MMG Dugald River marks one year of sustained results with AI-Assisted Process Control

One year after commissioning, MMG Dugald River continues to demonstrate how AI can deliver measurable value when it becomes part of day-to-day operations. At the center of that success is AI-Assisted Process Control, which helps the site respond to changing plant conditions in real time, contributing to improved performance and operational consistency.

Developed by Hatch and implemented in partnership with MMG Limited (MMG), AI-Assisted Process Control (AIPC) combines digital twin technology, advanced process control, machine learning, and metallurgical expertise to continuously adjust setpoints, helping operators maximize recovery while maintaining concentrate quality.

This milestone marks a year of sustained operation following commissioning, with the site continuing to realize improvements in zinc recovery and concentrate grade while achieving payback in less than three months.

Alec Malcolm, senior metallurgist

“The results have been positive, exceeding our previous performance benchmarks. I'm also encouraged by the flexibility of the system and how it can be tailored to different process goals.”

Tim Akroyd, Dugald River general manager

“As an operation, we are focused on identifying and implementing the right technology that can continue to drive safety and performance improvements. This is effectively like an always-on assistant that continuously adjusts how the plant runs to get the most zinc out of every tonne of ore processed.”

Unlike traditional control strategies that rely on fixed operating targets, AIPC continuously evaluates changing process conditions and helps keep the plant operating closer to its economic optimum. The system adapts as feed characteristics change while maintaining transparency into every decision.

The implementation was delivered through close collaboration between Hatch and MMG's operational and metallurgical teams. By aligning the technology with existing workflows and providing visibility into how recommendations were generated, operators developed confidence in the system over time.

"MMG represents true forward-thinking for industry, and their successful adoption of AIPC through a closed-loop twin is giving confidence to others who want to explore how technology step-changes can greatly enhance their operations."

- Warwick Smith, Global Practice Lead, AIPC

Together with MMG's strong operational culture, willingness to innovate, and trust in the process, AIPC has become part of everyday operations at Dugald River. MMG recently shared its perspective on the project's first year of operation.

As mining companies continue to explore the role of AI in mineral processing, the Dugald River project demonstrates that the greatest value doesn't come from AI alone. Combining metallurgical expertise, operator engagement, and advanced digital technology helped create a solution that not only improved performance, but earned the trust required for long-term adoption. One year later, that trust continues to deliver results.

Explore the benefits of AI-Assisted Process Control.

For more information, please contact:

Lindsay Janca
Global Director, Public Relations
Tel: +1 905 403 4199
Email: media@hatch.com

About Hatch

Hatch is a global engineering, project delivery, and professional services firm. Whatever our clients envision, our teams can design and build. With over six decades of business and technical experience in the mining, energy, and infrastructure sectors, we know your business and understand that your challenges are changing rapidly. We respond quickly with solutions that are smarter, more efficient, and innovative. We draw upon our 10,000 staff with experience in over 150 countries to challenge the status quo and create positive change for our clients, our employees, and the communities we serve.

Find out more on www.hatch.com/About-Us.