This practical course targets engineers, managers, technicians, operators, and support staff in mineral processing. Participants gain foundational knowledge to collaborate with specialists or manage metallurgical projects, without becoming experts.

“Effective problem-solving in mineral processing starts with asking the right questions. Understanding what to ask—about data, equipment performance, process variability, or material behavior—often determines the quality of the solution.”

This course introduces mineral processing in extractive metallurgy, focusing on concentrating valuable minerals from ores while linking ore characteristics, process selection, and metallurgical requirements to key factors such as grade, recovery, CAPEX/OPEX, and environmental compliance. Learners will apply core concepts to optimize comminution, classification, concentration, and upgrading processes. The course covers equipment selection, circuit design, materials handling, and the integration of technical, economic, and operational considerations to maximize efficiency and value. Health, safety, and environmental (HSE) principles, including risk mitigation are also emphasized.

Summary of Topics

• Introduction: Role of mineral processing in metallurgy; key definitions and mineral value classes.
• Comminution & Classification: Principles, efficiency factors, and liberation control.
• Separation & Concentration: Gravity, magnetic, electrical, and flotation processes.
• Circuit Integration & Equipment: Design balance, trade-offs, and optimization.
• Materials Handling: Flow, storage, and reliability links to efficiency.
• Process Economics & Sustainability: Energy, water, maintenance, and lifecycle value.
• Health, Safety & Environment: Risk identification and mitigation within mineral processing systems.

About the Author

Rudi Steyn holds a B.Eng. degree in Metallurgy from the University of Pretoria (specializing in extractive metallurgy) and has over 20 years of experience in the mining and metallurgical industry. He began his career at AngloGold Ashanti, progressing from management trainee to plant manager, with roles in both production and technical support across several gold plants, including international exposure at Sunrise Dam Gold Mine in Australia.

In 2006, he co-founded Stelios Project Management Pty Ltd, an EPCM consulting firm focused on mining and metallurgical projects. As Technical Director, he led process design, construction, and commissioning across gold, uranium, coal, and infrastructure projects.

He is also a co-founder of Stelios Group NPC, an NGO focused on community development, where he oversaw operations across projects in education, orphan care, and skills development. His combined expertise bridges technical expertise with a commitment to sustainable and community-driven development.

Learning Outcomes

1. Explain the role of mineral processing within extractive metallurgy and its relationship to mineral and metal beneficiation.
2. Understand key mineral processing concepts—mineralogy, liberation, sampling, mass balancing, size reduction, Work Index, and Abrasion Index—to optimize processing systems.
3. Describe the factors influencing comminution efficiency, differentiating between crushing, grinding, classification, concentration, and upgrading, and explain how these processes interact to create value within the mineral processing system.
4. Identify and describe specific equipment, components, and configurations, and evaluate their designs by analyzing trade-offs to optimize performance for various operational contexts and process requirements.
5. Explain the role of materials handling in supporting mineral processing efficiency.
6. Integrate technical process requirements with value drivers such as reliability, maintenance, and operational efficiency to ensure sustainable value creation.
7. Identify and assess physical, chemical, electrical, and gaseous or dust-related hazards, and recommend appropriate safety and risk mitigation measures within mineral processing systems.

Duration: 15 Hours

Category: Mineral Processing

Level: Intermediate