The optimizationOptimization of mineral processingMineral Processing circuits plays a pivotal role in improving the efficiencyEfficiency and profitability of operationsOperation. This paper presents a case study illustrating the collaboration between Rio Tinto KennecottRio Tinto Kennecott CopperCopper (RTKC) and Woodgrove TechnologiesTechnology to enhance the molybdenum plant operationsOperation at the Kennecott facility in Salt Lake City, Utah. The project’s success was achieved through a comprehensive approach involving pilot plant (PP) testing and advanced modelingModeling. Woodgrove conducted an extensive series of approximately 100 PP tests to gain an in-depth understanding of the molybdenum flotationMolybdenum flotation circuit’s behavior and performancePerformance. This rigorous testing provided valuable insights that guided the subsequent phases of the project. Advanced modelingModeling techniques were employed to demonstrate the advantages of replacing legacy flotationFlotation equipmentEquipment with Woodgrove’s Direct Flotation ReactorDirect flotation reactor (DFRDFR ®). These reactors offer improved efficiencyEfficiency and performancePerformance, leading to enhanced product quality and reduced operational costs. The modelingModeling efforts provided a tangible basis for RTKC to carry out designDesign engineeringEngineering for retrofitting of the existing conventional flotationFlotation cells with DFRsDFR. The case study highlights the significance of data-driven decision-making in modernizing mineral processingMineral Processing facilities. By leveraging PP testing and advanced modelingModeling, Woodgrove and RTKC successfully optimized the molybdenum flotationMolybdenum flotation circuit designDesign to improve efficiencyEfficiency and operational excellenceOperational Excellence.