Case Studies

Real-world examples of how ZAG's analytics solutions have delivered measurable results across the mining industry.

01

Gold Plant Metal Accounting Automation

Client: A mid-sized South African gold mining company

Challenge

Relied on manual, spreadsheet-based metal accounting prone to errors, delayed reporting, and poor data visibility. An internal audit revealed a significant gap in compliance with AMIRA P754 standards, risking regulatory non-compliance and hidden revenue loss.

ZAG Solution & Process

  • Conducted a comprehensive Metal Accounting Audit to identify gaps in sampling, measurement, and reconciliation.
  • Designed and implemented a fully automated Metal Accounting system, integrating data from the plant's PLCs and lab systems into a single source of truth.
  • Developed a suite of executive and operational Dashboards providing real-time insights into production, recovery, and mass balances.
  • Conducted Training for metallurgists and plant operators on the new system and dashboard interpretation.

Hypothetical Measurable Impact

95% reduction in monthly reporting time
From 5 days to 4 hours
Achieved full AMIRA P754 compliance
Passed the next external audit successfully
Identified and resolved 0.5% consistent recovery under-reporting
Clarified true plant performance and prevented revenue loss
02

PGM Concentrator Anomaly Detection & Loss Prevention

Client: A Platinum Group Metals (PGM) concentrator in the Bushveld Complex

Challenge

Experienced unexplained, intermittent metal losses in their final concentrate, leading to revenue leakage and strained customer relationships due to inconsistent concentrate grades.

ZAG Solution & Process

  • Performed a deep-dive Advanced Analytics investigation on 12 months of historical plant data.
  • Built a predictive model and real-time anomaly detection system that monitored key flotation circuit parameters.
  • The system flagged specific operational conditions (a combination of density fluctuations and feed particle size changes) that preceded metal loss events.
  • Provided the client with a diagnostic dashboard and trained their control room supervisors on interpreting alerts as part of our Ongoing Monthly Analytics Support.

Hypothetical Measurable Impact

Identified the root cause of 80% of unexplained loss events
Enabling targeted operational interventions
Prevented an estimated 2% of annual metal revenue loss
Through early-alert operational adjustments
Improved final concentrate grade consistency by 15%
Enhancing product reliability and customer satisfaction
03

Copper-Cobalt Hydromet Plant Performance Optimization

Client: A large copper-cobalt operation in the DRC

Challenge

Struggled with highly variable throughput and recovery rates in their leaching and solvent extraction circuits, making production forecasting difficult and limiting capacity.

ZAG Solution & Process

  • Initiated the project with a Dashboard Development phase to create a unified view of circuit performance from disparate data sources.
  • Used Advanced Analytics and scenario modeling to analyze the complex relationships between ore blend, reagent consumption, residence time, and metal recovery.
  • Developed an optimization model that recommended ideal operating setpoints for different feed types.
  • Implemented the model's findings and established a continuous improvement cycle with the client's metallurgical team through targeted Training.

Hypothetical Measurable Impact

Achieved a 3% sustained increase in overall plant recovery
Directly improving metal output and revenue
Reduced reagent consumption variability by 25%
Lowering operational costs and improving margins
Enabled more accurate 30-day production forecasts
Giving management greater clarity and confidence in planning