About the Project
ComminuSense
Smart Comminution - Lower kWh/Ton, Better Uptime
The Problem
In mining operations, crushing and grinding (comminution) are essential for liberating valuable minerals from surrounding rock. However, these processes are among the most energy-intensive stages in mineral processing.
Energy Impact
Up to 50% of a mine's total energy consumption
Root Cause
Static control systems, equipment wear, and lack of real-time adaptability
Critical Pain Points
Excessive Energy Consumption
Comminution processes account for up to 50% of total mining energy usage, leading to skyrocketing operational costs.
Reduced Throughput
Static control systems fail to adapt to changing ore conditions, resulting in suboptimal processing rates.
Increased Maintenance Costs
Reactive maintenance approaches lead to unexpected downtime and expensive emergency repairs.
Higher Carbon Emissions
Inefficient energy usage contributes significantly to the environmental footprint of mining operations.
Why Optimization is Critical
Economic
Reducing energy costs by even 10-15% translates to millions in annual savings for large mining operations like NMDC.
Environmental
Lower energy consumption directly reduces carbon emissions, aligning with India's net-zero commitments and sustainable development goals.
Operational
Predictive maintenance and real-time optimization improve equipment lifespan, throughput, and overall operational reliability.
Who Benefits
NMDC & Mining Companies
Reduce operational costs and improve energy efficiency across crushing and grinding operations.
Process Engineers
Access real-time insights and predictive analytics to optimize equipment performance.
Ministry of Steel
Drive national sustainability goals and digital transformation in the mining sector.
Environment & Public
Contribute to reduced carbon emissions and sustainable mining practices.
Technology Stack
ComminuSense leverages cutting-edge technologies to deliver a robust, scalable, and secure solution:
Frontend & Visualization
Backend & API
Databases
ML Infrastructure
Simulator & Digital Twin
IoT & Edge Computing
Security & Compliance
DevOps & Monitoring
Transforming Mining Through AI
ComminuSense represents the future of sustainable, efficient mining operations. By harnessing the power of artificial intelligence, IoT, and digital twins, we're helping India's mining sector achieve operational excellence while reducing its environmental impact.