● brownfield operations

Brownfield mining operations: reduce variability and lift throughput without major CAPEX

Automation, process optimisation, APC, and digital solutions to stabilise, optimise, and future-proof your brownfield mining plant – without major capital investment.

29

YEARS IN MINING OT

730+

PROJECTS DELIVERED

110

PROCESSING PLANTS SUPPORTED

55

COUNTRIES GLOBALLY

the brownfield challenge

Mounting pressure to do more with less

Existing mining operations face a paradox: the assets are in place, but performance is constrained by ageing systems, fragmented data, and process variability that erodes margins every shift. Mipac helps you tackle these challenges head-on – without the need for major capital investment.

🔧

Ageing infrastructure

Legacy systems that are costly to maintain and difficult to integrate with modern technology.

⚡

Rising energy costs

Escalating energy and maintenance costs squeezing operational margins with every tonne.

📊

Process variability

Inconsistent throughput and unstable control causing unpredictable recovery and output.

👁

Limited visibility

Poor asset performance data leaving operators reactive rather than proactive.

our approach

From instability to operational excellence

We don’t just implement technology, we solve operational problems. A structured four-stage framework that builds on itself, delivering measurable results at every step.

Stabilise

Reduce variability, improve control

›

Automate

Modernise systems, reduce risk

›

Optimise

Extract more from existing assets

›

Enable

Empower teams, sustain performance

01 – stabilise

Build the foundation for performance

When your plant is running below its constraint, you’re leaving recoverable metal on the table every shift. We identify and address the root causes of instability, combining metallurgical insight with advanced control expertise to unlock hidden capacity without adding capital.

APC APC Readiness Audit Process Control Strategy MPA Apps Delay Accounting

Brownfield

Copper / Cobalt

Process plant optimisation – Kamoto Copper Company

At Glencore’s Kamoto copper and cobalt operation in the DRC, Mipac commissioned and optimised mill control across seven grinding mills at the KTC concentrator and automated CCD underflow control at the Luilu Refinery: all delivered remotely, without a single engineer setting foot on site.

CCD throughput increases of at least 10% per unit, with stabilised plant operation and reduced operator involvement

●Kamoto Copper Company (Glencore) · Democratic Republic of Congo

Brownfield

Zinc / Lead / Copper

Plantwide control system upgrade – Kazzinc

Contracted through Glencore Technology, Mipac designed and commissioned a plantwide Emerson DeltaV DCS for the Kazzinc zinc, lead and copper complex in Kazakhstan – one of the world’s largest polymetallic operations. Scope included ISASMELT™ lead and copper plants, the copper refinery, and deployment of Mipac’s CellView® wireless cell monitoring solution.

Increased electro-refining efficiency and copper cathode quality – with improved operator safety across the complex

●Kazzinc (Glencore Technology) · Ust-Kamenogorsk, Kazakhstan

02 – automate

Modernise without disrupting production

Ageing PLCs and legacy DCS platforms create risk: unplanned failures, cybersecurity vulnerabilities, and operational bottlenecks. We upgrade and integrate control systems to ensure your plant runs reliably, efficiently, and securely for the long term.

PLC/DCS/SCADA MAC Functional Saftey Instrumentation Engineering Electrical Engineering Alarm Manager Loop Performance

03 – optimise

Extract more value from what you already own

Reactive maintenance is expensive. Limited visibility into asset health means you’re managing by exception, only finding problems after they’ve cost you. Our optimisation services move you from reactive to proactive, improving reliability and reducing cost per tonne.

Loop Tuning Asset Performance Management Aspen Mtell Rt Duet Production Monitor ShortMeter® Copper Monitor® CellView®

Brownfield Copper / Gold

Predictive maintenance implementation – Ok Tedi Mining

Unplanned maintenance was holding back Ok Tedi’s copper and gold operations in Papua New Guinea. Mipac implemented Aspen Mtell® across critical crushing and grinding assets, using machine learning to detect early signs of equipment degradation and deliver timely, actionable maintenance insights.

Reduced unplanned maintenance and improved asset reliability – expanded to 38 additional assets in year two

●Ok Tedi Mining Limited · Papua New Guinea

Brownfield Gold

Production reporting digitalisation – Newmont Merian

Newmont’s Merian gold mine in Suriname was losing hundreds of hours each year to manual Excel-based production reporting. Mipac deployed the MPA software suite — integrating with the site’s AVEVA PI system to automate metals accounting, digitalise logsheets, and give metallurgists real-time visibility across the plant.

Hundreds of hours saved annually — metallurgists freed from manual data entry to focus on production optimisation

●Newmont Mining Corporation · Suriname, South America

04 – enable

Empower your team to sustain performance

Technology only delivers results if your people can use it confidently. We combine strategic consulting, real-time data visibility, and hands-on training to ensure your operation continues to improve – long after we’ve left site.

Historian Upgrade Data Analytrics and Visualization AVEVA PI TCard Production Monitor Logsheets Digital TARP Digital Maturity Automation Roadmaps Mining 4.0

why mipac

The brownfield specialists

We’ve been doing this for the last three decades years. We know what works in operating plants – and what doesn’t.

🎯

Deep domain expertise

Rare combination of control systems, instrumentation, and metallurgy in a single team — we see the whole plant, not just one discipline.

🌏

Global track record

Proven delivery for Glencore, BHP, Rio Tinto, First Quantum Minerals, and others across multiple commodities and geographies.

🔄

End-to-end delivery

From process audits through to ongoing operational support — one partner accountable for the full improvement journey.

📐

Proven results

Measurable outcomes in variability reduction, throughput improvement, and cost per tonne – with the case studies to back them up.

💡

In-house innovation

Proprietary software and hardware – MPA, TCardCopper Monitor®, ShortMeter®, CellView® – built specifically for mineral processing plants.

💰

No major capex required

We deliver meaningful performance improvements through smarter use of your existing infrastructure — not by replacing it.

TRUSTED BY GLOBAL MINING OPERATIONS

Glencore BHP Rio Tinto First Quantum Minerals Hudbay ASARCO ANGLO AMERICAN

Brownfield Metallurgical Coal

Alarm rationalisation – Elkview Operations

Over 15,000 weekly alarms were inundating operators at this British Columbia coal site. Mipac rationalised alarms across 27 PLCs using ISA 18.2 standards, PlantPAx logic, and a cascade alarm philosophy – cutting alarm volume by more than 70%.

Alarm volumes reduced by over 70% – from 15,000+ to fewer than 5,000 per week

●Elk Valley Resources (Glencore) · British Columbia, Canada

Brownfield Copper | Gold

Control & instrumentation upgrade – Ok Tedi Kiunga Operations

Ok Tedi’s Kiunga port facility – the concentrate handling, storage and ship loading hub for PNG’s largest copper-gold mine – was running ageing, undocumented control systems with minimal automation. Mipac upgraded from a legacy GE Fanuc PLC and Citect SCADA to an ABB 800xA DCS, with remote commissioning completed entirely from Brisbane.

Delivered on time and within budget – with zero interruption to operations during cutover

●Ok Tedi Mining Limited · Papua New Guinea

Brownfield Copper

Legacy DCS modernisation – North American copper smelter

One of the world’s largest integrated copper smelting facilities was running critical flash-converting furnace control on an unsupported Windows NT system. Mipac migrated the application to a modern .NET infrastructure and integrated it into the DCS, eliminating the risk of outages caused by obsolete hardware and software.

Legacy system risk eliminated – operators now interact exclusively with the DCS, with no disruption to production during cutover

● Confidential client · North America

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+61 7 3212 5600 · sales@mipac.com.au

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Some common questions we get about brownfield operations in mining:

What is brownfield mining and how is it different from greenfield?

Brownfield mining refers to optimising, upgrading, or expanding an existing mining operation that is already producing. Unlike greenfield projects — which involve building a new mine from scratch, brownfield operations work within established infrastructure, making improvements through better control systems, process optimisation, and digital technology rather than new capital construction.

How can brownfield mining operations improve throughput without major capital investment?

Brownfield mining operations can increase throughput by addressing the root causes of process variability; poorly tuned control loops, inconsistent feed control, and inadequate visibility into plant performance. Advanced Process Control (APC), PID loop tuning, and real-time deviation monitoring tools like MPA can deliver measurable throughput gains using existing infrastructure. Mipac has achieved throughput improvements of up to 8% at operating concentrators without major capital expenditure.

How do you upgrade a legacy DCS at an operating mine without causing downtime?

Upgrading a legacy DCS at a brownfield mining operation requires detailed cut-over planning, staged commissioning, and functional safety reviews such as HAZOP and CHAZOP. Mipac has successfully completed full DCS replacements at operating mines with zero unplanned downtime by running new and legacy systems in parallel during commissioning, then executing the cut-over during planned shutdowns. The key is experienced brownfield automation engineers who understand both the technical and operational risks.

What are the biggest control system challenges in brownfield mining operations?

The most common control system challenges in brownfield mining operations include ageing PLCs and DCS platforms that are no longer vendor-supported, inconsistent alarm configurations that create operator fatigue, poorly tuned PID loops that allow excessive process variability, and limited OT network visibility that makes remote support difficult. These issues compound over time and are best addressed through a structured Stabilise–Automate–Optimise program rather than isolated point fixes.

How long does a brownfield process control improvement project typically take?

The timeline depends on scope, but a brownfield process audit and initial stabilisation program typically takes 4–12 weeks. A full DCS upgrade or APC implementation at an operating mine generally runs 6–18 months, including design, factory acceptance testing, and staged commissioning. Mipac structures brownfield projects to deliver value at each stage so operations see measurable improvements before the full scope is complete.

What does Advanced Process Control (APC) do for a brownfield mining operation?

Advanced Process Control reduces process variability by using model-based algorithms to hold a plant closer to its metallurgical constraints, shift after shift. In brownfield mining operations, APC is typically implemented after stabilising basic regulatory control, and can deliver significant improvements in throughput, recovery, and energy efficiency. It works within the existing DCS or SCADA infrastructure without requiring new equipment.

Brownfield mining operations: reduce variability and lift throughput without major CAPEX

29

730+

110

55

Mounting pressure to do more with less

Ageing infrastructure

Rising energy costs

Process variability

Limited visibility

From instability to operational excellence

Stabilise

Automate

Optimise

Enable

Build the foundation for performance

Process plant optimisation – Kamoto Copper Company

Plantwide control system upgrade – Kazzinc

Modernise without disrupting production

Extract more value from what you already own

Predictive maintenance implementation – Ok Tedi Mining

Production reporting digitalisation – Newmont Merian

Empower your team to sustain performance

The brownfield specialists

Deep domain expertise

Global track record

End-to-end delivery

Proven results

In-house innovation

No major capex required

Alarm rationalisation – Elkview Operations

Control & instrumentation upgrade – Ok Tedi Kiunga Operations

Legacy DCS modernisation – North American copper smelter

Download our capabilities guide

Speak directly to an engineer who's worked on your type of operation.

Subscribe

Enter your details to receive our newsletter.

Some common questions we get about brownfield operations in mining:

What is brownfield mining and how is it different from greenfield?

How can brownfield mining operations improve throughput without major capital investment?

How do you upgrade a legacy DCS at an operating mine without causing downtime?

What are the biggest control system challenges in brownfield mining operations?

How long does a brownfield process control improvement project typically take?

What does Advanced Process Control (APC) do for a brownfield mining operation?

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