Connected Process Performance: Plant and Metallurgical Reporting Software
Bring historian, SCADA, lab and manual plant data into one validated store, then report production, metal balance and delays the same way every shift.
Plant reporting still living in spreadsheets?
Historians hold millions of raw values, the lab holds the assays, and the plant report is rebuilt by hand every morning. Connected Process Performance removes the reliance on spreadsheet reporting.
- ✕Historian tags that nobody outside the control room can read
- ✕Daily and monthly plant reports rebuilt by hand
- ✕Metal balance adjustments with no record of who changed what
- ✕Mine tonnes and grade that never match what the mill measured
Connects to your historians and plant systems
Process control, historian and monitoring systems capture a vast amount of raw data. Connected Process Performance correlates it, applies your business rules and adds manual entry for anything the historian does not see.
Historians and SCADA
●OSIsoft PI●AVEVA Wonderware●Citect●Ampla●Rockwell
Mine data
●Crusher feed●Grade prediction●Original mine block source
Lab and samples
●Plant sample system●Sample review and approval
Manual entry
●Web data entry forms●Budgets, forecasts and targets●Comments
Four modules for the process plant
Each module matches a common requirement of beneficiation and bulk material shipping operations, and they all report from the same data.
Production
Capture, report and interrogate plant data from historians, SCADA and manual entry, against budget, forecast and target.
Metal balance
A running tally of metal in the plant, with balance adjustment, recovery calculations and bullion workflow.
Delay accounting
Every stoppage and slow running event captured and quantified in lost time and lost tonnes.
Bulk material
Stock, flow and delivery across mine, rail, port and ship for iron ore, coal and other bulk commodities.
Plant production and KPIs
Every plant measure captured at the frequency it happens and reported against budget, every shift.
- ✓Interfaces to OSIsoft PI, Wonderware, Citect and other historians and SCADA
- ✓Manual entry for anything not in the historian data stream
- ✓Budgets, forecasts and targets stored against every measure
- ✓Measures captured at any frequency and reported over any time span
- ✓Every value colour coded by its source, so you know where each number came from
- ✓Plant sample system and heap leach reporting
Month measure: plant and mine KPIs against budget, with daily values, trends and comments
Production entry: mill, reagent and gravity data, colour coded by source
Metal balance: gold in circuit, bullion poured, recovery and daily tail trends
Metal balance and metallurgical accounting
A running tally of metal in your plant, from feed to bullion, with every adjustment on record.
- ✓Metal in circuit entry, calculation and reporting
- ✓Raw and adjusted metal balance, with recovery calculations
- ✓Gold in circuit surveys, weekly, monthly or ad hoc, used only once marked as reported
- ✓Bullion workflow: record a smelt, a dip and refinery results, then lock in the period
- ✓Sample review with approval and an audit log
- ✓A workflow set up to suit the metal balance process at your operation
Survey, stockpile and metal balance corrections applied along the flow
Delay accounting
Find out exactly where the plant lost time and tonnes, and why.
- ✓Delays captured automatically from historian and SCADA tags, or entered manually
- ✓Tag generated events configured with filters and conditions
- ✓Every stoppage and slow running event quantified in lost time and lost tonnes
- ✓Delay hours by area and reason, compared with operating hours
- ✓Drill through to the plant unit and sub process
- ✓Your own terminology for productive units, equipment types and delay categories
Delay detail: plant delay events by cause, and delay duration against effective duration
Mine to mill reconciliation: mine-estimated and mill-measured tonnes and grade each day
From pit to product: reconciliation and bulk material
Pair it with Connected Mine Performance and the mine and the mill finally agree.
- ✓Mine estimated tonnes and grade to the crusher, from the original mine block source
- ✓Daily grade factor and weight factor between mine and mill
- ✓Gold recovered and recovery percent alongside the reconciliation
- ✓Bulk material stock, flow and delivery across mine, rail, port and ship
- ✓Rail, port and ship loading captured automatically or entered manually
- ✓Stockpile balances reconciled to survey and shipment
Material traced from the mine block through stockpiles and the plant to shipping
Plant numbers you can audit, not just report
Raw historian data is correlated, validated and run through your business rules before anyone reports on it.
A transparent calculation engine
View every calculation and its components. Calculations are evaluated in order of dependency.
Adjustments on record
Adjust a historian value over a time range with a required comment, kept in the adjustment log.
Locked once validated
Once manual entry is complete and imported values are validated, lock the form to prevent further changes.
Reporting your plant team trusts
Routine plant reports are automated, so metallurgists and process engineers spend their time on analysis, not on building reports.
- ✓Day, month and year to date actuals against budget, with comments
- ✓Process flow diagrams with live values and tolerance colours
- ✓User defined reports: change a measurement set and the report updates
- ✓KPI variance scorecards across regions and sites
- ✓Dashboards and analysis with Connected Data Analysis Services
- ✓Corporate reporting in Power BI, Fabric and Databricks with FactStream and StarStream
Connected Process Performance FAQs
What is Connected Process Performance?
Connected Process Performance is the processing module of the Connected Mine platform. It joins plant and process data to the mine data, automates routine plant reporting and covers plant production, metal balance, delay accounting and bulk material.
Which plant systems does it connect to?
It interfaces with common historians and SCADA systems, including OSIsoft PI, AVEVA Wonderware, Citect, Ampla and Rockwell, with web data entry for anything not in the historian.
Does it handle metal balance and metallurgical accounting?
Yes. It keeps a running tally of metal in circuit, calculates raw and adjusted balances and recovery, and supports gold in circuit surveys, bullion entry and sample review with an audit log.
How does delay accounting work?
Delays are captured automatically from historian and SCADA tags, using configurable filters and conditions, or entered manually. Each event is quantified in lost time and lost tonnes and can be analysed by area, reason and plant unit.
How does it reconcile the mine to the mill?
Combined with Connected Mine Performance, it compares mine-estimated tonnes and grade from the original mine block source with what the mill measured, and reports grade and weight factors every day.
Can plant data be adjusted without losing the audit trail?
Yes. A historian value can be adjusted over a time range with a required comment, and every adjustment is kept in the adjustment log. Forms can be locked once data has been validated.
See your plant data in one place
Bring your historian, lab and production data together, and see it running on your own operation.