MINERALS & METALS PROCESSING

Impressive experience in minerals processing has been earned through the exposure to design and commissioning of a wide range of gold greenfield and brownfield projects. DRA Global has installed over 120 mills, including a 23MW SAG Mill and an 18MW gearless drive mill, both world firsts. Due to well-established relationships with equipment suppliers and commercial laboratories worldwide, DRA Global’s process engineering team and process designs are unrivalled in the industry and are known to add value to all stakeholders involved.

MINERALS & METALS PROCESSING SERVICES

  • Preparation of test work programs and ore sampling strategies
  • Global metallurgical test work management
  • Test work program strategies aligned with international reporting code (NI43-101, JORC, SAMREC and others) requirements
  • Undertaking of studies from PEA (conceptual) through to DFS or BFS

 

  • Detailed engineering design
  • Techno-economic trade-off studies and quantitative risk analysis
  • Process modelling and simulation (steady state and dynamic)
  • Fit-for-purpose, through to advanced process control solutions
  • Commissioning and optimisation

 

MATERIALS HANDLING /

The ability to prescribe an effective materials handling design demands a robust understanding of variable ore types and subsequent flow characteristics. DRA Global has an established experience base covering overland conveyor, bulk storage, rail load and blending system design. In-house capabilities in the simulation of bulk materials flow enables a reliable and efficient operational solution to the design of chutes, reclaimers and crushers.

COMMINUTION /

DRA has an established track record able to offer an extensive range of comminution circuit design and configurations. These include 2CB, 3CB, ROMB, SAG, SAB, SABC as well as ultrafine milling using HIGMill, IsaMill, VertiMill and others. Our world-renowned process consultants are able to offer a bespoke design merging state of the art equipment with smart control systems applicable a wide spectrum of commodities.

FLOTATION /

DRA has garnered extensive flotation experience includes MF1, MF2 and hybrid circuit configurations using flash flotation, conventional flotation, column flotation, coarse particle rejection and other specialised flotation technologies. Leveraging off our in-house expertise and relationships with suppliers and commercial laboratories we are able to tailor a viable and practical technology application suited for a particular ore type.

HYDROMETALLURGY /

Hydrometallurgical projects offer unique challenges which often require extensive testwork campaigns and technologies evaluations in order to formulate a viable business case. Our strong hydrometallurgical capabilities, in-house technologies and relationships with suppliers and global laboratories is paramount to ensure a viable value proposition is realised. Our expertise cover a wide range of unit operations including decrepitation, acid roasting, heap leaching, atmospheric leaching (conventional, carbon or resin based), complex pressure leaching applications, BIOX, resin in pulp (RIP), ion exchange (NIMCIX, fixed bed and others), elution, solvent extraction, electrowinning, detoxification, impurity precipitation, product precipitation, electrolysis, crystallisation, evaporation and final product handling (dewatering, drying and packaging).

PRE-CONCENTRATION AND CONCENTRATION /

Pre-concentration is a fundamental requirement to ensure optimal plant design and operation. Pre-concentration enables removal to gangue or low grade material thereby reducing downstream plant requirements in terms of foot-print and equipment size in addition to significant reductions in reagents and utility requirements. DRA has successfully pioneered the use of dense media separation (DMS) technology in pre-concentration with successful application of sorting technologies (XRT, XRF, NIR, Optical). Our gravity concentration expertise extends to spirals, hydraulic classifiers and magnetic separation experiences (WHIMS, LIMS and others).

CLASSIFICATION & DEWATERING /

The design of classification and dewatering circuits can often be underestimated, however these circuits are immensely vital to the successful workings of downstream unit operations. Understanding of the complexities with bi-modal classification and rheology in combination with proven in-house circuit designs to maximize separation efficiencies without compromising metal recoveries are prevailing offerings at DRA. Our expertise include use of a wide range of dewatering technologies and processes which include filtration, centrifuges and thickening.

Commodities

DRA has a global engineering and project management track record, having delivered over 4 500 projects and studies around the world, operating across three core regional markets of Africa / Middle East / Europe, Asia-Pacific and the Americas. The Company has extensive expertise in various commodities including coal, platinum, uranium, chrome, diamonds, iron ore, gold, copper/cobalt, nickel, zinc/lead, lithium, graphite and rare earths.  

PRECIOUS METALS: GOLD /

Advanced knowledge of gold extraction, economics and projects database to support the undertaking of Conceptual Studies (PEA) through to Definitive Feasibility and Detailed Design.  In the early 1990s DRA Global pioneered African gold heap leach projects and developed a range of proprietary heap leach equipment.

PRECIOUS METALS: Platinum (PGE)

World leader in platinum (PGM) concentrator projects, having designed over 80% of the world’s platinum processing plants. The specialist team has an intimate understanding of the SADC PGM industry smelting, converting and refining processes, enabling the team to maximise value across the full value chain.

Pre concentration         

DRA Global pioneered the use of dense media separation (DMS) technology in pre-concentration (high chrome containing UG2 ore), and has experience with sorting technologies (XRT, XRF, NIR, Optical and others) and coarse particle rejection.

Classification and Dewatering    

Keen understanding of the complexities associated with bi-modal classification, and proven in-house circuit designs to maximise separation efficiencies without compromising metal recoveries. Extensive experience with concentrate and tailings dewatering in the PGM industry.

Comminution    

Crushing and milling using 2CB, 3CB, ROMB, SAG, SAB, SABC and Ultrafine milling using HIGMill, IsaMill, VertiMill and others.  Extensive concentrate regrind experience.

Refining           

Practical design and operational experience in all conventional unit processes commonly used in Base Metal (Cu, Ni, Co) and Precious Metal (Pt, Pd, Ru, Rh, Au, Os and Ir) refining.

Froth Flotation 

Extensive flotation experience includes MF1, MF2 and hybrid circuit configurations using flash flotation, conventional flotation, column flotation, coarse particle rejection and other specialised flotation technologies.

BASE METALS: Copper, Lead, Nickel, Tin, Zinc, Cobalt, Tungsten, Manganese, Chromium, Vanadium

Impressive experience in the delivery of base metal projects across multiple geographies, including some of the most remote and challenging locations around the world. Through state-of-the-art technical solutions, plants are designed specific to the ore-body and modifications increase recovery and throughput.

Pre concentration

DRA Global pioneered the use of dense media separation (DMS) technology in pre-concentration with successful application of sorting technologies (XRT, XRF, NIR, Optical)

Gravity concentration

Extensive experience includes:

  • Gravity concentration: DMS, Spirals and Hydraulic classifiers
  • Magnetic separation (WHIMS, LIMS and others).

Hydrometallurgy

Impressive hydrometallurgical capabilities that include complex pressure leaching applications, crystallisation, evaporation and precipitation.

Froth Flotation

Extensive flotation experience to concentrate oxides, transition and sulphide ores which includes Pyrite and Arsenopyrite flotation using flash flotation, conventional flotation cells, column flotation and other specialised flotation technologies

Solvent extraction and Electro-winning (SX/EW):

Completed more copper-cobalt solvent extraction (SX) and electrowinning (EW) plants on the African Copperbelt than any others in the market. MMI proven technology maximises recoveries and improves operational efficiencies.

Leaching

Full range of atmospheric leaching capabilities, including amongst others agitated leach, heap leach, VAT leach, inclusive of materials handling and agglomeration

Comminution

Full range of comminution circuit design and configuration includes, but is not limited to:

  • 2CB, 3CB, ROMB, SAG, SAB, SABC
  • Ultrafine milling using HIGMill, IsaMill, VertiMill

Practical design experience with Milling in Raffinate applications

BULK COMMODITIES: Iron Ore, Hematite, Bauxite & Alumina

Expertise across various ore types, regions and technology applications. Offerings range from a simplistic crushing and screening solutions to more complex beneficiation routes which include milling, magnetic separation and flotation depending on specific ore characteristics.

Pre concentration

DRA Global pioneered the use of Dense Media Separation (DMS) technology in pre-concentration with successful application of sorting technologies (XRT, XRF, NIR, Optical and others)

Materials handling

Expertise in overland conveyors, bulk storage, reclaim, rail load out and blending system design. In-house capabilities in the simulation of bulk materials flow which provide a reliable and efficient operational solution to the design of chutes, reclaimers, crushers and grinding mills.

Froth Flotation

Comprehensive flotation experience to concentrate oxides, transition and sulphide ores, using conventional cells, column flotation and other specialised flotation technologies.

Product handling

Capabilities in evaluating product transportation options including long distance pumping and conventional road and rail solutions. The use of a wide spectrum of dewatering technologies, including filtration and thickening, provide a holistic and logistically viable transportation solution.

Gravity concentration

Extensive experience includes:

  • Gravity concentration DMS, spirals, jigs and hydraulic classifiers
  • Magnetic separation (WHIMS, LIMS, VPHGMS and others)

Comminution

Broad expertise in comminution circuit design with installations of some of the world’s largest crusher and milling circuits for high capacity applications.

RARE EARTHS: Ce, Nd, Y, Dy, Eu, La, Pr, Tb, Sc, Sm, Gd, Lu, Ho, Er, Tm, Ye

Rare earth elements are often associated with complex geological structures which warrant an innovative approach to ore processing. DRA Global provides viable solutions that consider capital outlay, on-going operating expenses and environmental impact.

Pre concentration

Pioneered the use of dense media separation (DMS) technology in pre-concentration with successful application of sorting technologies (XRT, XRF, NIR, Optical and others)

Solvent Extraction (SX)

Extensive solvent extraction experience, using MMI proven technology, to maximise recoveries and improve operational efficiencies

Product handling

Rare earth deposits are often associated with radioactive material and can result in radioactive products and waste streams. Expertise includes the design and operation of storage facilities for containing radionuclides

Froth Flotation

Extensive flotation experience in the recovery of rare earth elements using conventional cells, column flotation and other specialised flotation technologies.

Gravity concentration

Wide range of experience includes:

  • Gravity concentration DMS, spirals and hydraulic classifiers
  • Magnetic separation experiences (WHIMS, LIMS and others)

Comminution

Full range of comminution circuit design and configuration includes, but is not limited to:

  • 2CB, 3CB, ROMB, SAG, SAB, SABC
  • Ultrafine milling using HIGMill, IsaMill, VertiMill

 

Hydrometallurgy

Expertise in processing technologies such as:

  • Caustic and sulphuric acid cracking
  • Whole ore hydrochloric leaching
  • Recovery of reagents
  • Complex solid/liquid separation
  • Thermal decomposition
  • Selective precipitation and re-dissolution
  • Double salt formation
  • Solvent extraction
  • Ion exchange
  • Acid retardation
  • Nano-filtration and flowsheet simulation

PRECIOUS STONES: Diamonds

Recognised as a leading contractor in the design, engineering, construction and commissioning of diamond recovery and dense media separation (DMS) plants, supplying diamond processing plants on six continents. First-tier supplier of engineering and project management services to the global market.

ORE PREPARATION

Extensive experience in the design of scrubbing, screening and ore-preparation circuits for efficient and effective ore preparation ahead of concentrating and recovery processes.

DMS Concentration

Practical design experience, in hot and cold climates, for efficient diamond recovery using dense medium separation (DMS) technology.

LIBERATION

Intimate experience with unit processes that include the use of jaw, gyratory, cone crushers, high pressure grinding rolls and successful use of AG Milling.

BULK SORTERS

Extensive experience with a wide range of bulk sorters (XRT, NIR, Optical and others).  Appreciation of the application and economics of using bulk sorters for diamond recovery.

RECOVERY PLANTS

Final diamond recovery experience, ranging from wet and dry magnetic separation, wet and dry X-Ray sorting through to glove box recovery, lazer sorting through to sort-house.

COAL: Thermal Coal, coking coal

Implemented more than 400 coal projects and studies globally, complete with materials handling facilities. DRA Global is recognised as specialists in coal processing plant design, a reputation which has been earned through the professional design of processing plants that to date, produce approximately 50% of all washed coal in South Africa.

MATERIALS HANDLING

Expertise in overland conveyors, bulk storage, rail load and blending system design. In-house capabilities in the simulation of bulk materials flow which provide a reliable and efficient operational solution to the design of chutes, reclaimers and crushers.

Froth Flotation

Extensive flotation experience treating coal fines using conventional cells, column flotation and other specialised flotation technologies.

COMMINUTION

In-depth knowledge in crusher circuit configurations which include the use of jaw crushers, feeder breakers, mineral sizers, double roll crushers and impact crushers.

GRAVITY CONCENTRATION

A wide range of gravity concentration experience for fine and coarse coal recovery, including gravity or pump-fed dense media separation (DMS) plants, as well as drum, spiral, jig separation plants and upflow/reflux classifiers.

THERMAL COAL TREATMENT

Established partnerships with leading technology providers to extend economical and technically advanced solutions to clients and reduce the sulphur dioxide (SO2), nitrogen oxides (NOx) and mercury (Hg) emissions when burning coal.  Fostered beneficial partnerships with leading technology providers to extend economical and technically advanced solutions to clients and reduce the sulphur dioxide (SO2), nitrogen oxides (NOx) and mercury (Hg) emissions when burning coal. Liquid pre-combustion chemical systems alter the coal’s composition before being burned in power plant boilers which reduces refined coal NOx emissions by up to 20% and Hg emissions by up to 90%. This results in a reduced environmental impact and compliance with stringent regulations.

DEWATERING

Broad knowledge of dewatering technologies and processes including filtration, centrifuges and thickening applications.

NUCLEAR FUELS: Uranium

Significant experience in designing uranium processing facilities and offers clients comprehensive solutions. Experience includes a variety of mining and processing options for both conventional and complex polymetallic deposits, providing clients with solutions that are both technically and economically viable.

Pre-concentration

Pre-concentration using a variety of sorting technologies (XRT, XRF, NIR, Optical and others) for rejection of low grade material.

Leaching

Full range of leaching capabilities, including amongst others agitated leach (acidic and alkaline) and heap leach (acidic) inclusive of materials handling and agglomeration.

Comminution

Full range of comminution circuit design and configurations include but are not limited to:

  • 2CB, 3CB, ROMB, SAG, SAB, SABC
  • Ultrafine milling using HIGMill, IsaMill, VertiMill

BY-PRODUCT RECOVERY

Recovery of by-products such as vanadium and molybdenum through selective precipitation, ion exchange or solvent extraction technologies.

Hydrometallurgy

Strong hydrometallurgical capabilities that include complex pressure leaching applications, resin in pulp (RIP), ion exchange (NIMCIX, fixed bed and others), impurity precipitation, product precipitation (ADU, SDU and peroxide) and final product handling (dewatering, drying and packaging).

WATER AND REAGENT RECOVERY

Applications using dewatering technologies, milling in raffinate, saline water utilisation and nanofiltration enable an optimal management of water utilisation and reagent consumption.

Froth Flotation

Extensive flotation experience in the removal of gangue material using conventional cells, column flotation and other specialised flotation technologies. Innovative Uranium circuit designs have relied on using froth flotation to separate sulphides and oxides/carbonates, whilst also using froth flotation for gangue acid rejection ahead of leaching.

Solvent extraction and Electro-winning (SX/EW):

Extensive Solvent Extraction and Electrowinning (SX/EW) experience, using MMI proven technology, to maximise recoveries and improve operational efficiencies.

BATTERY MINERALS: Lithium, Graphite

Implementation of lithium and graphite projects to add value regardless of location or size and to meet budget, time and safety expectations.

Pre-concentration

Pioneered the use of dense media separation (DMS) technology in pre-concentration with successful application of sorting technologies (XRT, XRF, NIR, Optical and others).

GRAVITY CONCENTRATION

Wide range of experience includes:

  • Gravity concentration: DMS, spirals and hydraulic classifiers
  • Magnetic separation experiences (WHIMS, LIMS and others)

Comminution

Crushing and milling covering a spectrum of crushing and milling configuration inclusive of regrind milling applications using technologies such as HIGMill, IsaMill, VertiMill, SMD, HPGR and others.

Froth Flotation

Extensive flotation experience in spodumene flotation inclusive of desliming, scrubbing and conditioning prior to flotation utilising conventional cells (forced or self aspirated), column flotation and other specialised flotation technologies.

Hydrometallurgy

Strong hydrometallurgical offering to produce either LiOH and Li2CO3 products. Knowledge of decrepitation, acid roasting, leach (acid and alkaline), impurity precipitation, ion exchange, electrolysis and crystallisation.

DEWATERING AND DRYING

Vast experience in a range of dewatering technologies and processes (filtration, centrifuges and thickening), appreciation of rheological challenges and practical experience with product drying technologies utilising a wide range of fuel sources.

MINERAL SANDS: Ilmenite, Rutile, Zircon

WASHING AND SCRUBBING

Expertise in washing and scrubbing of ore to aid in de-agglomeration that typically comprises of a combination of fine and coarse particles. The process entails scrubbing, screening and desliming for effective classification.

MAGNETIC SEPARATION

Broad experience in the use of magnetic separation processes including WHIMS, LIMS and others.

 

MATERIALS HANDLING

Use of jet pumps applied to the process of wet mining run of mine, which can either be offshore or in flooded areas.

GRAVITY CONCENTRATION

A wide range of gravity concentration experience, ranging from spirals to hydraulic classifiers.

FEATURED PROJECTS

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BOOYSENDAL PLATINUM PROJECT

Northam Platinum engaged DRA to provide a US$400 million total solution, designing and building every aspect of the project – the underground mining system as well as the above surface plant, materials handling facilities, full administration of the contractual requirements and all additional infrastructure, including bulk water storage and access roads.


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LEEUWKOP SHAFT PROJECT

Following the successful completion of a feasibility study and capital budget estimate, DRA Global was contracted to undertake the multi-level mine design of the Leeuwkop Shaft Project for Impala Platinum.


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IRENEDALE SHAFT

Irenedale was a replacement shaft project for SASOL mining rather than an expansion project. The project encompassed the establishment of an all inclusive main service shaft system in the Bosjesspruit Irenedale reserves with related support infrastructure to mine 8Mtpa.