Plant Audits and Debottlenecking

Plant Audits and Debottlenecking

Capabilities

Systematic survey of crushing, grinding, classification, flotation, leaching, gravity, thickening, and filtration circuits. Mass balancing, metallurgical accounting, and circuit efficiency analysis.

Bond work index correlation, cyclone efficiency analysis, ball/rod charge optimization, circulating load measurement, and throughput maximization for SAG, ball, rod, and HPGR circuits.

Cell-by-cell sampling, residence time analysis, reagent audit, froth depth and pull rate optimization, entrainment measurement, and circuit reconfiguration for improved grade-recovery performance.

Cyanide consumption mapping, dissolved oxygen profiling, residence time distribution, carbon activity and loading analysis (CIL/CIP), and pregnant solution assay for gold plants.

In-plant trials of alternative collectors, frothers, depressants, grinding media, flocculants, and leaching reagents. Cost-benefit analysis and operating cost reduction
pathways.

Identification of hydraulic, mechanical, and metallurgical bottlenecks limiting plant throughput. Engineering solutions with capital cost estimates and payback analysis.

Complete plant water balance, internal recirculating loads, and water quality impact on metallurgical performance. Critical for water-scarce operations and environmental compliance.

Specific energy consumption analysis for comminution circuits, pumping systems, and compressed air. Benchmarking against industry standards and identification of efficiency gains.

Design and review of plant sampling systems, composite schedules, and metallurgical accounting procedures. Bias testing and reconciliation.

Sub-sieve particle size analysis, brightness/whiteness measurement, bulk density, specific gravity (pycnometer), moisture content, and rheology.

Comprehensive operational assessments that find the gaps — and close them.

RDi/MTS conducts in-plant audits that combine metallurgical measurement with engineering analysis. Our team has decades of hands-on plant experience across grinding, flotation, leaching, gravity, and hydrometallurgical circuits worldwide. We identify where recovery, throughput, and cost are being lost — and deliver implementable solutions.

Industries

  • Gold Processing
  • Copper Concentrators
  • Polymetallic Flotation Plants
  • Coal Preparation
  • Iron Ore Beneficiation
  • Industrial Mineral Plants
  • Lithium Processing
  • Rare Earth Processing

All Services

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