KNOWLEDGE LIBRARY

Mineral Processing Plants That Are A Pig To Operate

Operating mineral processing plants, particularly crushing plants, can be a challenging endeavour. These industrial environments are inherently dirty and dusty, making them tedious to manage even under the best circumstances. However, when these plants are poorly designed and operated, the difficulties intensify, significantly affecting overall throughput and productivity.

For more information, please watch the video and download the ebook.

Mineral Processing Plants That Simply Work – Why Design Complexity Is The Enemy Of Client Success

At Mintrex, we believe in the power of simplicity. Our Zero-Base Design approach focuses on delivering the perfect solution to our clients’ unique objectives, without sacrificing efficiency or effectiveness. By reducing complexity, we’re able to minimise Capex and Opex expenditures while still delivering a high-quality end result.

A simple design is easy to fabricate and easy to construct onsite, which means less expensive fabrication and construction costs. The end result is a plant that’s a lot easier to operate.

Our design managers challenge their teams to vigorously question all assumptions and ensure that every component of the design is tailored specifically to the client’s needs. With an unwavering commitment to balance, we strive for perfection while always providing the right-sized answer for our clients.

Deception in Project Management – It Never Ends Well!

This is a compelling story of a sailor who dishonestly reported his progress during a round-the-world race. This cautionary tale serves as a reminder for project managers of the critical importance of honest reporting. By being transparent and addressing problems early on, we can harness the collective support of the entire team to tackle challenges effectively, rather than allowing issues to escalate until they become unmanageable. This story is being shared by our Senior Principal Engineer, Tom Kendall.

Unit Operation – Crushing

In Mineral processing or metallurgy, the first stage of comminution is Crushing. However, many challenges can arise in the crushing process such as:

• Spillage/Fugitive Materials
• Excessive Dust Generation
• Excessive Spillage
• Handling Crash Stops

However,  a well-designed crushing plant will take these challenges into account and have a good system for averting such problems, and controlling the consequences, should they occur from time to time.

As an overarching principle, the design engineer should never assume that he/she knows more than the equipment supplier. The manufacturers have people in the field all the time, and it is important to draw on this expertise. Also, it is prudent for the engineer to consult with operating personnel who have experience with the specific material being handled – and can provide real-world guidance that can inform your design.

There is no substitute for asking someone who’s done it!

Mintrex has extensive experience in the design and commissioning of crushing plants.

Watch Videos and Download our “Crushing White Paper” here

How to identify and remove bottlenecks in a mineral processing plant

Mintrex is frequently invited to collaborate with clients to optimise and increase the throughput of existing process plants. Here are some of the benefits that we have seen in the past:

• Increased throughput
• Increased recovery
• Reduced shutdown time
• Reduced replacement time and wear on components
• Safety improvements – including safer access to various plant areas.

Leaching and Purification

Separation and Classification

How to Maximise the Value of your Mine/Asset

A geometallurgical approach to improving your mine value chain via process parameters. Presented by Dr Leon Lorenzen.

How to maximise the value of your metallurgical testwork programme

A systematic approach to improving your design via process parameters.

• What is the purpose of Metallurgical Test Work
• Impact on CAPEX and OPEX
• How can Metallurgical Testing mitigate project risk?
• At what project stage do we start Met Test Work?
• Factors impacting on Process Test Work requirements
• How do we ensure that the Process Flow Sheet can handle variability?
• What are the major traps in regard to Metallurgical Testing?
• And much more!

How to Avoid Time & Cost Overruns on Mining Construction Projects

Presented by Tom Kendall

• The role of the project manager
• The importance of good communication
• Why control is over-estimated
• Keeping the client informed
• Root causes of overruns
• The need for systems and tools
• Why they should NOT be followed blindly
• Know what to check
• Unforeseen External Factors

Why ALL Processing Plants are Over-Designed

Presented by Tom Kendall

Why ALL Processing Plants are Over-Designed! – and how owners can minimise the problem by “vigorously questioning” throughout the design process i.e. a Zero-Base Design approach.

Mintrex Zero-Base Design Approch

Mintrex Zero-base design is a systematized approach that we have developed to ensure that we have a real focus on the client’s key objectives and therefore deliver the maximum value for a client.

The approach can be broken down into the following steps:

• Identify those outcomes that the client requires
• Apply focussed processes and peer review to challenge our assumptions, preferences and biases to get the best outcome for the project

The Result:

• Minimal capital and minimal operating costs and therefore the client has the ability to deliver success both at the beginning of their project and to their shareholders in the end result