Fundamentals of Mineral Processing and Extractive Metallurgy

The extraction of valuable metals from ores is both an art and a science, requiring a deep understanding of mineral processing principles and innovative technologies. This intensive 5-day course is designed to equip participants with advanced knowledge and practical skills in comminution, separation techniques, precious metals extraction, and tailings management. Through a blend of theoretical insights, hands-on tools like METSIM and HSC Chemistry, and analytical methods such as XRD and SEM-EDS, participants will gain the expertise needed to maximize metal recovery while minimizing waste and operational costs. Whether you’re a seasoned professional or a newcomer to the field, this course will empower you to tackle real-world challenges in extractive metallurgy.

Audience

This course is designed for:

Process engineers and metallurgists working in mining and mineral processing industries.
Plant managers and operators seeking to optimize operations.
Researchers and academics focusing on mineral processing and extractive metallurgy.
Environmental specialists involved in tailings management and sustainability initiatives.

Course objectives

Upon completion of this course, participants will be able to:

Understand the fundamentals and optimization strategies for comminution processes (crushing, grinding, SAG/Ball mills).
Master separation techniques such as froth flotation, magnetic separation, and leaching methods.
Gain proficiency in precious metals extraction, including cyanidation, electrowinning, and PGM recovery.
Learn best practices for tailings management, including dry-stack tailings and geochemical stability.
Develop hands-on skills using process simulation software (METSIM, HSC Chemistry) and analytical tools (XRD, SEM-EDS).
Be equipped to design and implement cost-effective, environmentally sustainable mineral processing solutions.

Course contents

Day-1: Fundamentals of Comminution

Introduction to Comminution – Crushing vs. grinding, energy efficiency, particle size distribution impact, SAG and Ball mill overview.
Optimization Techniques – SAG/Ball mill performance improvement, liner wear effects, and advanced control systems.
Case Study & Practical Exercise – Optimizing a SAG mill for energy savings, METSIM grinding circuit simulation.
Key Technologies & Innovations – Advanced mill configurations and wear-resistant materials.
Assessment – Quiz on comminution fundamentals and optimization strategies.

Day-2: Separation Techniques – Froth Flotation & Magnetic Separation

Froth Flotation Basics – Principles, reagent selection, and flotation cell operation.
Magnetic Separation Fundamentals – Theory, high- vs. low-intensity separators, and process integration.
Optimization & Case Study – Enhancing copper recovery through flotation improvements.
Hands-on Learning – SEM-EDS mineral surface analysis for process optimization.
Assessment – Quiz on flotation reagents and magnetic separation properties.

Day-3: Leaching Techniques – Heap, Vat, and In-Situ

Heap Leaching Fundamentals – Design, operation, and factors affecting kinetics and recovery.
Vat & In-Situ Leaching – Applications, environmental considerations, and bioleaching innovations.
Case Study & Practical Application – Optimizing a gold heap leaching project and vat leaching simulation with HSC Chemistry.
Emerging Technologies – Advances in pressure oxidation and microbial leaching techniques.
Assessment – Quiz on leaching parameters and recovery rates.

Day-4: Precious Metals Extraction – Cyanidation, Electrowinning, and PGM Recovery

Cyanidation Process – Chemistry, safety, and CIP/CIL circuit challenges.
Electrowinning & PGM Extraction – Principles, refining techniques, and emerging trends.
Process Optimization & Troubleshooting – CIP circuit case study for improved gold recovery.
Modeling & Simulation – Using METSIM to model electrowinning efficiency.
Assessment – Quiz on cyanide detoxification and PGM recovery techniques.

Day-5: Tailings Management & Final Assessment

Sustainable Tailings Solutions – Dry-stack benefits, reprocessing opportunities, and environmental risks.
Storage Facility Best Practices – Design, compliance, and community engagement.
Strategic Planning – Developing a sustainable tailings management strategy.
Final Assessment – Written test covering all training topics.
Course Wrap-Up – Group discussion, feedback session, and certification distribution.

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