Molycop advances Process Characterisation with OreVia

Molycop is advancing a new era of process intelligence with OreVia — an AI-powered suite that delivers real-time visibility across crushing, grinding and flotation.

Key Facts

• Intelligent visibility – OreVia combines AI, computer vision and machine learning to deliver real-time insight into ore behaviour across crushing, grinding and flotation processes.
• Modular by design – OreVia adapts to each site’s needs and grows alongside new technologies, ensuring long-term performance and value.
• Comprehensive control – The OreVia suite spans three integrated technologies – OreVia Rock, OreVia Slurry and OreVia Froth – each addressing a key stage of the mineral processing circuit.

In an era defined by efficiency, recovery and sustainability, the mining industry is being reshaped by data and intelligence. Despite significant progress in automation and control, process variability remains one of the sector’s most persistent challenges. Understanding how ore behaves – and how that behaviour changes in real time – is critical to achieving stable, high-performing operations.

With the launch of OreVia, Molycop is redefining what process characterisation means for modern mineral processing. This new suite of AI-powered technologies brings a level of clarity, precision and adaptability that allows operators to see, understand and optimise their processes like never before.

OreVia uses AI, computer vision and machine learning to enhance circuit performance.

Turn insight into foresight

Molycop’s new OreVia suite of technologies represents a shift from static measurement to dynamic intelligence. Using advanced computer vision and machine learning, OreVia continuously captures and interprets data from across the processing circuit – from crushing and milling through to flotation.

High-resolution imaging and intelligent analytics provide a live picture of ore behaviour, enabling early detection of changes that could impact recovery or throughput. When conditions shift, OreVia alerts operators in real time, empowering faster, data-driven decision-making that keeps performance stable and predictable.

Integrated with the Molycop VIP Platform and existing plant control systems, OreVia delivers visibility and actionable foresight, helping teams anticipate issues before they affect productivity or cost.

Adaptable to every operation

OreVia has been designed as a flexible, modular ecosystem that can adapt to any plant’s needs and evolve over time. The suite spans three interconnected technologies:

• OreVia Rock – Uses AI-driven vision to monitor coarse ore in real time, stabilising mill feed, reducing liner wear and enhancing circuit performance.
• OreVia Froth – Delivers live froth imaging and AI analysis to support consistent flotation control and recovery optimisation.
• OreVia Slurry – Provides continuous, high-accuracy particle size and shape analysis to improve grinding efficiency and flotation outcomes.

Each module can operate independently or as part of an integrated network, offering a scalable approach to smarter process control.

Expert perspectives: From reactive to predictive

According to Edgar King, Molycop’s Manager of Machine Vision, OreVia Rock represents a major leap forward in process visibility.

OreVia Rock uses AI-driven machine vision to continuously monitor particle sizes in real time across the crushing and milling circuit – unlike conventional systems. It automatically adapts to variations in ore type and installation conditions without the need for recalibration.

OreVia Rock monitors coarse ore in real time using a camera positioned above the conveyor.

The same principle of real-time intelligence underpins OreVia Froth, which tackles one of mineral processing’s most dynamic challenges – flotation control.

“Using a combination of AI-powered bubble sizing, pulp velocity measurement and anomaly detection, OreVia Froth gives operators real-time visibility into what’s happening above the flotation tank,” Edgar says. 

“The technology allows plants to stabilise mass flow between cells, optimise air addition and react immediately to anomalies,” he adds. “The result is better flotation recovery, improved consistency and greater control across the board.”
Similarly, Damian Thorpe, Manager of Advanced Milling Instrumentation, highlights the significance of OreVia Slurry in filling a long-standing visibility gap in the process stream:

OreVia Slurry gives operators the ability to see inside the process, not just infer what’s happening.
“Operators are no longer working in the dark,” Damian explains. “They can make dynamic adjustments, reduce downtime and continuously optimise without expensive interruptions.”

Towards predictive, connected operations

As the industry moves toward more autonomous and digitally enabled operations, the ability to connect every stage of the process becomes essential. OreVia’s adaptive AI and machine learning capabilities enable this transition – shifting plants from reactive control to predictive optimisation.

Continuous data from OreVia modules feeds directly into advanced control systems, empowering operators with the ability to anticipate process variability. The result is improved recovery, reduced energy and reagent use, and stronger overall margins.

“OreVia gives operators the eyes they’ve never had before,” Edgar says. “It’s not just about more data – it’s about actionable insight that changes outcomes.”

Molycop – Progress Together