Run a wedge on one circuit
Froth-vision recovery control, grind-size energy or reagent dosing, with a metric you already measure.
Contact
Start with the circuit that is costing you the most.
Orebex starts with a paid pilot on one grinding or flotation circuit and a baseline agreed in writing. Tell us the circuit, the metric and the systems on it. We will say plainly whether the wedge fits and what the first ninety days would look like.
Reasons
Why people get in touch
Ship Orebex-ready
Mill, flotation, analyzer and froth-vision OEMs, APC and MES vendors, engineering firms and integrators.
Send the questionnaire
We answer plainly, including what is planned rather than done.
Found something
Edge perception, OT integration, simulation, metallurgy.
Ask a question
On recovery, grinding, flotation, the twin and autonomy in the concentrator.
Pre-seed conversation
Pre-revenue, pre-institutional. We do not claim traction we do not have.
First 90 days
What an engagement looks like
The first-release plan, applied to your circuit. Pilots run 90 to 120 days.
- First weeks. Connect and observe. Read-only connection to the wedge circuit, the time-aligned circuit and lot record built, the baseline measured from your own assays and meters.
- Then assist. Recommendations with evidence in the review console; your metallurgist approves each one; accuracy and ROI measured against the signed baseline.
- Graduated autonomy, if you are satisfied. Pre-approved low-risk grinding and flotation loop moves run inside declared limits; reagent-scheme changes and lot release stay with named humans.
- Decision. Convert to the Circuit tier and expand, or stop with the record of what was measured.
Run timeline · scenario
What we would be deploying
Every Orebex run is an ordered, inspectable sequence. This is run_4b9e27 on Line 1 · SAG and ball circuit, rougher bank 2 · copper porphyry blend. Scenario completes in 10 steps with one approval gate. P80 held at 148 µm as the blend hardened, froth stability recovered on rougher bank 2 after an air trim, a collector-dose change was approved by the shift metallurgist, predicted recovery held inside the plan, lot C-20931 released with full genealogy.
run_4b9e27
Line 1 · SAG and ball circuit, rougher bank 2 · copper porphyry blend
illustrative scenario
SUCCEEDED
-
01
ingest.shift
SUCCEEDED
0.7 s
Concentrator Orchestrator · Pulled the shift plan from the concentrator MES: copper porphyry blend B-14, P80 target 150 µm, concentrate grade at or above 25% Cu, recovery target per the geometallurgy model, energy and water budgets. Locked the operating envelope for the blend.
-
02
twin.simulate
SUCCEEDED
58 s
Concentrator Twin · Simulated 32 candidate grind, air and reagent schemes on the as-run twin for the hardening blend, ranked on predicted recovery, concentrate grade, kWh per tonne and water per tonne. Two candidates breached the thickener bed limit and were discarded.
-
03
grind.setpoint
SUCCEEDED
3 m 40 s
Crush-and-Grind · SAG-1 feed trimmed 3% and cyclone water raised as load and power signatures read a harder feed. P80 from the particle-size analyzer held at 148 µm against the 150 µm target; mill power stayed inside the energy budget.
-
04
froth.read
SUCCEEDED
continuous
Grade-and-Froth · Twelve froth cameras and the online XRF on rougher bank 2 fused at the edge. Froth stability on cells 3 and 4 fell as the blend hardened; predicted recovery drifted 0.4 points below plan. Early warning published to the control agents.
-
05
approve.human
APPROVAL
1 m 12 s
Concentrator Orchestrator · Scheme #7 raises collector dose 6% on rougher bank 2, above the standing reagent scheme. Reagent-scheme changes stay supervised on this blend, so the step was held for the shift metallurgist and approved at 07:19:44.
-
06
float.dose
SUCCEEDED
2 m 05 s
Float-and-Reagent · Approved collector dose applied with an air trim of 4% down on cells 3 and 4 inside the envelope. Froth stability recovered within eight minutes; predicted recovery returned to plan with concentrate grade read at 25.6% Cu.
-
07
classify.cyclone
SUCCEEDED
42 s
Separate-and-Classify · One cyclone brought online in cluster 1 as feed density rose with the hardness change, holding overflow size and circulating load inside the plan.
-
08
dewater.thickener
SUCCEEDED
continuous
Thicken-and-Dewater · Tailings thickener TH-2 flocculant dose trimmed as bed pressure rose; underflow density held and overflow clarity stayed inside the water-recovery target.
-
09
optimise.targets
SUCCEEDED
18 s
Throughput-and-Recovery · Whole-plant targets recomputed for the hardened blend: feed rate, P80, air and reagent targets handed to the control agents with recovery, grade, energy and water inside the budget. The losing candidates and their scores are in the run record.
-
10
lot.release
SUCCEEDED
1 m 30 s
Quality-and-Conformance · Concentrate lot C-20931 released: genealogy written (blend, grind record, reagent and air moves, froth and grade reads, approvals, dewatering record, assays as they land) and dispositioned against the concentrate spec with cited evidence for the metallurgist's sign-off.
Pricing
Priced per circuit, per plant, per group
Land on one workflow with a measured baseline. Expand by circuit, area, concentrator and autonomy level. Outcome components are available on recovery, energy, water and reagents. Annual prepay carries a 15 to 20% discount.
Comminution or flotation control, or grade sensing, for one circuit. For concentrators validating ROI on the wedge.
- One circuit, one agent module
- Plant-edge inference node included
- APC, DCS and sensor reads, guarded writes
- Run log, audit trail, lot genealogy
- Business-hours support
The whole plant: crush and grind, float and reagent, separate and classify, thicken and dewater, grade and froth, throughput and recovery, circuit and takt, robotic handling and the twin.
- All control agents on every circuit
- Froth-vision and analyzer fusion on every bank
- Whole-plant optimisation and circuit stabilisation
- Robotic sampling and handling
- As-run concentrator twin
- 24/7 support, quarterly model review
Multi-site mining groups standardising on Orebex, with custom ore, mineralogy and recovery models.
- Multi-site fleet management
- Custom ore, mineralogy and recovery models
- Plant edge fleet with on-prem option
- Group autonomy policy and approval chains
- SLAs, SSO and RBAC, dedicated engineer
Guardrails
An agent that can move a reagent pump needs a leash
Orebex writes to production equipment. Every capability is scoped, every write is policy-checked against the operating envelope, and every action is written to an append-only audit log the plant owns.
- Bounded action space. Each agent writes only to an explicit tag allow-list, inside per-tag rate and magnitude limits and the operating envelope for the blend.
- Policy engine before every write. Autonomy level, shift, ore type, interlock state, water and tailings constraints and metallurgist policy are evaluated before a setpoint moves.
- Human-in-the-loop gates. Reagent-scheme changes and lot release wait for a named approver. Robotics stays assistive until the site safety case is proven.
- Immutable audit log. Append-only and exportable. Every action records source evidence, the envelope applied, confidence, estimated recovery, grade, energy, water and reagent impact, rollback path, approver and lot scope.
- Hard fallback. Loss of the edge node, the network or a model returns control to the APC or DCS last known-good state. Interlocks are never in Orebex's path, and the edge runs fail-safe through a network outage.
- Tenant and ore-body isolation. Ore-body data, geometallurgy models, reagent schemes and recovery records never cross a customer boundary. On-prem and edge deployment is available for remote sites.
Compliance posture
| Item | Scope | Status |
|---|---|---|
| SOC 2 Type I | Cloud control plane | QUEUED Planned, first 6 months |
| SOC 2 Type II | Cloud control plane | QUEUED Planned, 6 to 12 months |
| SSO and RBAC | Console and approvals | QUEUED Planned, 6 to 12 months |
| Environmental and water assurance packages | Recovery, energy, water and tailings evidence | QUEUED Planned, 6 to 12 months; not a certification claim |
| Standards-cited reasoning | ISO, ICMM, tailings and water governance documents | RUNNING In the design, every answer cites its source |
| Per-tenant and ore-body isolation | Ore data, schemes, models, memory | RUNNING In the design from day one |
| On-prem and plant-edge deployment | Remote and IP-sensitive sites | RUNNING Design option |
Integrations
It speaks concentrator, not cloud
Orebex reads and writes through the systems already in the plant. No rip and replace, no parallel historian, no new HMI to learn. Vendor names are examples of systems found in concentrators, not certified integrations; connector availability is confirmed per site.
Mill control and APC (Metso, FLSmidth, ABB, Weir class systems)
Load, power, feed and water reads, guarded writes
Flotation APC and expert optimisers (ABB Expert Optimizer, Metso ACT, Honeywell, Andritz class systems)
Air, level and reagent reads; supervised reagent writes
Froth cameras and froth-vision systems (Metso VisioFroth, Stone Three, JKTech class tools)
Camera streams fused by Frothix
Online XRF and particle-size analyzers (Malvern Panalytical, Thermo Fisher and CIDRA, Metso, FLSmidth PSI class systems)
Grade and P80 reads per stream
Collector, frother, depressant and flocculant dosing systems
Dose reads; supervised and bounded writes
Cyclone clusters, separators, thickeners, filters
Pressure, density, bed and cycle reads, guarded writes
Plant DCS tags and time-series historians
Backfill, replay, time alignment
LIMS and assay results
Delayed labels for every prediction
FAQ
Straight answers
The questions processing managers, metallurgists and sustainability leads ask in the first meeting.
Yes, but only within an explicit tag allow-list with per-tag rate and magnitude limits, inside the operating envelope for the blend, and only at the autonomy level your plant has set. Design partners start in shadow mode, where Orebex writes nothing. Reagent-scheme changes stay supervised by a named metallurgist until the ore type is characterised.
Control returns to the APC or DCS last known-good state. Orebex is a supervisory layer on top of the control systems and interlocks you already run, never a replacement for them, so an outage degrades the circuit to its current way of running, not to a stop. The edge is designed to run fail-safe through a network outage.
Advisory recommendations start from the twin and the shift plan in the first weeks. Froth, grade, recovery and grind-response prediction improve as circuit history and assay-labelled outcomes accumulate per ore type. The compute plan sizes training at 2,000 to 8,000 GPU-hours per commodity model family once partner data exists, a design target.
Only if you choose cloud training. Ore-body data, geometallurgy models, reagent schemes, process models and recovery records are isolated per tenant and never used to train another customer's models. A fully on-prem deployment at the plant edge is available for remote and IP-sensitive sites, and federated learning across sites is planned and waits on data-rights agreements.
You are, the same as with any control strategy, which is why every write is policy-checked, bounded, logged and reversible, and why anything above your risk threshold waits for a named approver. The audit log records the request, the evidence, the envelope applied and the human decision.
A paid pilot of 90 to 120 days on one grinding or flotation circuit, scoped to a single wedge with a success metric written into the order form: recovery gain, energy per tonne saved, water reduction or reagent per tonne. The first weeks baseline recovery, energy and water in shadow mode from your own assays and meters.
Get started
Or just send the numbers
Recovery per shift, energy per tonne, reagent per tonne, water per tonne. We will tell you which wedge fits.