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Over the past decade, automation has swept through control rooms, transforming mineral processing plants' operations. Advanced process control (APC), machine learning algorithms, and digital twins are slowly becoming mainstream tools.

Flotation remains one of the most powerful methods of mineral separation in processing plants. When dialled in, it delivers high recovery, consistent grade and stable throughput. But when it’s off — even slightly — the knock-on effects can be felt across the whole circuit.

This article is a collaboration with Mark Franklin from First Principles Consulting, creators of the Mining Value Index. Mark and his colleague …