ComminuSenseNMDC - India’s Largest Iron Ore Producer
ComminuSense: Smart Communition - Lower kWh/Ton, Better Uptime
Overview
ComminuSense is an AI-driven energy-optimization and predictive-maintenance platform designed for iron-ore comminution circuits. By integrating high-frequency IoT telemetry, cloud analytics, machine-learning models and an interactive digital twin, ComminuSense delivers real-time kWh/ton insights, AI recommendations, and predictive alerts to reduce energy intensity, improve throughput and minimise unplanned downtime. The platform is built to industry security standards and role-based access, enabling safe pilot deployments at plant scale and providing government and plant managers with auditable energy and maintenance intelligence.
Real-time Energy Monitoring
Live kWh/ton, power draw and throughput telemetry with trend alerts and historical comparisons.
AI-Driven Optimization
Regression & policy models that recommend RPM, feed and load set-points to minimise energy per tonne while preserving throughput.
Predictive Maintenance
Vibration and signature-based anomaly detection with RUL estimates and maintenance windows to reduce unplanned downtime.
Digital Twin & What-If Simulator
Interactive circuit simulator for safe evaluation of set-point changes and design alternatives before implementation.
The Comminution Energy Challenge
Comminution processes consume 40-50% of total mining energy, translating to massive operational costs and carbon emissions. Traditional systems lack real-time optimization, resulting in equipment inefficiency, unplanned downtime, and throughput losses.
Key Components of ComminuSense
Our modular AI-powered platform integrates cutting-edge technologies for unparalleled mining efficiency.
How We Maximize Plant Efficiency
A six-step framework integrating digital modeling, predictive analytics, and real-time automation to deliver peak industrial performance.
Digital Twin Modeling
Create a virtual replica of the plant to simulate changes and predict performance without physical downtime.
Predictive Maintenance
Use AI to analyze sensor data, accurately forecasting equipment failures before they occur, maximizing uptime.
Real-time Resource Allocation
Dynamically adjust power, water, and material inputs based on immediate production needs, minimizing waste.
Automated Process Optimization
Implement machine learning models to fine-tune operational parameters 24/7 for peak throughput.
Sustainable Output Management
Track and optimize energy consumption and emissions, ensuring efficiency goals align with environmental standards.
Integrated System Feedback
Establish a loop where operational data immediately informs and adjusts the strategic planning models.
NMDC's Operational Footprint
Critical mining complexes and production facilities driving India's industrial growth
Major Facilities
Bailadila Mining Complex
Donimalai Mining Complex
Kumaraswamy Iron Ore Project
Panna Diamond Mine
Steel Plant
Built for Every Role in Comminution
ComminuSense provides actionable intelligence tailored to the decision-making needs of your entire team.
Operator
View live telemetry, acknowledge alarms, start/stop local simulator runs. (Can't change model thresholds.)
Shift Supervisor
All Operator + accept/implement AI suggestions, manual setpoint override.
Process Engineer
Run simulations, view ML model explainability data, change recommended setpoint tolerances, export reports.
Maintenance Engineer
View PdM alerts, schedule maintenance tasks, download vibration logs.
Plant Manager
View KPIs, confirm major parameter changes, approve maintenance budgets.
NMDC Admin / Auditor
View audit logs, system health; higher-level governance access (read-only to raw data, download permitted).
See ComminuSense in Action
Watch a comprehensive walkthrough of the platform architecture, ML models, digital twin simulation, and live dashboard capabilities.
System Architecture
Three-tier industrial architecture designed for reliability, scalability, and ISA-95 compliance.
Edge & Data Layer
- • IoT sensor simulation (RPM, kW, load, vibration)
- • MQTT/WebSocket ingestion
- • Time-series storage (InfluxDB/TimescaleDB)
- • Data lake for historical analysis
Intelligence Layer
- • Energy optimization ML model
- • Predictive maintenance model
- • Digital twin physics engine
- • Closed-loop policy controller
Application Layer
- • Next.js industrial dashboard
- • REST/GraphQL API gateway
- • RBAC with ISA-95 role mapping
- • Real-time visualization engine
Trusted by Industry Leaders
See what top mining professionals are saying about the impact of ComminuSense.
Real-time energy optimization with ML has been a long-standing requirement for our comminution circuit. The simulation results demonstrate significant potential for kWh reduction.