Mineral Processing Plant Operator Course

Lesson 1 • Operator Roles and Responsibilities

Defines the duties, shift structure, and accountability of a plant operator. Frames professional conduct expectations throughout the course.

Lesson 2 • Ore Types and Mineral Properties

Covers physical and chemical properties of common ore types and gangue minerals. Establishes the material basis for all downstream processing decisions.

Lesson 3 • Health, Safety, and Environmental Basics

Establishes core safety principles and environmental obligations relevant to mineral processing. Provides the compliance mindset required before entering any plant area.

Lesson 4 • Plant Layout and Equipment Familiarization

Introduces major equipment categories and their physical arrangement in a typical plant. Helps operators navigate the facility and understand material flow paths.

Lesson 1 • Screening Equipment and Classification

Teaches vibrating screen operation and screen efficiency measurement. Ensures operators can maintain correct cut sizes for downstream processes.

Lesson 2 • Jaw and Gyratory Crusher Operation

Covers startup, shutdown, and steady-state operation of primary crushers. Links crusher settings to downstream feed size requirements.

Lesson 3 • Cone and Impact Crusher Operation

Addresses secondary and tertiary crushing equipment used to achieve finer product sizes. Connects crusher selection to ore hardness and circuit design.

Lesson 4 • Principles of Size Reduction

Explains comminution theory, energy input, and breakage mechanisms. Provides the technical basis for selecting and adjusting crushing equipment.

Lesson 1 • SAG Mill Operation and Control

Addresses the unique operating challenges of semi-autogenous grinding mills. Builds on ball mill knowledge to handle variable ore hardness and load management.

Lesson 2 • Grinding Theory and Mill Types

Explains liberation size, grinding media action, and mill design differences. Provides the conceptual foundation for all grinding circuit decisions.

Lesson 3 • Hydrocyclone and Spiral Classifier Use

Teaches classification equipment operation and its role in controlling grinding circuit product size. Links classifier overflow to flotation or leach feed specifications.

Lesson 4 • Grinding Circuit Optimization

Integrates mill and classifier variables into a circuit-level performance framework. Prepares operators to diagnose inefficiencies and apply corrective actions.

Lesson 1 • Flotation Cell Types and Setup

Covers mechanical and column flotation cell designs and their operating differences. Connects cell selection to circuit objectives and ore type.

Lesson 2 • Air and Froth Management

Addresses airflow rate, froth stability, and froth removal as key operating levers. Ensures operators can visually assess and adjust froth quality in real time.

Lesson 3 • Reagent Addition and Control

Teaches dosing, mixing, and monitoring of flotation reagents. Links reagent control to recovery, grade, and operating cost outcomes.

Lesson 4 • Flotation Principles and Chemistry

Explains surface chemistry, bubble-particle attachment, and selectivity mechanisms. Provides the scientific basis for all reagent and operating variable decisions.

Lesson 1 • Solution Purification and Metal Recovery

Covers solvent extraction, electrowinning, and precipitation for final metal recovery. Connects solution quality to product purity and downstream refining requirements.

Lesson 2 • Heap Leach Pad Operation

Addresses ore stacking, solution application, and drainage management for heap leach systems. Links pad management to metal recovery and solution inventory control.

Lesson 3 • Agitated Tank Leach Operation

Covers startup, steady-state control, and shutdown of agitated leach tanks. Connects tank operating variables to extraction efficiency and reagent consumption.

Lesson 4 • Carbon-in-Leach and Carbon-in-Pulp Circuits

Teaches carbon adsorption, elution, and regeneration in gold recovery circuits. Builds on leach fundamentals to cover the full gold extraction sequence.

Lesson 1 • Drying and Thermal Processing

Covers rotary dryer and fluid bed dryer operation for final moisture reduction. Links drying parameters to product quality and energy consumption.

Lesson 2 • Water Recovery and Recycle Management

Integrates thickener overflow, filtrate, and process water into a plant water balance. Prepares operators to minimize fresh water use and manage water quality.

Lesson 3 • Thickener Operation and Control

Covers feedwell design, flocculant addition, and underflow density control in thickeners. Links thickener performance to water recovery and downstream filter feed quality.

Lesson 4 • Centrifuge and Screen Bowl Operation

Addresses high-speed centrifugal dewatering for fine and coarse products. Builds on filtration knowledge to cover mechanical dewatering alternatives.

Lesson 1 • Tailings Storage Facility Operation

Addresses embankment construction methods, beach management, and decant control. Links operational decisions to long-term facility stability and safety.

Lesson 2 • Tailings Reprocessing and Closure

Introduces tailings retreatment opportunities and progressive rehabilitation practices. Connects end-of-life planning to environmental compliance and community obligations.

Lesson 3 • Tailings Characterization and Classification

Covers physical, chemical, and geotechnical properties of tailings streams. Establishes the material knowledge needed for safe storage and disposal decisions.

Lesson 4 • Geotechnical Monitoring and Inspection

Covers instrumentation, visual inspection, and trigger action response plans for tailings facilities. Prepares operators to detect early warning signs of instability.

Lesson 1 • Advanced Process Control Concepts

Introduces model-predictive control, expert systems, and online analyzers for circuit optimization. Builds on DCS knowledge to prepare operators for automated plant environments.

Lesson 2 • Instrumentation and Measurement Systems

Covers flow, density, pressure, and level measurement devices used throughout the plant. Provides the sensor knowledge needed to interpret and trust control system data.

Lesson 3 • Distributed Control System Operation

Teaches DCS interface navigation, alarm management, and setpoint adjustment. Connects control room actions to physical process outcomes across all circuits.

Lesson 4 • Plant-Wide Troubleshooting and Optimization

Integrates all circuit knowledge into systematic fault diagnosis and performance improvement. Prepares operators to lead shift-level optimization and respond to complex upsets.