Mineral Process Plant Optimisation Technology and Continuous Improvement

Mineral Process Plant Optimisation Technology and Continuous Improvement

Reliability, Energy Management, and Risk-Based Maintenance for Mineral Processing Plants

Claim 3 CPD Points

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Platform:
Online
In-class
Revised and Updated: 07 October 2026
Date Venue Duration
26 - 28 October 2026 Sandton, Gauteng 3 Days
25 - 27 January 2027 Sandton, Gauteng 3 Days
22 - 24 March 2027 Sandton, Gauteng 3 Days

Course Introduction

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

 

This requires effective management of maintenance operations and optimisation of equipment and plant reliability and availability. It also involves effective inspection and maintenance strategies and planning methods. Plant optimisation can be an effective way to achieve improved profitability. An important aspect of process plant optimisation relates to system energy management and energy consumption reduction — industrial processes and systems offer significant potential for savings. Process changes such as advanced controls and new technologies also present opportunities for plant optimisation.

Course Objectives

By the end of this Mineral Process Plant Optimisation Technology and Continuous Improvement course, delegates will be able to:

  • Understand the main elements of plant optimisation and how to achieve and realise its potential benefits
  • Enhance their business focus and be equipped to make a greater contribution to sustainable plant profitability
  • Select the most appropriate methodologies for maintenance decision-making, as maintenance professionals, planners, and engineers
  • Identify the potential for reduction of energy consumption
  • Apply practical and effective methods and tools to perform technical and economic evaluations of the alternatives available

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 requirements.

Who should attend?

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

  • Process Engineers
  • Plant Engineers
  • Mining and Production Engineers
  • Mechanical Engineers
  • Technicians and Operators
  • Project Engineers
  • Production Supervisors
  • Operations Managers
  • Maintenance Personnel
  • Engineering Managers
  • Engineering 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

Day 1 — Module 1: Optimisation Technologies and Plant Reliability
Session 1 — Overview of Optimisation Technologies
  • Overview of optimisation technologies for process plants
  • Elements of the process plant optimisation procedure
  • Constraints in optimisation: production, operation, economy, and environment
  • Optimisation approaches: mathematical models and physical models (prototype units)
  • Correlation between process optimisation and process control in a typical process plant
  • Case Study and Solutions
Session 2 — Reliability, Availability, and Effectiveness
  • Relationship between plant reliability and availability
  • Optimisation of plant reliability
  • Optimisation of plant availability through improved maintenance
  • Analysis of the effectiveness of individual equipment
  • Optimisation of overall plant effectiveness
  • Case Studies and Solutions
Session 3 — Case Study: Optimisation Technologies and Process Plant Reliability, Availability, and Effectiveness
  • Case Study: applying the optimisation, reliability, and availability concepts from Sessions 1 and 2 to a mineral processing plant scenario

Day 2 — Module 2: Energy Management and Mineral Processing Optimisation
Session 4 — Best Practices for Energy Consumption
  • Optimisation strategies aimed at energy consumption reduction
  • World standards and benchmarking guidelines
  • Best practices in process plant energy management
  • Energy conservation checklist for typical industrial plants
  • Optimisation of heat production and steam distribution and consumption
  • Case Studies and Solutions
Session 5 — Mineral Processing Optimisation Case Studies
    A significant part of this session is devoted to examples of the most common mineral separations, and the effect of variability on the current process plant, covering:
    • Sulphide minerals
    • Coal
    • Oxide minerals

Day 3 — Module 3: Maintenance Management and Risk-Based Decision-Making
Session 6 — Maintenance Management System
  • Optimisation of utilisation of piping systems and pipelines
  • Optimisation of utilisation of pumps, compressors, and fans
  • Optimisation of the maintenance management system and frequency of maintenance
  • Optimisation of spare parts management through predictive maintenance
  • Optimisation of repair and alteration programs in accordance with existing codes
  • Workshop: Examples and Solutions
Session 7 — Minimisation of Equipment Failure
  • Risk-Based Inspection (RBI), in line with API 580
  • Procedures for minimising the risk of equipment failure
  • Fitness-for-Service (FFS) analysis and estimation of remaining equipment life, in line with API 579
  • Optimisation of plant economy through planned equipment replacement
  • Summary and Course Review
Session 8 — Organisational Impact
  • Optimisation 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 session, delegates will be able to critically analyse the methodologies employed within their organisation and instigate improvements where required.
Session 9 — Closing, Course Review, and Open Table Discussion
  • A facilitated closing discussion for delegates to raise organisation-specific challenges and consolidate key takeaways from the course.

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FAQs – Mineral Process Plant Optimisation Technology and Continuous Improvement

Master mineral process plant optimisation, learning metallurgical circuit evaluation, process control technology, bottleneck analysis, throughput maximization, and continuous improvement strategies for mining plant efficiency.

What is covered in the Mineral Process Plant Optimisation, Technology, and Continuous Improvement Training?
The course covers mineral processing unit operations (comminution, flotation, leaching, and separation), process control technologies, plant bottleneck analysis, continuous improvement frameworks (Lean/Six Sigma), mass balancing, and resource efficiency.
Who should attend this Mineral Process Plant Optimisation Training?
This program is designed for process engineers, metallurgists, plant managers, extraction supervisors, chemical engineers, and continuous improvement specialists operating within the mining, metallurgy, and mineral processing sectors.
How does this course address bottleneck identification and plant throughput?
Participants learn systematically to conduct circuit audits, evaluate equipment performance parameters, apply mass balance equations, and pinpoint physical or operational bottlenecks to maximize throughput and recovery rates.
Will delegates learn about modern process control and automation technology in metallurgy?
Yes. The training explores advanced process control systems (APC), online slurry analysis, automated dosing technology, real-time data integration, and digital twin concepts used to stabilize plant operations.
Does the program cover sustainable mineral processing and energy efficiency?
Yes. Attendees learn strategies for reducing comminution energy consumption, optimizing water recirculation, minimizing chemical reagent usage, and decreasing the environmental footprint of tailings and effluent management.
Why is continuous improvement vital for mineral processing facilities?
Applying structured continuous improvement techniques ensures mineral plants remain profitable during ore grade fluctuations, lowers operating expenditures (OPEX), extends equipment lifespan, and maintains consistent target recoveries.

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