Manufacturing, Engineering and Technology Fabrication and Extraction

Mineral Processing Activities In Mining And Minerals Sector Training

SAQA US 110430 | NQF 1 | Credits 14 | Duration 11 Days
From $2,074 per delegate

Description

This course equips learners with the fundamental knowledge and skills required to perform mineral processing activities within the mining and minerals sector. It covers key processes such as crushing, grinding, screening, and classification, emphasizing operational efficiency, safety, and quality control. The training ensures compliance with South African mining regulations and industry best practices.

Learning Outcomes

  • Apply basic principles of mineral processing to crushing, grinding, and screening operations.
  • Demonstrate safe operating procedures for mineral processing equipment and machinery.
  • Analyze process parameters to optimize recovery and product quality.
  • Implement quality control measures and sampling techniques in mineral processing.
  • Evaluate environmental and health impacts of mineral processing activities.
  • Interpret process flow diagrams and standard operating procedures.

Target Audience

This course is designed for entry-level and experienced operators, process controllers, and technicians working in mineral processing plants within the mining and minerals sector.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Introduction to Mineral Processing and the Mining Sector

Objectives:
• Define mineral processing and its role in the mining value chain
• Identify key stakeholders in the South African mining and minerals sector
• Describe the regulatory framework governing mineral processing activities
• Recognize the importance of safety and environmental stewardship

Topics:
• Overview of the mining and minerals sector in South Africa
• Stages of the mining value chain: exploration, extraction, processing, beneficiation
• Key legislation: MHSA, MPRDA, NEMA
• Role of SAQA and unit standards in skills development
• Introduction to mineral processing terminology

Day 2: Ore Characteristics and Sampling

Objectives:
• Explain the importance of ore characterization in process selection
• Describe sampling methods and techniques for quality control
• Perform basic calculations for grade and recovery
• Identify factors affecting sample representivity

Topics:
• Types of ores: metallic, non-metallic, industrial minerals
• Ore mineralogy and liberation
• Sampling theory: principles of representivity
• Sampling methods: grab, channel, core, and bulk sampling
• Sample preparation: crushing, splitting, pulverizing
• Introduction to mass balance calculations

Day 3: Comminution – Crushing and Grinding

Objectives:
• Differentiate between crushing and grinding stages
• Describe types of crushers and mills used in mineral processing
• Explain factors affecting comminution efficiency
• Calculate reduction ratios and energy consumption

Topics:
• Comminution theory: fracture mechanics, work index
• Primary, secondary, and tertiary crushing: jaw, gyratory, cone crushers
• Grinding mills: rod, ball, SAG, AG mills
• Classification: screens and hydrocyclones
• Closed-circuit vs open-circuit operations
• Energy considerations in comminution

Day 4: Sizing and Classification

Objectives:
• Explain the purpose of sizing and classification in mineral processing
• Compare screening and classification equipment
• Perform particle size analysis using sieving and sedimentation
• Interpret particle size distribution curves

Topics:
• Particle size analysis: sieving, laser diffraction, sedimentation
• Screening: vibrating screens, trommels, grizzlies
• Classification: hydrocyclones, spirals, classifiers
• Efficiency of classification: partition curves
• Cut size and sharpness of separation
• Applications in dewatering and closed-circuit grinding

Day 5: Gravity Concentration

Objectives:
• Describe principles of gravity separation based on density differences
• Identify equipment used for gravity concentration
• Explain factors affecting separation efficiency
• Calculate recovery and grade from gravity circuits

Topics:
• Principles of gravity separation: settling velocity, hindered settling
• Jigs, spirals, shaking tables, centrifugal concentrators
• Dense medium separation: heavy liquids, dense medium cyclones
• Applications for coal, diamonds, gold, and heavy minerals
• Operating parameters: feed rate, water flow, pulp density
• Troubleshooting common issues

Day 6: Flotation

Objectives:
• Explain the principles of froth flotation and its role in mineral processing
• Identify key reagents: collectors, frothers, modifiers
• Describe flotation circuit design and operation
• Interpret flotation kinetics and performance indicators

Topics:
• Surface chemistry fundamentals: hydrophobicity, contact angle
• Flotation reagents: collectors, frothers, depressants, activators
• Flotation machines: mechanical, pneumatic, column cells
• Flotation circuits: rougher, scavenger, cleaner stages
• Factors affecting flotation: particle size, pulp density, pH
• Flotation kinetics and grade-recovery curves

Day 7: Magnetic and Electrostatic Separation

Objectives:
• Explain principles of magnetic and electrostatic separation
• Differentiate between types of magnetic separators
• Describe applications for ferromagnetic and paramagnetic minerals
• Identify factors affecting separation efficiency

Topics:
• Magnetic properties: ferromagnetic, paramagnetic, diamagnetic
• Low-intensity and high-intensity magnetic separators
• Wet vs dry magnetic separation
• Electrostatic separation: principles and equipment (plate, screen, drum)
• Applications: iron ore, ilmenite, rutile, zircon
• Operating parameters and maintenance

Day 8: Dewatering and Solid-Liquid Separation

Objectives:
• Explain the importance of dewatering in mineral processing
• Describe thickening, filtration, and drying processes
• Calculate moisture content and solids recovery
• Identify factors affecting dewatering efficiency

Topics:
• Thickening: sedimentation, thickener types, flocculants
• Filtration: vacuum, pressure, and centrifugal filters
• Drying: rotary dryers, spray dryers, fluidized bed dryers
• Factors: particle size, cake permeability, pressure differential
• Water recovery and tailings management
• Environmental considerations in dewatering

Day 9: Hydrometallurgy and Leaching

Objectives:
• Explain principles of leaching and hydrometallurgical extraction
• Describe leaching methods: heap, vat, in-situ, agitation
• Identify factors affecting leaching kinetics and recovery
• Discuss solvent extraction and electrowinning basics

Topics:
• Hydrometallurgy overview: leaching, SX, EW
• Leaching reagents: cyanide, sulfuric acid, ammonia
• Heap leaching: design, operation, environmental controls
• Vat and agitation leaching
• Factors: temperature, pressure, particle size, reagent concentration
• Gold and copper leaching case studies

Day 10: Process Control and Optimization

Objectives:
• Explain the role of process control in mineral processing
• Describe common sensors and instrumentation
• Interpret process data for optimization
• Apply basic statistical process control (SPC) techniques

Topics:
• Process control fundamentals: feedback, feedforward, PID
• Sensors: density, flow, level, pH, particle size analyzers
• Control loops for grinding, flotation, and thickening
• Data acquisition and SCADA systems
• Statistical process control: control charts, capability analysis
• Optimization strategies: throughput, recovery, grade

Day 11: Integrated Plant Operations and Quality Assurance

Objectives:
• Integrate knowledge from previous days into a holistic plant perspective
• Develop a basic plant flowsheet for a given ore type
• Discuss quality assurance and quality control (QA/QC) in processing
• Apply safety and environmental best practices

Topics:
• Flowsheet development: from ore to final product
• Mass and water balance calculations
• QA/QC: sampling protocols, laboratory analysis, metal accounting
• Plant troubleshooting and debottlenecking
• Safety: lock-out/tag-out, confined space, hazard identification
• Environmental management: tailings storage, water management
• Case study: integrated plant simulation

Practicals

32 hours of practicals To be conducted online or on-campus or in-house
Overview

Hands-on practicals are essential to reinforce theoretical concepts and develop skills in operating, monitoring, and troubleshooting mineral processing equipment. Learners will engage in simulated and lab-scale activities covering sampling, comminution, gravity separation, flotation, and dewatering.

Practical Activities
  • Practical 1: Sampling and Particle Size Analysis — Learners collect samples from a simulated stockpile, split using a riffle splitter, and perform sieve analysis to determine particle size distribution. (6h)
  • Practical 2: Comminution – Crushing and Grinding — Learners operate a laboratory jaw crusher and ball mill, adjust settings, and measure power consumption and product size. (8h)
  • Practical 3: Gravity Separation and Flotation — Learners run a shaking table and a laboratory flotation cell, adjusting feed rate, water flow, and reagent dosage to optimize recovery. (10h)
  • Practical 4: Dewatering and Thickening — Learners perform a settling test using a graduated cylinder and flocculant, then operate a laboratory vacuum filter to dewater a slurry. (4h)
  • Practical 5: Process Control Simulation — Learners use a simulated SCADA system to monitor and adjust a grinding circuit, responding to disturbances and optimizing throughput. (4h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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