THE LEADER VOLUME 20 • NUMBER 12
Met digital twins
Editorial Director Paul Moore BSc( Hons), MSc paul @ im-mining. com
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This month’ s issue delves into the world of mineral processing plant control systems that are in the mix today- where AI is playing an increasingly important role. All the global mineral processing technology majors, including Metso, Weir, ABB and FLSmidth- have some kind of solution in this space, and while they all differ in the details and how they work- fundamentally they are all aiming at the same thing. That is, intelligent metallurgical digital twins. While the term digital twin has been around for years- today it is much more than just a nicely designed visual representation of the concentrator process with real time data.
With AI and process specific algorithms, some of the available options have the power to simulate changes such as variable ore grades, key equipment availability and performance, and material flows- and then actually react in the real world with the most efficient responses in the form of automatic adaptation, including within desired KPIs, all the time comparing the real situation with the simulation and learning at the same time.
Not only that, but they can do the same with energy and water use- making them a crucial tool in sustainability going forward. They also play a central role in the achievement of true proactive and predictive maintenance. Calibration is of course important- but this can be done as well- using metallurgical and mineralogical testing, expertise and data gathered over many years of sampling and analysis at operations, combined with in-depth knowledge of the equipment itself, from pumps to flotation cells to mills. Finally, these systems connect processing plants with mineral processing expertise at these companies in a deeper and more real time sense- because both the customer and the supplier are monitoring the same data. Of course that involves a high level of trust on both sides.
Looking at one of the solutions in more detail, FLSmidth’ s Global PerformanceIQ Hub is a state-of-the-art digital technology centre to help maximise mining customers’ plant potential. The Hub centralises information, visualisations and expertise to provide valuable insights aimed at increasing throughput, recovery rates and product output quality and developing analyticsdriven shutdown and maintenance schedules. It can also improve the safety and efficiency of maintenance operations, plus boost energy and water consumption efficiency, while also reducing CO emissions. It uses tools such as AI, IoT, big data and machine learning to achieve results.
FLS describes it as a digital technology centre that combines FLS process expertise, comprehensive data intelligence and innovative technologies with its digital solutions to help customers discover untapped potential. Cybersecurity measures are in place to minimise risks and provide peace of mind when customers are sharing site data with the FLS team, which is required to provide the best possible support. The PerformanceIQ Hub does have a physical location in the FLS Salt Lake City office. But FLS says it should be seen as a global connection point to all of its experts and technology to help support customer needs via easy-access communication channels. A centralised data repository stores all communication, data and any other important information that is related to that particular concentrator or plant location.
In tandem with PerformanceIQ, FLS offers its own process control system platform which has usual functions of a modern DCS system for effective operation of the mining process plant at all levels. It uses dedicated Programmable Logic Controllers( PLC) to control equipment, while providing an open interface. FLS supports multiple PLC and MCC brands for the highest flexibility. As well as providing precise process control, the system also includes features to help users improve productivity and uptime, such as plant data management, trending, alarm management and data logging, resulting in a complete full-featured control system.
The article in this edition beginning on p. 54 also goes into detail on three other state of the art process control technologies in this space- Metso Geminex™, Weir NEXT Intelligent Solutions and ABB’ s Ability™ System 800xA. From real time adjustments, to short interval control and medium to long term planning in processing plants, digital solutions are today making a real difference at a much higher level than before. And the evolution of the offerings to the point where these key companies have experts embedded in customer remote operations centres to help manage these systems is not far away.
Paul Moore Editorial Director paul @ im-mining. com
International Mining | JANUARY 2026 3