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Use case 073

Mineral Processing Plant HMIs

A deployment concept for mining companies, mineral processors, plant integrators and metallurgy teams.

Proposed deployment · Compatibility assessment required
Energy, Utilities and Resources

Why this environment matters

For mineral processing plant HMIs, the system allows operators to monitor crushers, mills, flotation, separation and material handling. The risk extends beyond a conventional endpoint: malware or malicious setpoint changes can damage equipment, reduce recovery or create unsafe process interactions. A NØNOS deployment concept would treat every software component, data source and device interface as separately authorised rather than assuming that anything running on the host should be broadly trusted.

The security challenge

Energy and resource systems combine high-energy equipment, geographically distributed assets and operational technology that cannot be patched or restarted like an ordinary office computer. In mineral processing plant HMIs, the decisive risk is that malware or malicious setpoint changes can damage equipment, reduce recovery or create unsafe process interactions. Even strong perimeter controls may not help once authorised software, a vendor tool or a valid user session has been compromised. Internal permission boundaries must remain enforceable after initial access.

How the capsule model could help

For this system, NØNOS could provide signed operator applications, isolated recipe and historian functions, and explicit control rights per process area. The design would combine minimal persistent administration state, a verified boot chain, signed control capsules and zone-specific capabilities. The intended result would be a set of small trust boundaries instead of one large operating environment where every service inherits broad ambient access.

Separate address spaces and capability checks can limit cross-process reach. They cannot stop harmful use of legitimate permissions, prove AI decisions correct or substitute for domain-specific safety controls.

Deployment requirements

Deployment would require site-specific engineering, segregation from independent protection systems, deterministic performance testing, change control and compliance review. NØNOS would not replace certified relays or safety systems by default.

Current public-beta limitations, hardware support and application availability must be assessed before any pilot. Neither this use case nor an industry source establishes NONOS certification or a current customer deployment.

Who could buy or integrate it?

  • Mine owners and mineral processors procuring operator environment upgrades
  • Mineral processing OEMs embedding HMIs in equipment packages
  • Plant automation integrators delivering process-area control systems

Industry examples: Metso, FLSmidth. Organisations shown illustrate the industry. No NONOS customer, partner or endorsement relationship is implied.

Market opportunity

Market benchmarks and device scenarios.

Published industry benchmark
US$6.2 billion

Mining automation

Global · 2025 · annual market estimate

Equipment automation, software automation and services across metal, mineral and coal mining.

Modelled global devices
30K–750K

Candidate OS endpoints

Hypothetical planning range · 2025

Low confidence: planning assumptions. Hardware compatibility, procurement and adoption have not been validated.

Illustrative annual licensing
$3M–$300M

USD / year at full model coverage

Device scenario × assumed US$100–$400 per device / year.

Not a revenue forecast, announced price or measured serviceable market.

Device calculation

Hypothetical global planning range, 2025 scenario: assume 10,000–50,000 mineral processing and concentrator facilities × 3–15 candidate OS endpoints per site/asset = 30,000–750,000 endpoints. Counting unit: operator/engineering HMI computers. Site and asset counts, and devices per site, are planning assumptions. The installed base has not been measured. Coverage is limited to the defined equipped subset; includes all candidate endpoints within that assumed subset. Hardware eligibility, certification, adoption and achievable NØNOS share are unverified; overlaps other cases.

Mining Automation Market Size, Share Report, 2026-2033 ↗

Market context only; separate from device and site population estimates. Original monetary-market scope and geography are preserved in benchmark. This source does not establish the assumed worldwide site count or endpoint density.

How to interpret the figures

Adjacent or broader commercial market benchmark; not the NØNOS OS market, licensable-device count or revenue forecast.

Modelled candidate endpoints multiplied by an assumed annual USD price per endpoint. Pricing is a planning assumption, not a vendor quote. This illustrates the full scenario range, not revenue or total addressable market. It excludes adoption timing, procurement, certification, support costs, channel economics and achievable market share. Use cases can overlap, so their totals do not represent unique devices.

Research from 2026. Publisher estimates have not been independently audited.

Read the full methodology

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