Mining Production and Plant Services

Energy efficiency is becoming more important than ever with increasing energy costs and environmental impact.

Wasting energy reduces your profitability and sustainability footprint. ECBH can partner with you to provide cost-effective energy optimization solutions. We provide a framework for continuous improvement in efficient and sustainable energy use. From selecting the optimal grinding size at the bench-scale to prior to start-up to performing full plant energy audits of existing plants, our global technical leadership and industrial expertise provides a respected benchmark of experience and value.

ECBH has a range of strategies for energy mitigation. We can help you to:

• Understand mineralogy and geological variability within an orebody to make the right grinding choices. ECBH uses High Definition Mineralogy to document variations in hardness of grindability across the deposit. Modeling and simulation of this data allows us to determine the exact size of grinding mills needed for your project, before capital equipment is specified.
• Make the right grinding choices before start-up or during expansion/upgrades. Using computerized models, ECBH simulates your flowsheet using a variety of possible equipment choices. This modeling will highlight the optimal equipment type and size to generate the throughput you need while limiting your energy costs.
• Simulate and model to make the right equipment choices in feasibility and during expansions. ECBH documents your ore’s hardness from the perspective of semi-autogenous milling using the SAG Power Index (SPI®) test. The data from SPI is used to map out the deposit’s grindability, placing the metallurgical data directly on the block model for interpretation and modeling.
• Optimize your flowsheet and manage power needs.  ECBH’s computer modeling software, Comminution Economic Evaluation Tool (CEET), uses grindability data assigned to ore blocks and other operational parameters to simulate a virtual mining circuit. CEET provides you with throughput per hour and the grain size needed for operations.  This operational data is captured back on the block model.  When combined with the mine plan, CEET can be used to virtually process the entire deposit and thus demonstrate the energy output required for the mine life of your operation.
• Use process and systems control to get the most of existing energy intensive equipment. ECBH offers advanced process control solutions through the implementation of expert systems to closely control your operations. When throughputs stay within optimized levels, your energy usage remains within a predictable range. Keeping your energy usage in control will limit any potential energy waste and results in increased savings.
• Perform technical audits and plant optimization. ECBH conducts technical audits and plant optimization studies in operating plants. Our technical expertise allows us to review many plant parameters and make recommendations that will reduce or optimize your energy usage, thus increasing your overall profitability.
• Perform management audits. ECBH’s energy audits examine energy production, planning and protection for the duration of the mine life. Audits provide protection against any potential energy market instabilities. ECBH’s energy audits provide you with a competitive advantage through the identification of cost savings and allow you to showcase your corporate social responsibility awareness through the efficient management of your electrical and power needs.

ECBH provides proven services for controlling energy costs and mitigating energy supply risks. We continually develop and offer new innovative solutions to help you optimize your energy usage. Partner with ECBH to increase your operation’s energy efficiency and environmental sustainability.

Asset performance management (APM) enables the optimal operation of a physical asset to realize maximum benefits at minimum cost.

The goals of APM are:

• Continuous (pre-emptive) monitoring of asset health, incorporating stability and performance considerations
• Early detection of incipient problems
• Applying corrective measures proactively on a just-in-time basis, thereby reducing time and cost of problem resolution
• Reliably identifying persistent plant issues to drive capital/time investment decisions

Intelligent asset performance management employs advanced systems and technologies to help automate and support the APM process. ECBH’s Asset Health, Effectiveness and Diagnostics (AHEAD) is a platform for intelligent APM. AHEAD addresses certain industry needs at the plant level:

• Increased business and process complexity – there is a high skill level required to operate and troubleshoot processes effectively and analysis is time consuming
• Operational and HSE considerations – AHEAD minimizes unnecessary maintenance and limits personnel exposure to dangerous environments
• Difficulty finding and retaining experienced staff, especially in remote locations – AHEAD allows you to operate with leaner staffing levels

AHEAD provides an advanced process condition monitoring system that intelligently analyzes and assesses plant asset performance on a continuous, pre-emptive basis. A comprehensive and effective tool, AHEAD helps you achieve and measure compliance with operational excellence standards, with the ultimate goal of better asset utilization, optimized product quality and lower operating costs. AHEAD achieves optimal asset (equipment, process and controller) performance through:

• Monitoring of asset health continuously and consistently 
• Detecting existing or incipient problems which may affect equipment or process operation and or efficiency
• Diagnosing the root cause of detected problems
• Making timely and problem-centric advice available via web based displays and summary reports
• Assisting operations personnel in minimizing the effects and duration of identified problems
• Mitigating the impact of employee turnover by helping retain key process knowledge

AHEAD reliably automates process monitoring and troubleshooting tasks to consistently and quickly detect deviations from desired performance targets (Key Performance Indicators, or KPIs). The system then diagnoses the causes of such deviations and recommends appropriate actions to rapidly return the process to normal operation.

One of the unique strengths of AHEAD is its fully automated Root Cause Analysis (RCA) functionality that is based on heuristics (modeling the troubleshooting reasoning of the process or asset specialist). This methodology provides a framework for real-time fault management in large-scale systems while protecting the operator from 'alarm-flooding' and increased workloads.

AHEAD delivers concise and targeted communication in a consistent and repeatable manner within a plant organization.  At operating sites where AHEAD has been integrated into staff’s performance management culture, ECBH’s approach enables closer adherence to operational discipline, helps standardize Performance Management within unit operations, and ultimately reduces or eliminates the impact of operational loss events.

AHEAD can further play a role in consolidated control centers, where centrally-located specialists and operators manage several geographically dispersed and at times remote operating sites. Consolidation of large volumes of data and events from several sites has the potential to rapidly overwhelm the control center staff; being able to react to a prioritized problem list and quickly identify each problem’s causes will be of paramount importance to the center’s and each site’s effective operation. 

Trust ECBH to deliver quality intelligent asset management solutions to contain costs, reduce risk and enhance value.

Geometallurgy is the integration of geological, mining, metallurgical, environmental and economic information to maximize the Net Present Value of an orebody while minimizing technical and operational risk.

The ECBH Geometallurgical Framework:

• Allows the definition of the optimum extractive metallurgy flowsheet design over life-of-mine based on the documented geological, geochemical, mineralogical, textural and metallurgical characteristics of an ore deposit
• Involves state-of-the-art methodologies that take into account the specific characteristics of an ore deposit

Geometallurgy quantifies the variability of an ore deposit in terms of process parameters such as ore hardness, flotation, leach response and environmental impact. This data is then applied to the deposit block model or the mine plan, typically through use of geostatistics. Then, geometallurgically enabled mathematical models such as CEET and FLEET can be used to generate economic parameters such as throughput, grind size, grade and recovery. These can then be returned to the block model and mine plan for further handling. Scenarios can then be developed and compared to evaluate and optimize operational scenarios such as mine strategy, energy use, capital equipment needs, carbon footprint etc.

This is achieved through the application of the six stages of ECBH’s Geometallurgical Framework.

Stage 1 – Multivariate Spatial Domain Definition: Definition of spatial domains with similar geological, geochemical, geophysical, geotechnical, mineralogical and textural characteristics in the ore deposit. This takes into account the extensive information data set associated with the exploration drillhole and geochemical database of the deposit.

Stage 2 – Sample Selection: Selection of samples from various domains across an orebody to provide representative materials for mineralogical, metallurgical and environmental testing.

Stage 3 – Parameter Determination: Determination of the suite of tests needed to generate the technical parameters needed for flowsheet design and environmental testing.

Stage 4 – Multivariate Model Definition: Definition of multivariate relationships that correlate characteristics such as geochemistry, mineralogy and texture with processing parameters related to grindability, flotation and leachability.

Stage 5 – Multivariate Spatial Model Generation: Use of geostatistical methods to populate each domain in the block model with geological, geochemical, geophysical, geotechnical, mineralogical and textural parameters either determined by testing or extrapolated from test results.

Stage 6 – Joint Mining and Mineral Processing Optimization: Optimization of geological, mining, mineral processing, environmental, marketing, economics and corporate strategies to maximize the project value while minimizing risk and several sources of uncertainties.

Geometallurgy significantly reduces the impact of spatial uncertainty in mine planning because it documents the variability in a deposit. The application of the ECBH Geometallurgy Framework:

• Lowers project risk
• Optimizes mine resources
• Improves plant performance
• Minimizes Net Present Value

Our technical experts have been actively developing and using geometallurgy in project development for many years. We have supported the development of hundreds of projects using the Geometallurgical Framework for large and small companies throughout the world. Team with us and share our intellectual expertise and reduce your technical risk.

Metallurgical plant upgrades and retrofits – ECBH can help you meet your operational objectives.

Plant upgrades and retrofit engineering call for an experienced technical partner. We can help you to meet your objectives, whether they are to:

• Increase capacity
• Improve recovery
• Increase throughput
• Achieve higher product quality
• Improve safety
• Add new technology
• Meet permitting or environmental requirements

Our integrated process engineering team leverages its proven operational experience to deliver on-time and cost effective engineering solutions for your plant and infrastructure upgrade. Our comprehensive expertise allows us to integrate process, civil, structural, mechanical and electrical engineering aspects during design. Our team has demonstrated experience in overcoming the challenges in designing plant upgrades within existing buildings and infrastructure. We will thoroughly evaluate your processing operation, recommend and implement the optimal technology, plant and facility upgrades.

Our experienced engineering teams can:

• Perform plant audits, make troubleshooting and optimization recommendations
• Conduct metallurgical testing for plant process optimization and trade-off studies
• Ensure designs account for optimal space, water and energy use
• Analyze and cost various options for design
• Perform economic analyses including detailed capital and operating cost estimates
• Present economic analysis for management evaluation
• Provide detail design and engineering
• Provide procurement and construction management
• Ensure that your plant design addresses health, safety and environmental concerns
• Monitor and evaluate performance on a continuous basis

With ECBH as your partner you can be confident that your plant is designed to optimize your specific product, capital, safety and environmental requirements. For the mitigation of operational and financial risk as you expand your plant, contact us today.

Statutory inspection and voluntary inspection services from ECBH – ensures that your assets meet all quality and performance requirements, whether they are statutory, voluntary or customer based.

To ensure quality, integrity, and health and safety, your installations, equipment and materials must meet a number of legal and voluntary requirements. We offer you both statutory inspections and voluntary inspections to help you meet all quality and performance requirements – whether they are statutory, voluntary or customer based.

WHY CHOOSE STATUTORY INSPECTIONS AND VOLUNTARY INSPECTION FROM ECBH?

We have accreditations to all major standards and regional regulations, enabling us to offer you a comprehensive range of statutory and voluntary inspections to help you ensure:

• The health and safety of employees in the workplace 
• Installation integrity
• Environmental sustainability 
• Regulatory compliance within defined standards 
• The availability, safety and reliability of your assets
• The sustainability of your business operations

 

To mitigate risk and optimize your plant, we offer you the Integrated Geometallurgical Simulator (IGS) tool. IGS simulates comminution and flotation circuits either separately or as combined processes. Using previously determined results from bankable ECBH comminution and metallurgical test work, IGS enables you to easily see how changes made to any part of your grinding or flotation circuit will affect your overall performance. IGS can be used for a variety of purposes including plant design and scenario testing, energy optimization and production forecasting.

Once you have completed the necessary ECBH testwork to obtain the required input parameters, you can simulate your existing comminution and/or flotation circuits using IGS.

You can manipulate your operating conditions, perform basic circuit layout changes and see how these changes affect the circuits and final product quality. Such modeling will allow you to make decisions that will ensure that your operations run at peak efficiency. IGS enables a geostatistically sound mill and flotation circuit design with optimized equipment selection and an accurate prediction of power consumption.

Upon downloading the IGS software, you can draw and configure your circuit based on two data types:

• Operational data: This is day-to-day information that you gather from your plant.
  
  For comminution circuits, these include:
  • Circuit configuration
  • Installed power
  • Grate and screen sizes
  • Average circulating load
  • Average mill load
     
  For flotation circuits, these include:
  • Circuit configuration
  • Cell sizing
  • Operating parameters
     
• Ore characterization: These are the input parameters determined from your samples using ECBH testwork.
  
  The ore characterization data for your comminution circuit includes results from:
  • Bond Ball Mill grindability tests
  • Bond Work Index (BWI) tests
  • ModBond grindability tests
  • SAG Power Index (SPI)
  • Static Pressure Tests (SPT)
  
  For your flotation circuit, these data would be mineralogical and mineral flotation tests results from:
  • MFT tests
  • Cleaner Flotation tests
  • Locked Cycle tests
  • Bulk Mineral Analysis (BMA)
  • Particle Mineral Analysis (PMA)
  • Specific Mineral Search (SMS)

Required tests vary according to your specific requirements (Greenfield or brownfield design, optimization or production forecasting). On-going development work can require additional tests or different types of tests depending on the technology.

Partner with ECBH today and run your plant at optimum efficiency with our IGS tool.

ECBH mining equipment maintenance (MEM) services help you reduce equipment downtime. 

This, of course, enables you to meet cost objectives and optimize profits in your oil sands mining operation. ECBH provides services in oil sands mining equipment inspection and maintenance, fire suppression (FS) systems and HVAC (heating, ventilation, air conditioning) inspection.

MAINTENANCE SOLUTIONS

ECBH’s life cycle maintenance solutions are centered on reliability. Our well trained teams of experts focus on identifying and establishing the operational, maintenance and capital improvement strategies that most effectively manage the risks of equipment failure. The introduction of our new data management system helps you to track and trend failures, transitioning you from preventative to predictive equipment strategies and practices. The quality and reliability of our audits, hazard analysis, installation and staffing services are recognized worldwide.

Executive search solutions from ECBH – save time, money and reduce risk when recruiting.

Successful headhunting is about investing time, understanding clients industry, vision, values and business strategy.  We actively hunt for talent that is not on the market, not searching for their next career move or on job boards. We understand that talent needs to be made aware of great opportunities that meet their career aspirations

Employing our executive search solutions means working with ECBH on an exclusive basis with a dedicated consultant providing your main point of contact, plus we deliver the following key activities:

• Assignment Brief:  Understanding the role, key competencies, and technical requirements
• Company target list: Working alongside a client we present a company target list for approval
• Research and selection: Produce a list of suggested candidates to approach which you would approve
• Pre-screening and preliminary interviews: We conduct pre-screening and preliminary interviews to gauge the interest and experience of candidates
• ECBH interview: We conduct a thorough interview along with competency-based questioning. This phase addresses experience, goals, ambitions, integrity, salary expectations and provide in-depth information on the position and client company
• Candidate shortlist: A comprehensive list of the most suitable candidates who have passed the screening process
• Client interviewing: Arrange and coordinate first and second round interviews between client and candidate
• Feedback meeting: Once all candidates have been interviewed we would help you to reach a successful conclusion
• Formal offer: You would identify the most suitable candidate and we would support you and the candidate throughout the offer process to ensure both parties reach an agreement

Using this method and working exclusively with ECBH will save you time, money and reduce risk in finding the perfect employee.

WHY CHOOSE EXECUTIVE SEARCH RECRUITMENT SERVICES FROM ECBH?

Our team of professional consultants have developed an effective and successful headhunting process.  Every search is different and specially tailored to our clients’ needs. A dedicated team of consultants drive the search process, giving you the confidence they we will find the talent you need.
 
Contact ECBH today for more information on our executive search solutions.

We have high-level expertise in fields such as chemical engineering, mineralogy, environmental and process design that can provide innovative solutions from fresh angles. Our systematic approach can determine if improvements can be made in your plant. Plant optimization studies range from basic audits and plant surveys, to complete troubleshooting programs. At all times, the work is done in close association with your plant personnel.

Optimizing of plant operations can considerably increase your profits. Payback time is commonly weeks or months. Any improvement in product recovery or quality, with minimum capital outlay, results in additional revenue that directly increases profit. 

The following situations would most likely benefit from plant optimization

• Newly-commissioned plants
• Mines with highly variable ore and many ore types  
• Plants that have experienced gradual changes in feed type, evolution of the treatment scheme, addition of new equipment and/or personnel changes Operations that have been operation many years and want to investigate new reagents or technologies
• Existing operations that do not have a formal and systematic optimization program
• Existing operations that require confidential debottlenecking and troubleshooting

ECBH’s proven approach to plant optimisation typically comprises several of the following aspects:

• Round-table “brainstorming” discussions and briefing sessions to clearly define objectives and limitations.
• Continuous close contact to ensure maximum input from all angles to define the problem and ensure that the resolution is implemented in a sustainable manner.
• Collation of data surrounding the existing flowsheet.
• Visit to site to physically inspect the plant, discuss potential problem areas with plant staff and collect samples.
• Review the feed types and overall implications for processing.
• Identification of areas where adjustments to the flowsheet or operating conditions may improve throughput or recovery, cut costs, improve effluent quality, reduce emissions or decrease possibilities for litigation.
• Review of existing and novel technologies that may be applicable to the problem.
• Critical techno-economic assessment of possible changes to process flowsheets or operating conditions. This may include some of the following areas:
  • Process flowsheet definition
  • Metallurgical accounting
  • Grindabilty
  • Calculation of process inputs
  • Component mass-balancing
  • Speciation modeling
  • Simulation modeling
  • Potential technical viability
  • Estimated product yields and qualities
  • Estimated equipment capital costs, operating costs and economic viability
  • Chemical considerations that may impact upon processing 
  • Mineralogical considerations that may impact upon processing
  • Environmental compliance baseline, potential recycles and consideration of locality.
• Planning and management of testwork programs to confirm or negate potential process changes.

Statutory inspection and voluntary inspection services from ECBH – ensures that your assets meet all quality and performance requirements, whether they are statutory, voluntary or customer based.

To ensure quality, integrity, and health and safety, your installations, equipment and materials must meet a number of legal and voluntary requirements. We offer you both statutory inspections and voluntary inspections to help you meet all quality and performance requirements – whether they are statutory, voluntary or customer based.

STATUTORY INSPECTIONS AND VOLUNTARY INSPECTION FROM ECBH

We offer you a comprehensive range of statutory and voluntary inspections to help you ensure:

• The health and safety of employees in the workplace 
• Installation integrity
• Environmental sustainability 
• Regulatory compliance within defined standards 
• The availability, safety and reliability of your assets
• The sustainability of your business operations