Phosa, our proprietary operating system for AI in mining and AI in process industries, provides real-time improvements for all stages of a continuous-process operation—delivering higher values and improving decision making.
Just as miners use headlamps to light their way, Phosa helps clients in continuous-process industries—such as metals and mining; forest products, paper, and packaging; oil and gas; chemicals; and agribusiness—uncover opportunities hidden in existing processes. Our industry-agnostic AI applications go beyond black-box solutions by combining domain expertise with analytics, proprietary trade secrets, and code libraries to create transformational changes to frontline operations and advance their digital transformation.
Phosa recommendations can be integrated into multiple client systems, including control systems, existing diagnostic displays, or custom dashboards. In addition, recommendations can be fully automated in process control systems, entered into the systems manually by client operators, or integrated into the systems but applied only when an operator reviews and approves them.
Existing clients have paired AI and mining or other process industries to realize hundreds of millions of dollars in value by optimizing multiple operating setpoints in response to changing raw material and environmental factors. Examples of our work include:
A copper mining client engaged BCG X to assess advanced analytics opportunities and enable next-gen integrated operations. Phosa provided a value-driven, modular, sequenced approach and implemented a customized solution across the entire value chain, creating the most digitally advanced mining operation in the world. The client is now realizing over $100+ million increase in annual copper production, while reducing annual operating costs by $18 million.
Using Phosa, BCG X and an oil & gas client demystified plant operations, enabling a transformation to more efficient operating procedures and practices. Drawing upon a hypercube of optimal operating control settings, Phosa combined machine learning models and optimization to create new operating directives for plant managers. Once fully implemented, the client saw a 25% reduction in annual process losses and $50 million in additional revenue.