Together with partners, M HEAVY TECHNOLOGY provides services for the development of technologies for processing raw mineral materials.
The company’s experts have extensive experience in designing and engineering crushing and processing factories, flotation and concentration plants, manufacturing of the main process equipment and automation systems, and the adjustment and optimization of crushing and concentration processes.
To fulfill the assigned tasks, we pay much attention to digitalization systems, ecological aspects, the maximum reduction of negative impact on the environment, and improving quality and labor safety at enterprises.
M HEAVY TECHNOLOGY provides comprehensive services for the creation or reconstruction of mining and processing plants:
- Laboratory tests and pilot studies;
- CFD modeling of mineral concentration processes;
- Development of innovative technologies;
- Design works;
- Development, manufacture, and supply of the main process equipment and automation systems;
- Services on installation supervision, designer’s field supervision, and commissioning, bringing the facility to warranty or design indicators.
Together with its partners, M HEAVY TECHNOLOGY performed all the above works for enterprises in Ukraine, Kazakhstan, Uzbekistan, and other countries.
Stages of mineral processing technology development
Study of mineral raw material composition
At this stage, the composition and quantity of elements that should be mined at the investigated deposit are determined. Research makes it possible to evaluate the rationality of extracting each presented element.
In cooperation with reputable international laboratories, the company’s experts perform the following:
- Chemical analysis;
- Analysis of physical and mechanical properties;
- Evaluation of mineralogical composition;
- Analysis of grain size and other characteristics of the material under examination.
Study of mineral raw materials dressability
The study makes it possible to determine all possible methods and technologies for dressing necessary elements.
The company carries out laboratory and pilot investigations for iron ore, copper, manganese, coal, chromite, and gold deposits. M HEAVY TECHNOLOGY experts have completed over 100 research projects in processing mineral resources and obtaining a marketable product compliant with all technical and economic indicators requirements.
Conducting laboratory and pilot tests of dressing technology
At the client’s request, M HEAVY TECHNOLOGY provides a full range of laboratory and pilot studies on dry- and wet-type dressing, flotation, use of electrostatic separators for separating ilmenite raw materials, tests on direct iron reduction, and other necessary works.
These studies determine the optimal elements’ dressing method and technology for specific conditions.
Development of a technical procedure for processing
A processing procedure is developed based on the results of laboratory tests, pilot studies, technological calculations, CFD modeling, and the experience obtained from previous projects.
The processing procedure includes:
- Water-slime balance;
- Product yield and extraction ratio;
- Particle size distribution of the crushed product, as well as the requirements for classification and circulation;
- A set of necessary equipment and a complete process chain.
Design of crushing and processing plants
Development of a conceptual project, basic technical solutions (BTS)
At this stage, the customer receives a complete description of the technological process, material and raw material balances, and a technological diagram of the materials processing.
Besides, M HEAVY TECHNOLOGY experts justify the choice of technology, a master plan, basic plans and sections for equipment arrangement, a structural diagram of automation of technological processes, and a preliminary assessment of the length and composition of external utility networks and structures.
BIM model detailing corresponds to LOD 100 – the minimum level of model development. It is a conditional object with basic detailing required for identification, suitable for sketch design. Elements and their parameters are presented approximately for preliminary calculations of technical and economic indicators.
Feasibility study
A feasibility study is the main pre-design document for the construction of facilities, the volume of which must be sufficient to prepare tender documentation and bidding for construction, the conclusion of construction contracts, and getting construction financing.
In addition to the more detailed technical part described at the previous BTS (basic technical solutions) stage, at this step, the economic aspect is worked out in detail: analysis of the industry situation in the area under consideration, comprehensive research of the market, analysis of the financial and economic activities of enterprises, assessment of current costs, evaluation of labor resources and development of the enterprise structure, economic calculations, assessment of financial prospects of the project, evaluation of the effectiveness of the investment project, economic justification of the project, assessment of financing needs, development of schemes for attracting investments, financial evaluation of the project, risk assessment.
BIM model detailing corresponds to LOD 200 – a conditional object with the minimum information required to make economic decisions. The elements of the model correspond to their actual shapes and locations but still have a high degree of convention.
Development of a project. Basic engineering (BE)
List of information that the customer will receive:
- Explanatory note;
- Architectural solutions;
- Constructive and space-planning solutions;
- Technological solutions;
- Power supply systems;
- Water supply, sewerage;
- Ventilation and air conditioning systems;
- Heating;
- Communication systems (TV, telephone and broadcasting, computer network);
- Construction management plan;
- Management plan for demolition and dismantling of the civil structure facilities;
- Measures for the protection of the environment;
- Cost estimate;
- Fire safety measures and other additional and specific chapters.
BIM model detailing corresponds to LOD 300 – a design model with specific and accurate shape, position, and basic attribute values. However, there is still no exact information about the manufacturer, suppliers, etc.
Development of working documentation. Basic engineering (DE)
At the stage of development of working documentation, the customer will receive all chapters announced at the previous stage – project documentation- but in much more detail.
BIM model detailing corresponds to LOD 400 – a high level of elaboration with the properties’ most detailed graphical representation and information content. A model element is graphically represented in the model as a specific system, object, or assembly in terms of size, shape, location, quantity, and orientation with detailed information, fabrication, assembly, and installation information. Non-graphical information can also be attached to a model element.
Audit and adjustment of mineral processing technology
Analysis of crushing and processing to assess possibilities of increasing efficiency of the enterprise and, depending on the initial conditions, it may include the following studies:
- Study of design documentation for the analyzed technology and potential inconsistencies, as well as data on the actual operation of the enterprise;
- Technological testing of the process being analyzed;
- Study of the processed raw materials composition and their compliance with the design;
- Study of dressability of processed raw materials and their compliance with the design;
- Development of recommendations for modernization of the technological process;
- The possibility of using more innovative technologies to improve efficiency and reduce costs.
Equipment supply for the mining and processing complex
In cooperation with members of the strategic alliance, in particular, the STAL company, M HEAVY TECHNOLOGY supplies essential process equipment for mining and processing enterprise:
- Ball mill
- Hydrocyclone
- Wet magnetic separation
- Flotation machine
- Wet high-intensity magnetic separation
- Electrostatic separators
- Pressure filter
