Metso Geminex

Geminex is Metso's metallurgical digital twin platform, launched in March 2022 and winner of the Mining Magazine 2022 Software Award. It combines operational data from plant sensors and external sources with Metso's proprietary HSC first-principle process models — dynamic simulations calibrated with live plant data and continuously refined by machine learning algorithms. Unlike purely data-driven approaches, Geminex uses mechanistic models of physical and chemical processes, meaning it can produce reliable predictions even in operating regimes not previously encountered.

The platform generates soft sensors — derived measurements that cannot be obtained from physical instruments but are calculated through dynamic process models — providing insight into process conditions that would otherwise be unobservable. Geminex enables scenario simulation, operator training, production planning optimisation, and what-if analysis across minerals processing, pyrometallurgical, and hydrometallurgical operations. Deployments at Dundee Precious Metals' Ada Tepe mine have contributed to gold recovery milestones, and recent work at Newmont Lihir has demonstrated mine-to-mill optimisation using digital twin technology.

Geminex is designated a Metso Planet Positive product for its sustainability benefits, including reduced energy consumption and improved resource efficiency. The platform continues to expand into DRI smelting and other metallurgical applications.