Digital Advisor System Deployed at Donskoy Mining and Processing Plant

The deployment took place at the Donskoy GOK (mining and processing plant) operated by TNC Kazchrome, part of the international Eurasian Resources Group (ERG). The holding company specialises in the extraction and processing of mineral resources and integrates mining, processing, energy and logistics assets across its operations.

AI as a Valuable Operational Tool

The “Digital Advisor”, designed to support the operation of the OMK-1 sedimentation machine, combines machine vision, sensor data and predictive deviation analysis. Using the system, operators receive recommendations for adjusting beneficiation parameters. A unified interface displays multiple indicators simultaneously, including forecast chromium content, loading dynamics, ore composition and visual guidance for process optimisation.

Following implementation, the plant increased the actual chromium recovery rate from ore from 9.89% to 10.33%, while chromium losses declined by 2.4%. The share of tailings with high chromium content fell by 3.2%, and overall metal losses decreased by 2.4%. The economic benefit of the system is estimated at approximately $246,000 per year.

A Precedent for the Mining Industry

Successful AI deployment in a large-scale mineral processing operation indicates a growing level of technological maturity for industrial digital solutions in the mining sector. Importantly, the system was not purchased as a ready-made product but developed internally.

The trend toward process automation continues to accelerate. In the coming years, DCLogic experts expect the share of operations performed without direct human involvement to increase by 20%. This includes the use of remotely operated equipment that allows operators to manage extraction processes outside hazardous zones, as well as the deployment of autonomous drilling rigs and transport systems. These solutions not only improve safety but also accelerate production processes by reducing dependence on the human factor

Andrey Steblevsky

Business Development Director at DCLogic

Industry analysts say that changing the approach to ore beneficiation is becoming a key competitive factor in mining. Artificial intelligence enables more efficient use of resources and allows producers to extract more metal from every tonne of ore. While digital technologies previously focused primarily on monitoring operations and collecting data, the industry is now entering the next stage of evolution. Artificial intelligence systems can forecast the optimal course of production processes.

Industrial AI Experiments in Mining

The trend toward digital transformation in heavy industry continues to accelerate. However, cases where artificial intelligence operates in real time within production environments remain relatively rare. For this reason, the experience of TNC Kazchrome and other companies is attracting considerable attention across the sector.

At the Lebedinsky GOK, which is part of Metalloinvest, a digital platform was introduced in December 2025. The system integrates production data with maintenance and repair operations. It processes information around the clock from automated control systems, industrial sensors, cameras, video analytics modules and predictive monitoring platforms. The platform is connected to the company’s corporate control centre in Moscow, where operational data from all production sites is consolidated. A similar system is scheduled to be launched at the Mikhailovsky GOK in 2026.

Another widely cited example comes from ALROSA, which applies machine vision and automation during ore preparation. Artificial intelligence monitors transport loading and analyses the composition of raw materials. At the underground Udachny mine, a machine vision system has been deployed to control loading of underground haul trucks. After one year of operation, the mine transported an additional 56,000 tonnes of ore. The utilisation rate of truck payload capacity increased by 11.3%. The same mine also operates a robotic rock breaker that automatically crushes oversized boulders at depths exceeding one kilometre, reducing strain on personnel and improving safety.

ALROSA is also testing the Horus Mine system at the Udachny mining and processing plant. The technology combines machine vision, laser scanning and neural network algorithms to automatically measure rock mass volumes and analyse particle size distribution.

At Karelskiy Okatysh, part of Severstal, computer vision solutions have been implemented since 2022. Data analysis and visualisation rely on the company’s proprietary MES system KlientPRO. In 2023 the enterprise equipped excavators with machine vision and high-precision positioning systems as part of the “Digital Mine” initiative.

Overall, the emergence of commercially viable AI systems is becoming an increasingly important competitive advantage in the global mining industry.