwide coverage .”
66 International Mining | JANUARY 2025