MINERALS  PROCESSING

As a partner of choice in minerals processing, since 1984, we have successfully completed over 300 projects, in 26 countries. Our extensive experience comprises all fields of engineering – electrical and instrumentation, process, mechanical, civil and structural, infrastructure – as well as materials handling.

We deliver mineral processing plants that meet world-class standards and exceed client expectations. All our projects, their surrounding infrastructure and materials handling functions, operate in line with the highest quality standards, systems and procedures (ISO-based) and every project is managed according to the highest safety standards.

Through the diverse skills of our process engineering team, we offer comprehensive skills in all minerals recovery processes, such as coal and diamond dense media separation (DMS), comminution, flotation, gold recovery, gravity separation processes, SX/EW and pyrometallurgy.

Our processing experience includes crushing circuits, ore stockpiling and reclaim systems, pre-concentration, milling circuits, flotation plants, solids dewatering, dryers, roasting and smelting, leaching, bio-leaching, absorption and elution circuits, gold refining, DMS plants, gravity concentration, diamond concentrate handling and final recovery, high intensity magnetic and electrostatic separation techniques, slurry pumping and tailings disposal systems and laboratory design and equipping.

Due to our well-established relationships with equipment suppliers and commercial laboratories worldwide, we are able to provide clients with optimal and cost efficient process designs.

COAL

As the industry leader, we are acknowledged by our clients as the experts in coal processing plant design. Our impressive reputation has been earned through the professional design of processing plants that to date, produce approximately 50% of all washed coal in South Africa. Over the years we have partnered with clients to implement more than 350 coal processing projects globally, complete with materials handling facilities, which attests to our ability to deliver only the best.

Our coal experience extends beyond the borders of Africa to China, USA, Australia, India, Russia, Trinidad and Indonesia.
From feasibility studies and plant design, through to project implementation and process plant commissioning – we are able to provide the full spectrum of coal processing services. Clients have entrusted us with their projects and our consistent delivery of turnkey solutions, particularly in coal washing plants, is why we are now regarded as industry world leaders.
We are able to deliver varied- and multiple-stage washing plants, including gravity or pump-fed DMS plants, drum plants, spiral plants, flotation plants and jig separation plants.Clean Coal Technologies and Emissions ControlWe have 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 of our projects. In addition to providing sustainable solutions, clients know ours as solutions that improve coal’s heading value. Our proven coal cleaning and processing technologies separate impurities and waste from raw coal and convert this product into a quality-controlled fuel source.Since 2009 DRA has engineered and constructed 15 refined coal facilities for several U.S. utilities. The facilities use liquid pre-combustion chemical systems to alter the coal’s composition before being burned in power plant boilers, this reduces refined coal NOx emissions by up to 20% and Hg emissions by up to 90%.

 

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GOLD

For 30 years we have grown our knowledge in the gold mining industry and, as a result, we are able to meet the design requirements of gold mines and gold plants, for any application. Our success is owed to our team of leading gold processing engineers, their expert capabilities and global experience in this field are unsurpassed in the industry.

Now comprising the collective knowledge of more than 60 process engineers, and their relative design and plant operation expertise, our process department adds significant value to our clients’ gold projects. Our gold specialists are experts in the testing of refractory ores and specifically in gold processing, through cyanide destruction, resulting in the delivery of optimal and cost-efficient process designs, for even the most challenging projects.We have established critical relationships with equipment suppliers and commercial laboratories, worldwide, so that together with our cutting-edge technology we can deliver the best in gold processing plants and mine designs. Clients have grown accustomed to our high level of customer service and often request our plant operations team to train their in-house operators in the commissioning and running of gold plants.

 

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URANIUM

We have significant experience designing uranium processing facilities, with an established performance history we are able to offer clients comprehensive solutions. DRA has successfully completed uranium scoping or preliminary economic assessment (PEA), pre-feasibility and feasibility studies (NI 43-101 and JORC compliant) for Mantra Resources, Uranium One, Rockgate Resources and Peninsula Energy, as well as a 2.3 million tonnes per month tailings retreatment study for Goldfields.

These studies explored a variety of production rates and processing methods, including acid heap leach, acid and alkali agitated leaching, resin-inpulp (RIP), ion exchange (NIMCIX, Fixed Bed IX and others), counter-current decantation (CCD), solvent extraction (SX), nanofiltration, energy recovery systems and various back-end precipitation circuits (ADU, SDU and Peroxide).
We are fortunate to have comprehensive heap leach experience, which includes both static and dynamic heap leaching with uranium recovery via IX and SX, and clients appreciate the valuable insight this brings to their projects. Our process engineers have managed and supervised uranium test work campaigns in South Africa, Australia and Canada, offering customers their expert advice in the design, execution and commissioning of projects.
Our close and established relationships with key contractors, suppliers and consultants in the global uranium industry facilitate our production of comprehensive trade-off studies on processing options. During project development, from the conceptual phase through to construction and commissioning, we focus on economic value-add and risk mitigation.

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BASE METALS

Revered for our state-of-the-art technical solutions in the base metals sector we are recognized as industry leaders in concentrator plant design. We offer practical solutions in processing strategies, including comminution circuit design, flotation, leaching, solvent extraction and electrowinning.

Our orebody-specific processing plants are designed with an acute awareness of feasibility and flexibility and, as a result, we implement plant modifications that boost recovery and throughput. We acknowledge the need to innovate beyond current and we drive this by pioneering the use of dense medium separation (DMS) technology in the pre-concentration of base-metal ores.We are routinely called to assist clients with testwork programme management, conceptual and final process-option selection and engineering development, complete processing plant and infrastructure engineering design and implementation management, electrical and control systems design, and the design and construction of mining infrastructure.

 

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RARE EARTH

From upfront beneficiation and concentration, through to the production of either rare earth oxides or chlorides, or purified rare earths, we have thorough knowledge in the development of rare earth hydrometallurgical projects. Our generic rare earth beneficiation and concentration capabilities include crushing, radiometric or X-ray fluorescence (XRF) sorting, dense media separation, gravity separation, milling, low intensity magnetic separators (LIMS), wet high intensity magnetic separators (WHIMS) and flotation.

Extending beyond conventional hydrometallurgical processing, our experience also includes more complex rare earth extraction technologies such as caustic and sulphuric acid cracking, whole ore hydrochloric leaching, recovery of reagents, complex solid or liquid separation, thermal decomposition, selective precipitation and redissolution, double salt formation, solvent extraction, ion exchange, acid retardation, nanofiltration and flowsheet simulation.

 

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IRON ORE

Our ferrous metals processing capabilities include iron ore, chromite, manganese and vanadium projects using crushing, screening and milling, washing and scrubbing, gravity concentration, magnetic separation, flotation, pressure leach and dry separation processes. We have skillfully designed and built numerous processing plants and projects within this sector.

We have designed and constructed processing plants for ferrous metal operations on four continents. Our flagship project in South Africa, Khumani Iron Ore, is a result of our decade-long partnership with the mine, since 2006 DRA has provided mining-related infrastructure development for the entire operation, including the load-out system and tailings handling facility. Recently, DRA upgraded the hematite iron ore through a process of crushing, screening, jigging and WHIMS (Wet High Intensity Magnetic Separation).

 

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PLATINUM

We are renowned for our service offering and delivery in platinum concentrator projects. Within this unique field of mineral processing we undertake the necessary testwork, design concentrators for specific ore bodies, implement plant modifications to increase recovery and throughput, and offer both plant design and construction.

Characterized by the in-house comminution design, our platinum processing plants offer an advanced level of process control and automation. In prioritizing efficiency, our engineers provide innovative solutions that deliver the most cost-effective plants in the industry.

We have distinguished ourselves in pre-concentration technology; by pioneering the use of DMS in PGM concentrators, to process UG2 ore with a high chromite composition, we set ourselves apart from others in the industry. Our expert knowledge is a culmination of more than 30 years’ experience gained through the design and construction of over 40 concentrators in the southern region of Africa.

Clients have utilized our knowledge for more than 3 decades and, through these partnerships, we have proudly delivered 80 percent of platinum plants in South Africa and Zimbabwe, with a combined throughput of approximately 40 Mtpa.

 

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DIAMONDS

Specialising in the design, construction and commissioning of diamond recovery and dense medium separation (DMS) plants, we are proudly recognized as the leading contractor in this field. We have cultivated the best team and their technical expertise, together with the application of leading edge technology, deliver processing plants beyond compare.

We have proudly delivered diamond processing plants to the largest diamond producers on five continents. Our plants are designed to meet unique client requirements and to treat various ores ranging from alluvial to marine, and from fissure to kimberlite. These unit processes include liberation by primary, secondary and tertiary crushing using jaw, gyratory, cone, high pressure grinding rolls (HPGRs), scrubbing and milling.

In many cases waste sorting in pre-concentration is becoming increasingly prevalent and is utilised more often as a pre-concentration step prior to further crushing. Final diamond recovery is achieved through any combination of wet or dry magnetic separation, X-ray sorting and the use of grease belts.

We recently acted as the engineering, procurement and construction management (EPCM) contractor on the Karowe Mine Diamond Project for Boteti Mining in Botswana. The Karowe processing plant is the first in Southern Africa to use autogenous milling as a primary liberation technique. In addition to this pioneering methodology, the mine recovered a 1,111-carat stone about 500km (300 miles) north of the capital, Gaborone. It is the biggest diamond to be discovered in Botswana and the largest find in more than a century.

 

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FEATURED PROJECTS

Khumani

Khumani

Client: Assmang

Location: South Africa

We were contracted to manage and design of the Khumani Iron Ore Greenfields Project in South Africa. The project was delivered ahead of time and under budget and resulted in a brownfields expansion. Our specialised project team was tasked as the lead contractor for end-to-end project management and integration of the crushing facility, processing plant, stockyards and infrastructure during the construction phase. Due to this highly successful implementation, we were contracted to manage various other phases of the project, including the EPCM contract for a super fines beneficiation plant in 2011. This plant uses WHIMS technology to process -1 mm super fines for the extraction of saleable product.

Kibali

Kibali

Client:  Randgold Resources and AngloGold Ashanti

Location: DRC

We expertly managed the EPCM contract for the Kibali Gold mine, located in the Democratic Republic of the Congo (DRC), for RandGold Resources, AngloGold Ashanti, SOKIMO. Our team delivered the design, procurement and project management of the metallurgical plant, infrastructure, a 45 MW backup power system, tailings system for a 6.1 Mt lined concentrate tailings dam and 7.6 Mt float tailings dam. Our scope of work on the processing plant included the design and construction of a facility to treat 3.6 Mtpa of oxide ore through the oxide circuit, and 3.6 Mtpa plant for the treatment of sulphide ore through the sulphide circuit. The project deadline was brought forward, but we rose to the challenge and first gold was poured a month ahead of schedule.

Stornoway 1

Renard Diamond Project

Client: Stornoway Diamonds

Location: Canada

Our team of experts was contracted by Stornoway Diamonds to provide engineering, detailed design and field support services for the processing plant and recovery circuits at Quebec’s first diamond mine.  Our scope of work covered process, concrete, structural, mechanical and EC&I engineering and detailed design for most of the process plant areas, including scrubbing, secondary crushing, screening, DMS, HPGR and the recovery plant. We also provided technical advice to the procurement partners, and technical support during fabrication and construction to ensure compliance with the design and for forthcoming commissioning. Commissioning is planned for the second half of 2016, with commercial production beginning in 2017.

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