Field notes, fundamentals, best practice and tutorials for mineral processing — crushing, grinding, classification, flotation and dewatering, and the control that ties them together.
Where the losses hide on a mineral processing plant, and what smart instruments and advanced process control do about each one.
Fear of overload keeps mill load conservative. The safety margin is unmilled tonnes paid for in lost throughput every shift — and a smart instrument can give that margin back.
Read more → Flotation CircuitBubble structure and surface velocity shift minutes before the assay catches up. A camera that reads the froth gives the controller a head start on grade.
Read more → Crushing CircuitPebble recycle is the leading indicator of ore hardness. Measure it well, and the SAG and crusher stop fighting each other for tonnes.
Read more → Comminution · Our researchImpact-rate signatures hide in the vibration of the shell itself — live mill fill and liner health, legible without new sensors. Our Fill Analyzer prototype pulls them out with a digitizer-side DSP pipeline.
Read more → Flotation Circuit · Open researchA decade of froth-imaging research has tightened the link between bubble-size distribution and recovery. Where the literature now stands, and where our camera picks up the baton.
Read more →The physics behind each unit operation, in plain language — the numbers every metallurgist sizes equipment with.
How the cake filters itself, what each cycle step buys, and where the minutes go
Read more → Ball MillThree numbers that size a ball mill: how hard the ore is, how fast the shell turns, and how big the balls are
Read more → ScreenHow a vibrating screen stratifies, separates, and how to tell whether it is doing its job
Read more → CycloneHow a cyclone decides where each particle goes, and the three numbers that describe it
Read more → CrusherHow jaw, gyratory and cone crushers break rock, and why it matters for the mills
Read more →Operating habits that hold throughput, grade and equipment life — drawn from published plant experience.
Keep the cut honest: read the deck, measure the apertures, fix the root cause
Read more → CrusherKeep the chamber full, the gap honest and the liners worn evenly
Read more → Flotation Cleaner / ColumnWhy cleaner circuits drift, and the habits and controls that keep final grade steady
Read more → SAG MillKeeping the mill in its sweet spot: load, motion, feed, media, discharge, relining and control
Read more → APC GeneralWhy advanced process control drifts into manual, and what sustaining sites do differently
Read more →How the variables in a circuit trade off against each other, and how control strategies use those trade-offs.
Kinetic tests, mass pull, liberation limits and how to compare the plant with the lab
Read more → CycloneDensity sets the grind, pressure fine-tunes it, and the cyclone count sets the pressure
Read more → ThickenerHolding inventory, density and clarity together, and returning more water to the plant
Read more → Flotation RougherHow level, air and froth velocity are controlled in layers, and how a plant moves along its grade-recovery curve
Read more → Ball MillWhy more recycle adds capacity, why classification efficiency matters more, and where the practical limit sits
Read more →How Aeterna's instruments and controllers read the plant, and the published work they build on.
How a constraint-aware expert system uses bearing pressure, sound and power together - with Rock Analyzer feed-forward and neural-network foreign-object protection
Read more → SAG MillWhat the mill's sound says about fill, impacts and media, and how three instruments turn it into numbers a controller can use
Read more →Step-by-step guides to building process models in ProcessOpt, from the physics to the screen.
Configure a flotation cell with level, air and entrainment - step by step in ProcessOpt
Read more → CycloneConfigure a hydrocyclone cluster with the Plitt model - step by step in ProcessOpt
Read more → Ball MillBuild a ball mill model with Morrell power - step by step in ProcessOpt
Read more → ThickenerConfigure a Bürger-Diehl thickener model and watch it respond - step by step in ProcessOpt
Read more → CrusherSet the CSS, cavity and power of a cone crusher model - step by step in ProcessOpt
Read more → SAG MillBuild a SAG mill model that tracks filling, power and product size - step by step in ProcessOpt
Read more →