Most mineral processing facilities have invested heavily in data capture – sensors, historians, SCADA, OEM platforms – yet operations teams still spend hours reconciling data that should be integrated. This article explains why operational data fragmentation persists, what a well-integrated environment looks like, and the diagnostic questions worth asking first.
Mineral processing is the set of physical and chemical processes – crushing, grinding, flotation, dewatering – that separate valuable minerals from ore. This guide covers the core stages, how they differ from mining itself, and why automation and process control increasingly determine whether a plant hits its production targets.
Electrical and Instrumentation (E&I) engineering keeps mineral processing plants running – from sensors and PLCs to SCADA and DCS control. This guide covers what E&I engineering involves, the challenges engineers face, and how it drives precision, efficiency and reliability across mining and mineral processing operations.
According to McKinsey, fewer than 10 percent of installed APC systems are properly optimised in some industrial companies. This article covers the four most common causes of Advanced Process Control failure in mineral processing, how to identify the warning signs, and what a structured remediation approach looks like.
APC readiness in mineral processing goes well beyond selecting the right software. Mipac’s Optimisation Team Lead Drew Clements draws on direct site experience to explain why most APC projects underperform – from instrumentation gaps and model drift to operator trust and change management – and what a structured readiness audit actually reveals on the ground.
Advanced Process Control (APC) is a category of automation technology that uses predictive, multivariable algorithms to stabilise and optimise mineral processing circuits in real time. It operates above standard PID control – coordinating multiple interacting variables simultaneously to improve throughput, recovery, energy efficiency and process stability.
Operational efficiency in mineral processing is increasingly defined by stability, control quality and decision confidence, not new equipment. As ore variability increases and operating windows narrow, plants that focus on control, data integrity and operator capability are unlocking sustainable throughput and recovery gains without major capital spend.
Control system design is one of the most overlooked economic levers in mineral processing. When done well, it stabilises circuits, reduces downtime and transforms data into meaningful decisions. This article explores the hidden financial impact of strong control foundations and why they matter for leaders, metallurgists and control engineers alike.
Greenfield mining projects shape operational performance for decades. The most successful plants are not defined by equipment alone, but by how they are designed to behave under real variability. Lessons from major projects show that stability, control quality, digital architecture and commissioning readiness must be engineered from day one to create future-ready, optimisation-capable operations.
When control philosophy drifts from plant reality, stability drops and APC underperforms. This article explains how drift develops in brownfield operations, the most reliable sequence to rebuild operating truth and why foundations matter more than dashboards for throughput, recovery and reliability.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.
Simply fill out the below form and we will send you the details of the webinar directly to your email.
Simply fill out the below form and we will email you a copy of the MIM Case Study.
Simply fill out the below form and we will email you a copy of our MPA product guide.