Digital Solutions

Integrated Extraction Simulator

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

Evaluate mining and processing scenarios to unlock operational improvements.

Evaluate mining and processing scenarios to unlock operational improvements.

The Integrated Extraction Simulator (IES) is a cloud-based modelling, simulation and optimisation platform that creates a site-specific digital representation of mining and mineral processing operations.

Configured using site data, engineering models and operational constraints, IES enables operations to evaluate how changes in ore characteristics, blast outcomes, mine plans, plant configurations and operating strategies can influence downstream performance. By combining configurable flowsheet modelling, scalable simulation and advanced optimisation capabilities, IES helps teams understand the complex interactions that exist across the extraction value chain.

The platform supports a range of modelling approaches, including phenomenological, empirical, physics-informed and data-driven models, selected according to site requirements and available data. Neural network models developed through ModelNet can also be incorporated where appropriate.

Unlike traditional evaluation methods, IES allows operations to assess thousands of potential scenarios and identify achievable strategies that respect real-world equipment and process constraints. The result is a practical decision-support capability that can be applied across planning, operations and long-term mine development initiatives.

IES complements Orica's Blast Design and Execution solutions by helping quantify how upstream mining and blasting decisions can influence downstream processing outcomes.

Customer stories

Resources

Login

Benefits

Benefits

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

Downstream processing efficiency

Operational efficiency and performance

Maximise resource recovery

Total cost of ownership

Key Features

Key Features

Connect upstream and downstream performance

Understand how ore characteristics, blast fragmentation, feed size distribution and operating strategies influence processing outcomes across the value chain. Evaluate the impact of upstream decisions before implementation to support more predictable plant performance.

Simulate thousands of operational scenarios

Test a wide range of mining, processing and planning scenarios in a virtual environment without disrupting production. Identify promising opportunities and understand trade-offs before committing resources.

Enable better cross-functional decisions

Provide mining, geology, planning and processing teams with a common framework for evaluating operational strategies. Replace assumptions with quantified insights that support aligned decision-making.

Optimise throughput and recovery

Assess the relationship between ore variability, operating conditions, throughput and recovery using site-specific models. Evaluate strategies that help maximise value while balancing processing constraints.

Operate within real-world constraints

Apply equipment, process and operating limits directly within simulations and optimisation workflows. Generate recommendations that are practical, achievable and aligned with site operating conditions.

Create a reusable digital twin of your operation

Build a site-specific flowsheet model that can be used across planning, operational and life-of-mine studies. Reuse a consistent decision-support platform to evaluate future opportunities as conditions change.