Mining less waste and more value with AI-driven insights

Nexa Resources is a global leader in the mining industry, specializing in the extraction and processing of non-ferrous metals, such as zinc and copper. With operations in several countries, Nexa is committed to innovation, sustainability and operational excellence. However, the organization faced significant challenges with their legacy data architecture and centralized operational model. Data and AI expertise were confined to the IT team, which created bottlenecks for innovation and restricted business units’ ability to independently leverage data for decision-making. This also led to fragmented data ownership and a lack of governance across departments, limiting Nexa’s ability to democratize data access and insights.

Nexa relied on a traditional architecture to organize and analyze structured data. However, this setup became increasingly unsuitable for handling the exponential growth in data volumes. The lack of seamless integration between data engineering and machine learning (ML) tools created silos, hindered team collaboration and delayed workflows. This inefficiency led to higher costs and slower time to market for analytics and machine learning models.

Nexa recognized that to remain competitive in the mining sector, it needed to transition to a modern, scalable and unified data platform. The goal was to address immediate inefficiencies while building the foundation for a scalable, AI-driven future. The Databricks Data Intelligence Platform stood out as the ideal choice, offering a unified solution with an intuitive interface, dedicated support and the flexibility of open source technologies. “Databricks was a turning point for us, allowing us to transition from a fragmented, centralized system to a unified, scalable platform that drives collaboration and innovation. Their support and tools showed us a new way to work with and present data across Nexa,” Vinicius Santos, Data and Digital Service Manager at Nexa, said.

Databricks provided a unified solution that seamlessly integrated data engineering, analytics and AI, enabling Nexa to consolidate fragmented systems and foster collaboration and innovation across the organization. Nexa divided their data transformation journey into two key phases: enabling foundational capabilities and delivering impactful use cases. The first phase focused on creating a robust infrastructure to address governance, security and operational bottlenecks. A key component of this modernization was the implementation of Delta Lake, which introduced a medallion architecture to structure data into raw, cleaned and ready-for-analysis layers. This architecture allowed Nexa to efficiently process large volumes of data from diverse sources, such as sensors in manufacturing operations. By eliminating data silos, Delta Lake enabled centralized yet flexible data access, improving consistency and reliability for predictive analytics and business intelligence.

SQL Serverless workflows further enhanced automation by orchestrating data pipelines and automating repetitive tasks. This capability reduced operational overhead, allowing data engineers to focus on strategic projects. The serverless architecture also ensured scalability and cost efficiency, as resources were allocated only when needed.

Next, Nexa deployed Unity Catalog, which provided a centralized system for managing access permissions, data lineage and compliance. Unity Catalog empowered business units across HR, supply chain, ESG and operations to independently access and analyze data while maintaining strict governance protocols. This decentralization allowed teams to make data-driven decisions without relying heavily on IT, fostering a culture of autonomy and innovation. The addition of an ingestion framework improved productivity, standardization and data quality, reducing development cycles by 300% and providing the agility required for faster innovation.

The second phase of Nexa’s transformation focused on delivering impactful solutions and practical applications through the Databricks Platform. By developing a robust data and AI platform that integrated DataOps, ML and LLMOps pipelines, Nexa enabled advanced analytics across the organization. Using MLflow, the company streamlined the machine learning lifecycle, ensuring efficiency, traceability and faster iteration, while Mosaic AI facilitated the integration of pretrained models like GPT-4 and Llama 3.1, accelerating the development of custom AI applications tailored to their needs. These advancements empowered Nexa to scale AI capabilities across departments, enhancing operational efficiency, supporting teams with actionable insights and enabling executives to make informed, data-driven decisions.

The adoption of Databricks not only resolved Nexa’s technological challenges but also fundamentally transformed how teams worked with data. As Jose Carlos Santos, Tech Lead, Data and AI, at Nexa, observed, “Databricks has given us the ability to integrate governance, analytics and AI seamlessly. It has completely changed how we view and use data, allowing us to unlock new levels of productivity and innovation.” 

One of the most impactful results was the optimization of key operational processes. Predictive models for zinc filtration and cadmium removal, developed and deployed using Databricks, generated combined annual savings of $370,000. These models not only enhanced resource utilization but also reduced waste and improved overall process efficiency. 

Automation was another major area of impact. Nexa implemented AI agents to address various operational challenges. For example, the AI-powered IT supplier contract analysis tool reduced processing time by 800%, enabling faster decision-making and freeing up resources for more strategic initiatives. Similarly, the digital library agent allowed employees to instantly access critical operational guidelines, manuals and policies through natural language search, boosting productivity and simplifying workflows. In the health and safety domain, AI agents provided real-time insights, such as safety equipment requirements and accident analysis, helping to enhance workplace safety and ensure regulatory compliance.

Beyond financial and operational benefits, Databricks’ scalable and unified platform enabled Nexa to integrate governance, analytics and AI into a cohesive framework, providing a foundation for long-term innovation and growth. Reflecting on the journey, Nexa’s leadership emphasized how the platform has fundamentally transformed their operations. Jose noted, “Databricks has completely changed how we view and use data, allowing us to unlock unprecedented levels of productivity and innovation.” By embracing a data-driven culture, Nexa has not only addressed immediate operational inefficiencies but also laid the groundwork for a future where AI and analytics play a central role.