Inconsistent decision making, dependency on a shrinking talent pool, declining ore grades, and difficulty optimizing for economic outcomes all contribute to avoidable value loss.
Traditional control approaches weren’t designed to handle modern complexities, which demands new technology for advanced decision support.
AI can assist your operators by handling this complexity in real-time to reduce the impact of these challenges to achieve site objectives.
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What is AIPC?
AI-Assisted Process Control (AIPC) adds an intelligent, predictive layer on top of your existing control system, acting like an operational co-pilot that works directly with operators to keep the plant ahead of changing conditions. By continuously learning from your data, it aligns its decisions to your site’s operational and economic objectives and adapts as those priorities evolve.
Unlike traditional control approaches, AIPC aligns setpoints at each unit of operation to site-wide objectives and adapts them based on day-to-day operating realities. By accounting for interactions across the flowsheet, it helps optimize performance throughout the value chain, not just within individual units.
Because it works with the infrastructure you already have, it’s a low-disruption way to unlock performance you already own. And with Hatch partnering on implementation and long-term sustainment, sites see the benefits compound over time.
Why move to AIPC?
Achieve closed loop automation
Economically aligned, autonomous control that stays on target.
Progresses from advisory to open loop to closed loop based on site readiness.
Operators retain visibility and control over the system.
Build trust through glass-box transparency
Explainable decision logic that reinforces collaboration with operators.
Learn and adapt to changing conditions
Models retrain automatically as ore and plant conditions shift.
Coordinate multi-unit decisions across the plant
Multi-unit optimization coordinates decisions across circuits and sites for broader value capture.
Preserve and apply operational expertise
Institutional knowledge and best practices embedded directly into the model.
Blend process knowledge with machine learning
First principles and AI work together for stable, adaptive control.
Is AIPC right for your process?
AIPC can unlock value across a wide range of processes, from foundational control challenges to multi-variable, non-linear processes with sub-minute decision intervals. While widely applied in mining operations today, AIPC is also being used in infrastructure and energy operations facing similar demands for coordinated decision making across varying objectives.
These are the latest areas where clients are applying AIPC:
• Flotation
• Flux control
• Concentrators
• Autoclaves
• Smelters
• And other complex process systems
If your process demands fast, coordinated, value-aligned decisions, AIPC will deliver.
Our holistic set of IROC offerings
Establishing a new IROC
Defining the IROC strategy, vision & roadmap and developing a business Case
Continuous Improvement of an IROC
Demonstrably and incrementally improving value delivery from IROCs (Value Diagnosis & Roadmap)
Upgrading a new IROC
Taking the existing IROC to the next level to match best-in-class (Benchmarking)
Integrated Operations
Digital Strategy & Roadmap, Integrated Planning & Scheduling, Value Chain Optimization, Benchmarking
Our IROC solutions have proven to deliver company-wide value
Up to 30% Incident reduction
Increased oversight as well as rapid response time to safety & evacuation time
25% Labour utilization
Improved operational efficiency and uptime, role consolidation
15% Performance improvement
Eliminate value leakage due to isolated decision making, establish best practices and ways of working
5-7% Equipment availability improvement
Faster maintenance response times and time for operators to re-enter repaired trucks
Interested in learning more?
Ready to unlock measurable value from your operations? Partner with us to design an AIPC solution tailored to your process, not just your data.
