Enhancing SAG Mill Efficiency and Tailings Safety with Qsee

Industry: Mining

Focus Area: SAG Mill Optimization, Tailings Control, ESG Performance
Products Used: Qsee Insights™, Zer0-Defect®

Challenge

A global mining operation faced significant challenges related to energy consumption, process variability, and environmental impact. Specifically, their SAG mill process exhibited inconsistent efficiency, and their tailings management system suffered from instability—both operationally and environmentally. Additionally, the mine's poor ESG score affected its ability to secure sustainable financing and maintain stakeholder trust.

Objectives

• Reduce SAG mill energy usage and operating costs

• Minimize standard deviation in tailings output

• Improve ESG and sustainability metrics

• Enable early detection of inefficiencies and risks

Solution

The mining company implemented both Qsee Insights™ and Zer0-Defect® to monitor, predict, and optimize key production parameters:

Qsee Insights™

Qsee’s AI-powered analytics platform was connected to the mine’s MES system to ingest real-time data across temperature, torque, and pressure variables. Using multivariate analysis and anomaly detection, Qsee Insights automatically:

• Identified root causes of inefficiencies in the SAG mill

• Delivered ROI-calculated, prescriptive recommendations to improve energy usage

• Forecasted deviations in tailings behavior and recommended proactive actions

Zer0-Defect®

Qsee’s flagship predictive quality engine, Zer0-Defect®, was used to:

• Predict and prescribe actions to prevent tailings quality defects before they occurred

• Stabilize the tailings storage facility by continuously analyzing chemical and geo-mechanical signals

• Automate alerts to operations teams for maintaining compliance and physical safety

• Reduce waste and increase production predictability

Results

• $20M+ in Annual Savings: A 1% performance improvement in SAG mill throughput and energy efficiency led to multi-million-dollar cost savings

• CO₂ Reduction: By reducing energy consumption, the mine lowered its carbon emissions and improved its ESG score

• Tailings Stability Improved: Standard deviation in tailings output dropped significantly, enhancing safety and reducing environmental risk

• Faster Decision-Making: Real-time operational recommendations allowed teams to make quicker, more confident adjustments

Why It Matters

For the mining industry, where safety, sustainability, and economics intersect, leveraging AI is no longer optional—it’s essential. By embedding Qsee Insights™ and Zer0-Defect® into their routine, this mine moved from reactive firefighting to proactive optimization. The combination of smart monitoring and predictive analytics created a resilient process that delivered tangible ROI and aligned with long-term ESG goals.