Construction Supervision

Gold Mine – Brownfield EP

Challenge

A Brownfield project to recommission a 2500 t/d gold concentrator in a remote location in Northern Canada with extreme winter conditions and accessibility challenges.

Process

Process areas included Coarse Stockpile Feed, SAG and Ball Mills, Gravity Concentrator, CIL, Electrowinning, CN Destruct, Tailings Thickening, Reagents, Goldroom.

Delivery

After completion of Basic Engineering, Consultec performed equipment and bulk procurement as well as detail engineering. Extensive refurbishment of existing structures and equipment was required.

Flotation Plant – Gold

Challenge

Detail Engineering and Procurement services for a new Carbon Preflotation Plant and Tie-Ins.

Process

BROWNFIELD project Including: (2) lines of (2) 600m3 Roughers (3) 300m3 Cleaners (3) 300m3 Scavengers Recleaner Column

Delivery

An existing Open Pit mine and processing facility located in Mexico has ore with high levels of carbonaceous material that when processed destabilizes the downstream lead and zinc flotation circuits leading to poor recovery and high operating costs. The project scope included diverting all of the existing plant’s mill feed to a carbon preflotation circuit consisting of roughers, cleaners, cleaner-scavengers and recleaner flotation cells in order to remove the carbonaceous material. The resulting “clean” tailings was pumped back into the existing lead/zinc flotation circuits. Consultec, in partnership with Outotec Canada, designed the plant and procured all equipment, plant services/utilities, and supported all bulk procurement, construction and commissioning activities. Basic + Detail Engineering were completed on a fast-track basis within an 8 month period and constructed/commissioned within 24 months of the start of basic engineering.

Cement Kiln Line, 3000 t/d

Challenge

A fast-track project was commissioned by the owner to take advantage of a robust local cement market. The onus fell upon the engineering integrator, Consultec, to bring together diverse equipment suppliers and construct a new facility, adjacent to an existing kiln line that remained in operation throughout the project.

Process

For a new 3000 t/d kiln line, a carefully planned phased design was scheduled to facilitate equipment tie-ins during planned plant shutdowns.

Delivery

Consultec was the overall engineering integrator for this $250M project, and was responsible for balance of plant equipment procurement, mechanical, civil, structural and electrical design as well as construction supervision.

Rail Terminal – Coal

Challenge

To meet the growing demand for energy, coal from this western US coal mine is loaded on rail cars at the astonishing rate of 70 tons in 10 seconds. A reliable discharge system needed to be designed that could deal with the difficult flow properties of coal.

Process

After a detailed flowablility analysis, design of the unique withdrawal hopper and concrete silo was done with particular geometric properties and lined with materials to promote mass flow.

Delivery

As a fast track project, detail design was done in four months to enable a 12 month overall construction schedule. Consultec provided detailed civil, structural design.

Cogeneration Plant – Biomass

Challenge

To serve the growing demand for Renewable Energy, this 25 MW cogeneration power plant was constructed on the premises of a saw mill in Alberta, Canada to take advantage of the abundant waste wood that was previously burned as waste.

Process

The extreme cold climate and difficult-to-handle wood fuel provided abundant design challenges.

Delivery

Consultec was responsible for equipment procurement, mechanical, electrical and civil design.

Silo – Ecuador

Challenge

An exceptionally large, 70,000 t capacity clinker storage was required for this cement producer in a remote, high seismic part of Ecuador. The silo was located in close quarters to the existing plant structures and had to be built in a timely manner.

Process

Extra large capacity storage silos run the risk of encountering eccentric flow on withdrawal. Advanced methods of calculating the impact of eccentric flow on material pressure was employed. Also, in order to speed up construction, the large roof and penthouse was designed such that it was integrated into the slipform deck.

Delivery

Consultec was responsible for mechanical and civil/structural design.

Slag Grinding Mill

Challenge

This global cement producer has a policy of maximizing cement replacement materials in order to minimize the carbon footprint of the end product and to reduce production costs. Ground slag can substitute up to 30% of the ordinary portland cement used in the making of concrete This was in fact the first vertical mill for slag grinding in Canada and one of the first in the world.

Process

Although vertical grinding is a very energy efficient technology, the supporting equipment and controls is complex and confined to a small area. Further complicating the design, the system was to be designed to grind future materials such as clinker so the overall capacity varied from 60 t/h to 100 t/h.

Delivery

Consultec was the overall engineering integrator for this project. Responsible for balance of plant equipment, mechanical, civil, structural and electrical design as well as construction supervision.

New Kiln Line

Challenge

Design and construction supervision of a 5600 mtpd clinker kiln line from raw material storage and handling, raw grinding, pyro-processing through clinker storage.

Process

5600 t/d Clinker production line (increased to 6300 t/d with process improvements)

Delivery

St. Marys Cement replaced 2 existing wet klins with one 5 stage, double string new kiln line with a capacity of 5,600 tpd. In 1999 Consultec engineered modifications to increase clinker production capacity to 6,400 mtpd. Projects included a new downcomer, ID Fan, indirect kiln coal firing system, dust collection, upgrades, cooler enlargement and new tertiary air duct.