PHOSA

AI in Mining and Process Industries

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.

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ABOUT PHOSA

Excavating data from mining operations is just as important as excavating ore. But in mining and other continuous-process industries, it’s hard to construct data models that can pinpoint exactly where changing operational controls could improve performance. Analytics alone aren’t enough. You need to account for the multiple variables and underlying physics involved in a given process.

Phosa, the proprietary “human in the loop” AI solution from BCG X, provides real-time recommendations for changes that yield higher values at any stage of a continuous-process operation.

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.

WHY PHOSA

The Benefits of Partnering AI and Mining

Our clients can use Phosa to progress through the five stages of AI for continuous-process industries. But even more critically, our AI in mining solution can be used to improve decisions at any level:

Operational

To improve short-term conditions for specific equipment, teams, or processes, or to coordinate structured processes according to shared KPIs. Examples of operational applications include optimizing haul dispatch or responding to unplanned downtime.
Tactical

To maximize midterm asset performance by aligning the organization to common objectives and evaluating tradeoffs across the value chain. Examples of tactical applications include making decisions about mine pit development or when to schedule major maintenance.
Strategic

To maximize the lifetime value of assets and inform long-term and life-of-mine planning. Examples of strategic applications of AI in mining include turnaround scoping and scheduling.

Diversified Metals Client

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.

$100+ million

increase in annual production

Oil and Gas Client

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.

25%

reduction in annual process losses

OUR EXPERTS

Meet Our Experts on AI in Process Industries

Our Phosa experts use their deep domain expertise and knowledge of end-to-end processes to develop and validate machine-learning methods, and then help clients operate and continue to refine.