Maximize Mineral Yield with AI-Driven Optimization
MinervaMineralix delivers real-time AI setpoints and predictive analytics that transform grinding circuit recovery, flotation energy efficiency, and plant-wide throughput for UK mineral extractors.
- 5–15% yield improvements across gold, copper & iron ore operations
- Real-time energy reduction in flotation circuits – up to 18% cost saving
- Seamless DCS integration with existing plant infrastructure
AI-Driven Mineral Processing Optimization
We synthesize real-time sensor data, machine learning algorithms, and predictive analytics to maximize metal recovery and minimize costs across every stage of mineral extraction and processing.
Real-Time Data Monitoring
Continuous feed of process variables — particle size, pulp density, reagent flow — feeding adaptive AI models for instant corrective setpoints.
Machine Learning Algorithms
Proprietary ML models trained on comminution, beneficiation, and hydrometallurgical datasets to predict optimal operating windows.
Predictive Analytics
Forward-looking models forecast ore variability, reagent consumption, and circuit bottlenecks before they impact metal recovery.
DCS / SCADA Integration
Plug-and-play connectivity with existing plant control systems. Our solutions require no full infrastructure replacement.
From Raw Sensor Data to Maximum Metal Recovery
Our AI optimization platform ingests process data from your comminution, flotation, and hydrometallurgical circuits, then deploys precision setpoint recommendations in real time. The result: higher metal recovery, reduced energy consumption, and a lower cost per tonne — measurably and repeatably.
Gold & Silver Mines: Grinding & Recovery Boost
Precious metal operations face persistent pressure from declining ore grades and fluctuating feed hardness. Our AI setpoints for grinding circuit recovery adapt in real time to ore hardness characterization data, maintaining optimal P80 without over-grinding — protecting reagent budgets and increasing throughput simultaneously.
Precise mill speed, feed rate, and water addition adjustments for consistent grind P80 across variable ore hardness.
Reagent dosing and air flow optimization to boost froth stability and precious metal recovery in flotation cells.
Carbon-in-leach kinetics modelling for silver circuits, maximizing gold and silver dissolution rate and carbon loading efficiency.
Geometallurgical domain classification ensuring circuit parameters match the actual ore block being processed.
Base Metals: Copper, Zinc, Nickel Efficiency
Base metal operations demand relentless cost discipline. Our specialized AI solutions target energy reduction, reagent dosing precision, and plant-wide control across copper, zinc, nickel, and combined lead-zinc circuits.
Copper Concentrators – Energy Reduction
AI models target flotation bank air flow, collector dosing, and pulp level to trim energy consumption per tonne of copper concentrate by up to 12% while maintaining or improving recovery.
Zinc Refineries – Plant-Wide Operations
Coordinating leaching, purification, and electrowinning circuits with unified AI control. Our zinc operations models reduce inter-stage imbalances and improve zinc plant utilisation rates.
Nickel Mines – Flotation Reagent Cost Reduction
Precision reagent dosing AI reduces xanthate and frother consumption by 10–20% in nickel sulfide flotation without sacrificing concentrate grade or nickel recovery targets.
Lead-Zinc Combined Flotation Optimization
Differential flotation sequencing AI manages complex mineralogy interactions in lead-zinc feeds, maximising separation selectivity and reducing cross-contamination in final concentrates.
Reducing Cost Per Tonne Across All Base Metal Circuits
With energy accounting for 30–40% of base metal processing costs, our AI-driven flotation energy reduction and reagent dosing precision deliver measurable P&L impact from day one. We model your specific mineralogy, throughput targets, and reagent inventory to generate sustainable, site-calibrated savings.
Whether you operate a single copper concentrator or a multi-metal refinery, MinervaMineralix provides the specialist AI optimization expertise to protect margins through commodity cycles.
Enquire About Base MetalsCritical Minerals: Lithium, Rare Earth, Uranium
Battery metals and clean energy supply chains demand extraction precision that traditional control cannot achieve. Our geometallurgy models and AI-driven process optimization deliver the yield certainty these strategic minerals require.
Lithium Extractors
Yield simulation and AI process control for hard rock spodumene and clay lithium operations, improving Li₂O recovery efficiency and reducing reagent waste.
Rare Earth Processors
Predictive mineral recovery models for REE flotation and acid roasting circuits, maximising separation of cerium, lanthanum, neodymium, and praseodymium fractions.
Uranium Extractors
In-situ leaching flow AI and acid heap leach kinetics models enhance uranium recovery while minimizing sulphuric acid consumption and groundwater risk.
Lithium Brine Processors
Evaporation pond optimization for brine lithium operations — AI manages solar evaporation rates, brine chemistry, and precipitation sequencing to increase yield.
Geometallurgy Models for Precise Critical Mineral Recovery
Critical mineral deposits are often characterised by significant spatial variability in mineralogy, liberation characteristics, and impurity profiles. Our geometallurgy-driven AI models predict the optimal processing route for each ore domain, enabling proactive circuit adjustments before the ore reaches the plant.
From solvent extraction yield boosts in REE hydrometallurgy to ion exchange optimization for uranium recovery, our AI solutions are calibrated to the chemical complexity of critical mineral flowsheets.
Bulk & Industrial: Iron, Phosphate, Coal, Bauxite
High-volume bulk mineral operations live and die on throughput and energy efficiency. Our advanced AI control systems address declining ore grades, wet circuit stability, and extraction efficiency at industrial scale.
Iron Ore Plants – Throughput Maximization
AI setpoints for crusher gap, screen efficiency, and wet processing circuit water balance to maximise ROM tonnes treated per hour while maintaining target Fe grade.
Phosphate Processors – Ore Variability Stabilization
Predictive AI models compensate for phosphate ore variability in beneficiation circuits, stabilising BPL grade and reducing losses to tailings in fatty acid flotation.
Coal Preparation Plants – Dewatering Efficiency
AI control of centrifuge speed, screen blind prevention, and filter press cycle timing reduces moisture content in final coal product and lowers thermal drying energy demand.
Bauxite Operations – Alumina Extraction Optimization
Bayer process AI models for digestion temperature, caustic concentration, and red mud separation — minimizing red mud volume and maximizing Al₂O₃ yield per tonne of bauxite.
Proven Results & Client Success Stories
From mid-tier gold producers integrating DCS to copper heap leach operations enhancing yield, our clients report measurable, auditable performance improvements.
Mid-Tier Gold Producer – DCS Integration
A mid-tier gold operation experiencing inconsistent grinding P80 integrated MinervaMineralix's AI setpoint engine with their existing Rockwell DCS. Within 60 days, grinding circuit recovery improved by 11.3% and recirculating load reduced by 18%, lowering mill liner wear costs.
Copper Heap Leach – Yield Enhancement
A copper heap leach operator with declining solution grade deployed our leach pad flow AI and pregnant leach solution optimization model. Copper recovery improved by 9.7% and acid consumption dropped by 14% in the first quarter — translating to £380,000 in annualized savings.
Chromite Spiral Concentrator Grade Improvement
A chromite processor struggling with poor spiral concentrator feed consistency deployed our AI wash water and feed density optimization. Concentrate Cr₂O₃ grade improved by 4.2 percentage points, enabling premium market access and a 7% improvement in product revenue.
UK-Based Mineral AI Expertise, Built Over a Decade
Founded by process metallurgists and data scientists with deep industry experience, MinervaMineralix has spent over 10 years developing AI solutions purpose-built for the complexities of mineral extraction and processing. We are headquartered in the United Kingdom (PH33 7AE) and serve mineral producers across the globe.
Our expertise spans the full mineral processing value chain: comminution and grinding, froth flotation, heap and tank leaching, hydrometallurgical refining, and tailings management. Every solution we deliver is grounded in both process metallurgy fundamentals and cutting-edge machine learning.
We are committed to sustainable, data-driven efficiency. Our AI implementations are designed to comply with environmental performance standards, helping mineral producers reduce energy intensity, water consumption, and chemical usage alongside improving yield.
Optimize Your Yield Today – Free Consultation
Request a no-obligation yield audit from our mineral AI specialists. We will analyse your current circuit performance and identify the highest-impact optimization opportunities — from potash flotation reagent dosing to molybdenum froth flotation optimization.
Request Your Free Yield Audit
Our team responds within one business day.