Optimizing Cement Paste Backfill Process at Tomingley Gold Operations – Setting a New Benchmark for Sustainable Mining Performance

In modern underground mining, backfilling plays a dual role: stabilizing mine cavities and minimizing surface environmental impact by storing tailings underground. Yet, for most operations, cemented paste backfill (CPB) remains one of the most cost-intensive and quality-sensitive processes.

At the Tomingley Gold Operations, the paste backfill system handles the transport and mixing of tailings with binder material to produce a durable, pumpable paste. However, achieving the right paste strength consistently while minimizing cement usage proved challenging. Fluctuating tailings properties, variable feed moisture, and limited visibility into process interactions often led to overconsumption of binder, escalating operational costs.

Alkane Resources set an ambitious goal: to understand, predict, and control the CPB process with scientific precision, not operational intuition.

Alkane selected Bosch Digital Twin Industries (BDTI) for its ability to combine engineering knowledge with hybrid physics and AI models that deliver measurable and explainable results. Bosch offered an industrial platform that integrates plant data, lab results, and process logic into one decision system.

Both teams worked together to build a digital twin for the Cement Paste Backfill process at Tomingley. The solution predicts paste strength, optimizes binder usage, and gives clear visibility into tailings variability.

BDTI brings four clear advantages:

• Hybrid AI physics models that provide explainable insights
• Deep process engineering experience in complex industrial operations
• A validated and scalable cloud platform
• Fast configuration for mining plants and easy integration with existing systems

Bosch Digital Twin Industries used a practical, outcome focused approach.

The work focused on three areas:

1. A deep view of the process

We worked with Alkane to understand how tailings, moisture and plant settings influence paste quality. This helped define the right inputs for reliable predictions.

2. One connected data system

Plant data, lab results and operations information were brought together in one place. This created a clean and consistent data foundation for the digital twin.

3. A hybrid model built for real operations

The twin uses a mix of physics and AI to predict strength and workability. It also shows how changes in the plant will influence quality and cost. This gives operators clear insight into what actions matter most.

1. Cement cost savings with clear numbers

• Alkane spends around AUD 4 million each year on cement for paste backfill.
• The digital twin enables up to 25 percent reduction in binder use.
• This equals a potential annual saving of around AUD 1 million.

2. Strength prediction without waiting days

• Strength testing at 7, 14 and 28 days is slow and depends on lab samples.
• The digital twin provides early prediction of UCS using live data.
• This removes long wait times and allows immediate process corrections.

3. Better control and visibility across the plant

• All tailings, lab and process data now sit in one place.
• Operators and engineers have a single view of workability and strength.
• This reduces rework, improves decision making and cuts variability.

4. Operational time saved

• The previous workflow relied on multiple data sources and lab cycles.
• The digital twin cuts repeated test cycles and reduces manual checks.
• This gives the team more productive hours each week.

5. Lower carbon footprint

• Less cement use lowers emissions linked to binder production.
• The reduction aligns with Alkane sustainability targets.

For Alkane, this digital project has become an operational unlock.

Bosch digital twin at Tomingley is now a continuously learning system. As more data flows in, its predictive accuracy increases, its recommendations sharpen, and its optimization value compounds.

Upcoming phases aim to introduce:

• Prescriptive process control
• Energy optimization
• Multi-site replication
• Semi-autonomous CPB decision support

Get in touch if you want to explore where this fits in your operation. We can help you identify where a digital twin can reduce cost, improve prediction and lift operational stability.

Bosch Digital Twin Industries empowers global industries with physics-infused, explainable digital twins built for high-stakes environments. By combining high-fidelity simulations with advanced AI, BDTI enables customers to enhance reliability, optimize cost, and unlock sustainable performance across Metals, Mining, Energy, Utilities and Manufacturing industries.

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