TwinOpt Platform 5.0 — Closed-loop RTO now GA

Physics-based digital twins. Real-time optimization.

TwinOpt fuses first-principles process models with live plant data to compute optimal setpoints every cycle — across mineral processing circuits, pipelines and energy systems. Simulate, predict and act before deviations become losses.

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LIVEtwin://concentrator-01/grinding-flotation

RTO cycle 00:00:30

Holographic digital twin of a mineral processing plant showing a SAG mill, flotation cells and thickeners

SAG Mill Throughput

2,418t/h

+6.2%

Flotation Recovery

91.4%

+1.8%

Specific Energy

8.72kWh/t

-4.1%

Mining operators served: 28
Countries across Asia: 6
Avg. energy reduction: 12%
Model-to-setpoint latency: <200 ms

01 / Core Solutions

One platform. Six engineering-grade software suites.

Every TwinOpt suite runs on a shared model kernel and data fabric — so the same validated twin powers design studies, live optimization and operator training.

TO-TWIN

TwinOpt Digital Twin Studio

Build high-fidelity, first-principles plant models with drag-and-drop flowsheets, calibrated against historian data.

Dynamic simulation
Model calibration
What-if scenarios

TO-RTO

Real-Time Optimization Suite

Closed-loop optimizer that solves for economic setpoints and writes them back to DCS/APC layers each cycle.

NLP / MPC
Steady-state detection
OPC UA write-back

TO-FLOW

Flow Assurance Engineering

Transient multiphase and single-phase hydraulics for oil, gas and water transmission networks.

Surge analysis
Hydrates & wax
Leak detection

TO-ENERGY

Energy Optimization

Minimize specific energy consumption across mills, pumps and compressors with tariff-aware load scheduling.

kWh/t tracking
Demand response
Carbon intensity

TO-OTS

Operator Training Simulator

Immersive, twin-driven training with interactive field manuals, procedures and abnormal-event drills.

Interactive SOPs
Scenario scoring
Competency tracking

TO-CONNECT

Industrial Data Fabric

Secure connectivity to PI, IP.21, OPC UA, MQTT and SCADA with data validation and reconciliation built in.

Data reconciliation
Edge gateways
IEC 62443

02 / Real-Time Optimization

RTO modules for mineral processing & hydraulic systems.

Each module ships with a validated unit-operation model, constraint library and closed-loop integration to your DCS — deployable independently or as an integrated circuit.

01Acquire
02Reconcile
03Detect steady state
04Optimize
05Validate
06Write setpoints

RTO-HYD

Hydraulic Network Optimizer

Steady-state and transient hydraulic solver for slurry, tailings and process water circuits.

Darcy–Weisbach & Durand slurry friction models
Critical deposition velocity monitoring
Pressure / flow balance across 10k+ nodes

Pressure drop error±1.5%

RTO-SAG

SAG Mill Optimization

Maximizes throughput within power, bearing pressure and load constraints using a calibrated mill twin.

Population-balance breakage & JKSimMet-type models
Mill load, speed and water-ratio setpoint control
Liner wear & ball charge estimation

Throughput uplift+4–8%

RTO-FLT

Flotation Circuit Optimizer

Balances grade and recovery across rougher, scavenger and cleaner banks in real time.

Kinetic flotation model with froth recovery
Air rate, level & reagent dosing optimization
Grade–recovery curve tracking per bank

Recovery gain+1.2–2.5%

RTO-THK

Thickener Performance Control

Predicts bed mass, underflow density and overflow clarity to stabilize downstream operations.

Kynch / Bürger sedimentation model
Flocculant dosing & rake torque constraints
Water recovery maximization

Flocculant savingsup to 18%

RTO-PMP

Pump Fleet Optimization

Selects pump combinations and VSD speeds to hit flow targets at minimum energy and wear.

Affinity laws & manufacturer curve fitting
NPSH margin and cavitation risk alerts
Best Efficiency Point (BEP) tracking

Pumping energy-10–15%

RTO-FOM

Field Operator Interactive Manual

Twin-linked digital procedures that guide field operators step-by-step with live equipment context.

3D equipment views with live tag overlays
Interactive SOPs, LOTO & permit checklists
Offline-capable tablet & HMI deployment

Procedure errors-35%

03 / Flow Assurance Engineering

Transient pipeline simulation for oil, gas and water.

From design-stage hydraulic studies to online pipeline management systems, TwinOpt flow assurance tools keep product moving safely, efficiently and within integrity limits.

Solver: Implicit MOC / FVM
Flow regimes: Single & multiphase
Standards: API 1130 · ASME B31.4/8
Network size: 5,000+ km

Oil & Gas Pipelines

Multiphase transient flow assurance

01
Multiphase Transient Simulator
Drift-flux & two-fluid models for slugging, terrain and hydrodynamic slug prediction.
02
Hydrate Management
Hydrate formation curves, MEG/methanol inhibitor dosing and cool-down time analysis.
03
Wax & Asphaltene Deposition
WAT tracking, deposition rate modeling and pigging frequency optimization.
04
Pipeline Pack & Line Balance
Real-time inventory, linepack forecasting and compressor station scheduling.

Water & Slurry Pipelines

Hydraulic transient & network integrity

01
Surge & Water Hammer Analysis
Method of characteristics (MOC) solver for valve closure, pump trip and column separation.
02
Real-Time Leak Detection
API 1130-aligned model-based leak detection and localization with mass-balance validation.
03
Network Pressure Management
PRV and pump setpoint optimization to reduce leakage and non-revenue water.
04
Slurry Transport Design
Deposition velocity, rheology and wear modeling for long-distance concentrate & tailings lines.

04 / Energy Optimization

Cut energy per tonne without cutting production.

TwinOpt Energy couples process twins with power system models to find the lowest-energy operating point that still meets throughput, quality and integrity constraints.

Specific Energy Tracking
Live kWh/t, kWh/m³ and Sm³/MWh KPIs per asset, circuit and site, reconciled against metered data.
Tariff-Aware Load Scheduling
Shift pumping, grinding and storage to off-peak windows while honoring production targets.
Equipment Efficiency Benchmarking
Compare pumps, compressors and mills to their design curves to flag degradation early.
Carbon Intensity Reporting
Scope 1 & 2 emissions per unit of output with audit-ready reports for ESG disclosure.

Site energy profile · Concentrator 01

8.72 kWh/t

-12.1% vs baseline

Grinding (SAG + Ball)52%-9.4%
Slurry & water pumping21%-14.2%
Flotation air blowers12%-11.0%
Thickening & tailings8%-6.3%
Auxiliary services7%-3.1%

Rolling 30-day average · Reconciled against substation metering

See your plant's digital twin in action.

Our process engineers will walk you through a live RTO session built on a circuit like yours — and quantify the opportunity in a free value assessment.

Request Demo Field Experience

05 / Field Experience

Trusted on the ground at Asia's largest mines.

TwinOpt engineers have delivered process models, digital twins and real-time optimization for 28 operators across India, China and Southeast Asia — from coal preparation and iron ore beneficiation to copper concentrators and nickel processing.