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Digital Solutions

Integrated Extraction Simulator

Rapid evaluation of processing scenarios across the mineral extraction value chain.

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Digital Solutions

Integrated Extraction Simulator

Rapid evaluation of processing scenarios across the mineral extraction value chain.

Video thumbnail

Digital Solutions

Integrated Extraction Simulator

Rapid evaluation of processing scenarios across the mineral extraction value chain.

Integrated Extraction Simulator logo

Enhancing plant productivity to maximise economic value and minimise the environmental impacts of mineral recovery.

Many mining operations invest in mine-to-mill optimisation studies only to find that the insights remain on paper, never fully implemented. Traditional approaches result in fragmented decision-making between mining operations and processing, heuristic blending strategies, and trade-offs between throughput and recovery with no clear resolution. To truly maximise value, mining operations need a way to turn insights into execution.

The Integrated Extraction Simulator (IES) is not just a modelling tool, it's a decision support system that operationalises mine-to-mill optimisation. 

  • From strategy to execution: IES ensures mine-to-mill initiatives don't stop at consultant reports, it delivers continuous, site-specific decision support.
  • Whole system optimisation: unlike traditional simulators, IES integrates the full mining value-chain; from blasting to final concentrate, providing fragmentation targets to alleviate comminution constraints and to fully utilise plant equipment capacities to maximise throughput and recovery.
  • Mass simulation for realistic planning: IES simulates entire processing circuits using constraint-based modelling, ensuring that strategies are not just theoretical, but operationally viable.

Unlike conventional approaches that focus on individual processes, the Integrated Extraction Simulator connects every stage of the mining value-chain to ensure mine-to-mill strategies work in practice. 

Benefits

IES provides many benefits which help operations enhance plant operations and minimise environmental impacts.

Downstream processing efficiency

Downstream processing efficiency

Operational efficiency and performance

Operational efficiency and performance

Maximise resource recovery

Maximise resource recovery

Total cost of ownership

Total cost of ownership

Features and benefits

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Holistic optimisation

IES has the unique capability to integrate all parts of an operation in a single simulation platform, enabling optimisation from individual equipment through to the entire value chain. Integrated simulations help identify and understand interdependencies and trade-offs between unit operations allowing for informed decision-making and promoting best overall operating practices.  

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Scenario evaluation

With the ability to easily configure multiple flowsheet options and run mass simulations, IES enables rapid processing of high-volume data for efficient scenario evaluation. Explore mine planning options and blending strategies, or use geometallurgical block models to predict throughput and recovery over the mine life, using a single powerful tool.

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Rapid simulation

Using a combination of scalable compute and machine learning, users can perform hundreds of thousands of simulations per hour.

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Constraint manager

IES features a Constraint Manager that allows users to specify set point ranges for key equipment operating parameters such as SAG Mill load or cyclone pressure, ensuring simulation results remain achievable by the plant. 

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Machine learning

IES platform includes a module for generating data driven models, allowing users to train and deploy machine learning models directly into flowsheets, making simulations more responsive to ore variability and plant conditions based on historical performance.

Industries

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Iron ore

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Surface metal

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Underground mining

Have questions?

Contact our global team of digital specialists to learn more about Integrated Extraction Simulator and how it can support your operations.

Integrated Extraction Simulator / Blast Design & Execution / Digital Solutions

Service & Support

Innovating IES with you at the centre

At Orica Digital Solutions, we pride ourselves on providing world-class support. Our structured implementation programs, and access to blast and technical expertise, ensures rapid deployment and integration of technologies, maximising productivity, reducing cost, and improving regulatory compliance across your operations.

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Customer story

An end-to-end flowsheet using the Integrated Extraction Simulator and ModelNet

The Antofagasta Minerals (AMSA) minerals processing team sought a tool to integrate all aspects of a mining operation into a single simulation platform, allowing for optimisation across the entire mining value chain and specific segments. One specific requirement was to ensure that the flow sheet simulations accounted for real-world operational constraints. 
 

Read the full case study

Contact an expert

Whether you need support or simply want to learn more, reach out to our Integrated Extraction Simulator team. We’re here to help.

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