Optimise Recovery from Pit to Concentrate
MavenProTech brings advanced process control, predictive maintenance, and AI-powered operator guidance to grinding circuits, flotation banks, and thickeners — maximising mineral recovery while reducing energy and water consumption.
The Complexities of Mineral Processing
Ore Variability
Constantly changing ore hardness, grade, and mineralogy make it impossible to run fixed setpoints. Processing plants need adaptive control that responds to feed variations in real time.
Energy & Water Costs
Grinding alone consumes 40-60% of a concentrator's total energy. Water scarcity in remote mining regions adds further pressure to optimise consumption and maximise recycling.
Remote Operations
Mine sites in remote locations face skilled-labour shortages and limited connectivity. Automation must be robust, self-diagnosing, and operable by smaller crews with mobile access to KPIs.
Solutions for Mining & Mineral Processing
Purpose-built automation tools that address the unique demands of comminution, flotation, and concentrate handling operations.
MAVEN APC
Multi-variable predictive control for SAG/ball mill circuits, flotation banks, and thickener underflow — optimising grind size, reagent dosing, and throughput against changing ore characteristics.
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Predictive maintenance for mill motors, conveyor drives, crusher liners, and cyclone packs — detecting bearing wear, liner erosion, and drive faults before they cause unplanned shutdowns.
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Automated plant startup and shutdown sequences for concentrators — coordinating crushers, conveyors, mills, and flotation circuits with water and reagent systems in the correct order.
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Real-time statistical monitoring of concentrate grade, recovery rate, particle size distribution (P80), and tailings losses — with automated alerts when performance drifts out of control.
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Digital twin models of comminution and flotation circuits — enabling what-if analysis for ore blend scenarios, reagent strategy changes, and circuit expansion planning.
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Field device management for harsh mining environments — health-scoring and calibration tracking for slurry density meters, pH probes, particle size analysers, and level instruments.
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Unified dashboards for recovery rate, throughput (tph), specific energy (kWh/t), water consumption, and reagent cost — with multi-site benchmarking and mobile alerts for remote teams.
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Operations companion for remote mine sites — real-time plant KPIs, asset health alerts, and shift handover notes accessible from any device, even on limited bandwidth connections.
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mAvenIt natural-language operations assistant — query mill load status, diagnose flotation recovery drops, summarise shift production, and get actionable guidance in plain English.
Learn MoreProven Mining Applications
SAG Mill & Grinding Circuit Optimisation
Deploy MAVEN APC on SAG/ball mill circuits to optimise mill loading, water addition, and cyclone pressure — adapting to ore hardness changes in real time to maintain target P80 grind size while maximising throughput.
- 3-8% increase in mill throughput
- Tighter P80 control with reduced overgrinding
- 5-10% reduction in specific grinding energy (kWh/t)
Flotation Recovery Control
Use MAVEN APC with MAVEN SPC to optimise air rates, froth depths, and reagent dosing across rougher, scavenger, and cleaner flotation banks — maximising mineral recovery while minimising reagent consumption.
- 1-3% improvement in overall metal recovery
- Reduced reagent consumption through optimised dosing
- Real-time grade/recovery monitoring with SPC alerts
Concentrator Plant Startup Automation
Automate the full concentrator startup sequence with MAVEN SEQ — from water system priming through crusher start, conveyor sequencing, mill ramp-up, and flotation circuit commissioning with safety interlocks at every stage.
- Consistent, repeatable startup in 50% less time
- Reduced operator workload during shift changes
- Full audit trail of every startup event