Modern Mining September 2025

MINING TECHNOLOGY

Weir charts the journey to smart mining with next intelligent solutions

The road to optimised mining is being charted at the level of both equipment performance and process optimisation; Weir is walking that journey with customers with the help of its NEXT Intelligent Solutions.

M arina Eskola, Director of Digital Solutions Management at Weir, explains the impact that artificial intelligence (AI) and digital twin modelling is having on productivity, efficiency and sustainability. Detailed knowledge of their equipment’s operation and performance over many decades has allowed Weir to build predictive models based on their extensive and reliable data. “Our in-depth understanding of how our equipment works – under a wide range of conditions – is harnessed by NEXT Intelligent Solutions to guide predictive maintenance of equipment for longer service life and better performance,” says Eskola. “Beyond that, we also leverage this digital technology further to optimise the broader metallurgical process.” In terms of predictive maintenance, Weir uses different AI tools such as machine learning algorithms to predict the remaining useful lifetime of equipment, as well as the probability of mechanical failure. “What positions us very well to do this is our engineering knowledge, allowing us to detect, predict and prevent failure modes using our extensive databases – and we know how to build this data into the algorithms,” she says. Another vital element of the digital journey is to adapt these models to the customer’s circumstances, where Weir collaborates in helping mines move from traditional to predictive maintenance strategies. She notes that Weir recognises the importance of change management and this is part of the journey with customers. “We also use digital twin modelling to collect data from equipment and other sources to simulate – in the virtual environment – the operation of the physical equipment,” she explains. “Our detailed technical knowledge and historical data allows us to predict the outcomes of machine performance, so that we can apply the necessary adjustments back onto the physical equipment.” In this way, she says, the simulations can guide the continuous optimisation and efficiency of equipment. AI is also invaluable in process optimisation,

Weir’s in-depth understanding of how equipment works is harnessed by NEXT Intelligent Solutions to guide predictive maintenance.

says Mauricio Vega, Head of Process Optimisation Technology at Weir. Based on the company’s depth of metallurgical expertise, it is able to create a digital model of the process circuits in which its equipment is being used. “We can use AI to find the right operating points in the process, taking into account the constraints, such as energy efficiency or remaining life of equipment,” explains Vega. “This allows us to generate and evaluate multiple scenarios as quickly as possible, allowing relevant and accurate recommendations to be given to the customer.” Eskola highlights that Weir takes a collaborative approach to customer partnerships, so the application of this technology is tailored to how the customer chooses to take their journey to smarter mining. Weir has designed NEXT Intelligent Solutions with this strategy in mind, providing three packages that allows a progressive approach to implementation. “These packages –Insight, Uptime and Production – align with the journey that customers can take in partnership with Weir to leverage real time data in making informed decisions, applying cutting-edge sensing technologies and boosting

Mauricio Vega, Head of Process Optimisation Technology at Weir.

Marina Eskola, Director of Digital Solutions Management at Weir.

SEPTEMBER 2025 | www.modernminingmagazine.co.za  MODERN MINING  31