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Mineral Process Plant Optimisation Technology and Continuous Improvement

3 Day Training

Dates: 17 – 19 July 2024
Locations: Johannesburg, South Africa
Platform: Available In-Class / Online

Price: Available on Request

Claim 3 CPD Points

Course Introduction

Process Plant Optimisation plays very important role in today’s industrial world. For optimisation benefits to be substantial, cost of production including operation interruptions must be kept to a minimum.


This requires effective management of maintenance operations and optimisation of equipment and plant reliability and availability. This also involves effective inspection and maintenance strategies, planning methods. Plant optimisation can be an effective way to achieve improved profitability. Important aspect of process plant optimization is related to system energy management and energy consumption reduction. Industrial processes and systems offer significant potentials for savings. Process changes such as advanced controls and new technologies also present opportunities for plant optimization.

Course Objectives

  • Understanding the main elements of plant optimization, the way how to achieve and realize potential benefits.

  • Enhance the business focus of participants and equip them to make more contributions to sustainable plant profitability.

  • Equipping maintenance professionals, planners, and engineers with the knowledge to select the most appropriate methodologies for their maintenance decision-making.

  • Learning how to identify the potential for reduction of energy consumption.

  • Providing participants with practical and effective methods and tools to perform technical and economic evaluations of the alternatives.

Continuing Professional Development (CPD)

Registered participants who attend the entire short course and complete an evaluation at the end of the course will receive a Certificate of Attendance and competence (subject to a test if required), confirming the Professional Development Hours or Continuing Education Units earned as per ECSA requirement.

Who should attend?

This Mineral Process Plant Optimisation Technology and Continuous Improvement is best suited for:

  • Process Engineer

  • Plant Engineer

  • Mining and production Engineer

  • Mechanical Engineer

  • Technicians and Operators

  • Project Engineer

  • Production Supervisor

  • Operations Manager

  • Maintenance Personnel

  • Engineering Manager

  • Engineer and technical personnel involved in improving process plant profitability and energy efficiency

Technical courses

Training Methodology

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.
– Course Material: Access well-crafted supporting resources.
– Group Work: Collaborate on discussions and case studies for practical insights.
– Workshops & Role-Play: Participate in immersive, scenario-based activities.
– Practical Application: Focus on applying theoretical knowledge in real situations.
– Post-Training Support: Receive extensive support after training for skill implementation.

Training Outline


Session 1 – Overview of Optimization Technologies

  • Overview of optimization technologies for process plants

  • Elements of process plant optimization procedure

  • Constraints in optimization: production, operation, economy and environment

  • Optimization approaches: mathematical models and physical models – prototype units

  • Correlation between process optimization and process control in typical process plant

  • Case study and solutions

Session 2- Reliability, Availability and Effectiveness

  • Relationship between plant reliability and availability

  • Optimization of plant reliability

  • Optimization of plant availability through improved maintenance

  • Analysis of effectiveness of individual equipment

  • Optimization of overall plant effectiveness

  • Case Studies and solutions

Session 3 – case study ton Optimization Technologies and Process Plant Reliability, Availability and E­ffectiveness


Session 4 – Best Practices for Energy Consumption

  • Optimization strategies aimed at energy consumption reduction

  • World standards and benchmarking guidelines

  • Best practices in process plant energy management

  • Energy conservation check list in typical industrial plants

  • Optimization of heat production and steam distribution and consumption

  • Case Studies and Solutions

Session 5- Mineral Processing Optimisation case studies

A significant part of the case studies will be devoted to examples of most common Mineral separations of:

  • Sulphide minerals,

  • coal,

  • oxide minerals,

  • and variabilities effect to the current Process plant


Session 6 – Maintenance Management System

  • Optimization of utilization of piping systems and pipelines

  • Optimization of utilization of pumps, compressors, and fans

  • Optimization of maintenance management system and frequency of maintenance

  • Optimization of spare parts management through predictive maintenance

  • Optimization of repair and alteration programs in accordance with existing codes

  • Workshop: Examples and Solutions

Session 7 – Minimization of Equipment Failure

  • Risk based inspection (RBI)

  • Procedures for minimizing risk of equipment failure

  • Fitness for service (FFS) analysis and estimate of remaining life of equipment

  • Optimization of plant economy through planned equipment replacement

  • Summary and course review

Session 8- Organisational Impact

Optimization of process plant operation, including equipment efficiency, energy consumption and maintenance management, is vital to the budgetary success of the organisation. On completion of this seminar, the delegates will be able to critically analyse the methodologies employed within the organisation and instigate improvements where required.

Session 9- closing and course review and open table discussion

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