Minerals Processing
Advanced simulation offers key advantages to the minerals processing industry by optimising plant performance, improving resource recovery and reducing operational costs. Through simulation, engineers can model complex processes such as crushing, grinding, and separation, allowing them to predict outcomes and refine designs for better efficiency. This proactive approach minimises bottlenecks, enhances equipment performance, and ensures the processes are fine-tuned for maximum yield with minimal energy consumption. Additionally, simulation helps identify potential issues before they occur, reducing downtime and improving safety. Overall, our engineering design and simulation services can contribute to more efficient, sustainable, and cost-effective minerals processing operations, ensuring better resource utilisation and environmental compliance.
We have extensive experience with engineering design applications and process modelling/simulation in the minerals processing industry, including:
- Sinter plants, coke ovens, reformers and iron ore pelletising furnaces/kilns.
- Aluminium/lead/zinc smelters, lime/cement kilns and alumina/cement calciners.
- Clinker, water bath and water spray coolers.
- Fluidised bed reactors (FBR) and fluid bed roasters.
- Flue gas chimneys/stacks (to ASME STS-1, CICIND, IS 6533 or similar).
- Thickeners, sedimentation/filtration tanks and magnetic separators.
- Bins/hoppers, chutes, transfer stations, belt/screw conveyors and car dumpers.
- Vibrating screens, cyclone separators and classifiers.
- Fans/blowers and slurry pumps.
- Crushing mills (SAG, rod).
- Process piping/valves and ducting (to ASME B31.3, AS 4041 or similar).
Fracture Mechanics
Combining fracture mechanics theory and simulation with measurement allows accurate prediction of crack growth in critical components.
Root Cause Failure Analysis
Root cause analysis of failures in equipment allows solutions to be developed that mitigate future issues.