832 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
Process characterization involves analyzing actual
plant performance from many perspectives. Different
approaches are intended to identify problems and
factors driving plant performance. For example, pro-
cess instability and decreasing process performance
result in improvement projects.
Modeling and Simulation involves model building
and exploration of different operating conditions to
identify improved conditions for plant operations.
Efficiency Analysis considers the efficiency of opera-
tions in comparison to laboratory testing and bench-
marking vs. similar operations to identify opportuni-
ties for improvement and possible paths to improve-
ment, e.g., best practice.
Geomet identifies operating conditions for process-
ing different ore types, identifies when the ore types
will be fed to the plant and ensures the best operating
conditions are used to process each ore type.
Characterization Testing is used to determine the
fundamental processing characteristics of ore samples
using laboratory testing. For example, this may be
the comminution characteristics. This information
supports comparison of actual plant performance
and experienced process behavior vs. laboratory pro-
jected process behavior. Observed gaps (plant vs.
laboratory) suggest opportunities for improvement.
Mass Balancing addresses potential issues with data
coherency and determining the process performance.
The goal of Mass Balancing is to create a coherent
data set describing actual plant performance from
the noisy data generated by plant sampling and sam-
ple analysis.
Sampling and Surveying is about collecting repre-
sentative samples to characterize plant behavior at a
fixed point in time and with a high level of detail
through observation of the processing plant. This is
at a more detailed level than commonly occurring
as the observation component of process control,
bottleneck management, or geomet. It is restricted
to a few fixed points in time with great detail at each
instance as opposed to plant sampling which com-
prises many points in time with much less detail.
COMPETENCY
Competency is the ability to efficiently and effectively
perform a function. Competencies are comprised of
knowledge, skills and motivations (Figure 4), which
lead to effective performance in an individual’s activities
(Wikipedia, accessed 2024):
• Knowledge (know what) consists of fundamentals.
Explicit knowledge can be readily articulated, codi-
fied and transmitted to others. Tacit knowledge is
difficult to express or extract. The latter is more diffi-
cult to transfer to others by means of writing it down
or verbalizing it.
• Skill (know how) is what one is able to do with
what one knows. These are abilities to apply knowl-
edge and perform tasks—manipulation of concepts,
knowledge, materials. In this work, we are specifi-
cally discussing MP/EM-related skills.
• Motivation is how one responds in a variety of situa-
tions. It propels individuals to engage in goal-directed
Figure 4. Competency as the product of knowledge, skills
and motivation (Seitz, 2014)
Table 2. Common problem types in processing plants
Role Common Problem Types
Process
Management
Supporting Control-Response (algorithmic
/logical /rule-based), either automated or
manual.
Supporting Decision-making
Supporting Planning
Supporting Strategy Development
Process Start-up/Shut-Down
Process Trade-off Analysis
Problem Solving Troubleshooting, diagnosis/solution
Process Upsets not addressed adequately by
control-response plans
Debottlenecking to address constrained
operation
Process Stabilization
Process Optimization
Turnaround and expansion
Process characterization involves analyzing actual
plant performance from many perspectives. Different
approaches are intended to identify problems and
factors driving plant performance. For example, pro-
cess instability and decreasing process performance
result in improvement projects.
Modeling and Simulation involves model building
and exploration of different operating conditions to
identify improved conditions for plant operations.
Efficiency Analysis considers the efficiency of opera-
tions in comparison to laboratory testing and bench-
marking vs. similar operations to identify opportuni-
ties for improvement and possible paths to improve-
ment, e.g., best practice.
Geomet identifies operating conditions for process-
ing different ore types, identifies when the ore types
will be fed to the plant and ensures the best operating
conditions are used to process each ore type.
Characterization Testing is used to determine the
fundamental processing characteristics of ore samples
using laboratory testing. For example, this may be
the comminution characteristics. This information
supports comparison of actual plant performance
and experienced process behavior vs. laboratory pro-
jected process behavior. Observed gaps (plant vs.
laboratory) suggest opportunities for improvement.
Mass Balancing addresses potential issues with data
coherency and determining the process performance.
The goal of Mass Balancing is to create a coherent
data set describing actual plant performance from
the noisy data generated by plant sampling and sam-
ple analysis.
Sampling and Surveying is about collecting repre-
sentative samples to characterize plant behavior at a
fixed point in time and with a high level of detail
through observation of the processing plant. This is
at a more detailed level than commonly occurring
as the observation component of process control,
bottleneck management, or geomet. It is restricted
to a few fixed points in time with great detail at each
instance as opposed to plant sampling which com-
prises many points in time with much less detail.
COMPETENCY
Competency is the ability to efficiently and effectively
perform a function. Competencies are comprised of
knowledge, skills and motivations (Figure 4), which
lead to effective performance in an individual’s activities
(Wikipedia, accessed 2024):
• Knowledge (know what) consists of fundamentals.
Explicit knowledge can be readily articulated, codi-
fied and transmitted to others. Tacit knowledge is
difficult to express or extract. The latter is more diffi-
cult to transfer to others by means of writing it down
or verbalizing it.
• Skill (know how) is what one is able to do with
what one knows. These are abilities to apply knowl-
edge and perform tasks—manipulation of concepts,
knowledge, materials. In this work, we are specifi-
cally discussing MP/EM-related skills.
• Motivation is how one responds in a variety of situa-
tions. It propels individuals to engage in goal-directed
Figure 4. Competency as the product of knowledge, skills
and motivation (Seitz, 2014)
Table 2. Common problem types in processing plants
Role Common Problem Types
Process
Management
Supporting Control-Response (algorithmic
/logical /rule-based), either automated or
manual.
Supporting Decision-making
Supporting Planning
Supporting Strategy Development
Process Start-up/Shut-Down
Process Trade-off Analysis
Problem Solving Troubleshooting, diagnosis/solution
Process Upsets not addressed adequately by
control-response plans
Debottlenecking to address constrained
operation
Process Stabilization
Process Optimization
Turnaround and expansion