Technological tests for Design Engineering
Technological tests for Design Engineering
– Preparation tests Procedures and instructions based on ore type and best technological type selection
– Performing all technological tests required to perform basic engineering in the process department
– Performing tests and material identification studies
– Performing processing tests including:
o Grindability and crushing Indexes
o Crushing test
o Minerals identification
o Gravity separation in various tests types, including heavy media and …
o . Magnetic separation
o Flotation tests
o Leaching tests
o Heap leaching tests
o Absorption and desorption test on charcoal and resin
o Organic solvent extraction tests
o Hydrometallurgical tests
o Providing required information for Basic and Detail Engineering Design
o Pilot plants tests
o Recommendations for plant Design and scale up factors according to tests data
o Tests results report
Researching and laboratory test works for new technologies
Researching and laboratory test works for new technologies
Ata’s Process Engineering Group has this ability to conduct research and laboratory studies to develop new methods to process non-common minerals,
Some activities we are doing in this regard:
– Obtaining information about the product specifications required by the client
– Obtaining information about the desired raw material (if any)
– Obtaining the available representative sample (if any)
– Carrying out research from the resources available for the design team (including design references, reputable research resources in the world)
– Designing the required experiments by reputable software are using in world research experiences
– Performing the required tests in reputable research centers
– Reviewing the results and designing and presenting the required data for plant design
– Preparation the flowsheet and mass balance
– Preparation chemicals requirement and consumption
– Select the main equipment required and provide a list of equipment
– Perform basic and detailed engineering if needed
Project management and control services
Project management and control services
– Prepare and submit projects activity list
– Prepare Project Engineering documents list
– Prepare Project work breakdown Structure (WBS)
– Prepare Project MDR
– Prepare Project time schedule
– Assigning project resources
– Prepare project costs schedule and provide S-Curve
– Review and control of all ongoing activities by contractors and project consultants
– Preparation and submission of periodic reports (daily, weekly and monthly, etc.)
– According to projects requirements Check all ongoing costs, and compare with the project plan
– Future cost estimating and forecasting the projects bottlenecks
– Project risk assessment
– Project time schedule review and identify the critical path and putting in order long lead items
– Visiting the project site and control the project progress
– Control the engineering documents preparation time
– Control the procurement and equipment supply
– Control site activities and construction progress
– Managing hole project and cooperate all disciplines together to have unique and integrated project
– Controlling Scope, Time and cost in all disciplines
– Provide solutions to compensate for possible delays that will occur as a result of unexpected events
Plants Commissioning, Operation Supervision and Performance Improvement
Plants Commissioning, Operation Supervision and Performance Improvement
– Review and finalize the plant process operation manual
– Checking all equipment installation
– Supervise the cleaning of systems according to the specified method and prepare for commissioning
– Reagent preparation procedures review and training
– Monitoring the calibration of process components – instruments
– Supervise the control of circuits and settings up safety relays of electrical equipment
– Supervise the control of the final levels of the relevant machines and lubrications
– Control different parts before installation team delivery, preparing check lists, and follow-up to eliminate the problems
– Match the drawings with the work done and determine the startup defects
– Check the consumables
– Review the consumables list and checking storage amounts in warhouse
– Control of instrumentation equipment at their adjustment points
– Set up and participate in the preparation of relevant operational forms
– Supervising the commissioning of machinery and facilities
– Supervising the delivery of mechanical completion (Mechanical Completion) of the units
– Cooperation with employers and contractors in issuing Mechanical Completion
– Supervising the elimination of defects related to the mechanical completion of projects, including main and auxiliary equipment
– Supervise the performance of tests to determine the maximum achievable capacity of all new equipment and various parts of projects
– Cooperation with the employer in the issuance of Provisional Acceptance Certificates and final delivery
– Operating manual and instructions required for technological type and selected equipment available in the plants
– Main equipment manual and special operation parameters and maintenance instructions to minimize spare parts
– Obtaining optimum parameters for process based on equipment’s capacity to increase equipment lifetime
– Minimizing consumables including chemicals, heat and energy to reduce operation cost as much as possible
– Identify the bottleneck of process and recommendations for increasing capacity by minimum changes in the equipment and piping
– Reagent preparation procedures training including chemicals MSDS
– Training Standard procedures for laboratory analytical methods
– Laboratory supervision including accuracy, precision and procedures review
– Training personnel to work with a variety of laboratory equipment
– Preparation and presentation of repair programs for equipment in the operational process
– Recommendation for laboratory equipment selection based on plant and ore type
– Designing and equipment selection for mineral processing laboratories
– – Training laboratory staff on how to perform tests and extract the required information from the test results
Troubleshooting the plants and increasing the capacity and performance of existing mineral processing plants
Existing plants Audition, Troubleshooting, performance and recovery improvement
Our Engineering team has both operation experiences and plant design experiences, so we know how to operate better and how to find the plant process audition, Troubleshooting, and finding the best ways to improve capacity and recovery by minimum stoppage and cost effects:
– Site visit in a time to identify the problems, doing site audition, checking the equipment performance, and plant process flowsheet and mass balance review
– Identify the plant process bottlenecks
– Checking the plant laboratory facilities to have some process tests in there, finding the optimum process parameters and compare them with existing plant’s parameters
– Finding the best reagent consumption and required changes in type and consumption amounts
– Checking laboratory accuracy and precision
– Checking the operation manual and its defects, completing the manual based on required changes if needed
– Provide solutions in all areas of processing, operational, mechanical, instrumental and electrical disciplines
– Assess the capabilities and skills of the operational team and provide training documents and booklets to the operators for each department
– Estimating operating costs and reporting on cost optimization
– Reduce chemical consumption and electrical power
– Proposals to increase production capacity by the lowest possible cost
Design and engineering of various mineral processing projects
Engineering Design Departments:
Mineral Processing department:
- Carrying out technological tests
- Laboratory tests design, using test design software
- Proposing plant flowsheet based on laboratory results
- Preparing mass balance based on laboratory tests results
- Main equipment selection
- Process plant reagent consumption optimization and checking the cost control
- Preparing plant facilities requirements
- Plant general layout and general arrangement
- Existing plants troubleshooting, capacity and recovery improvement
- Equipment sizing calculation and material selection
- Preparing process piping and instrumentation diagram ( P&I Diagram)
- Preparing plant process operation manual
- Equipment arrangement and installation supervision
- Preparing plant for pre-commissioning and commissioning
- Operators training
Mechanical Engineering Department (Equipment, Piping, Facilities and Safety)
The services provided in this Department can be summarized as follows:
- Cooperation with the process and electricity department to perform sizing calculations and equipment selection
- Preparing Mechanical Design Criteria and piping Design Criteria
- Mechanical and piping material selection
- Document Preparation for equipment specifications and datasheet
- Preparing the necessary documents to inquire, including PMR, MR
- Preparing HVAC Design Criteria
- Equipment supplier document review
- Performing plant 3d drawings by SOLID WORKS / PDMS software
- Cooperation with the process and electricity department regarding the preparation of documents and layouts of factory equipment according to the experiences of similar projects
- Pipe sizing and material selection
- Equipment installation supervision
- Piping installation supervision
- Maintenance manual preparation
- Plant pre-commissioning, commissioning
- Plants audition and troubleshooting
Civil and Structure Engineering Department
This department provided services can be summarized as follows:
- Review and compile documents for CIVIL and Structure design basics
- Preparing civil and structural Design Criteria based on the geographical area, earthquake zone, climate and national building regulations and international standards
- Concrete and structural modeling for production buildings, and industrial facilities, offices and administrative building
- Providing construction plans
- Providing all required drawings for building and equipment foundation
- Providing MTO for all construction activities
- Construction supervision
- Checking construction cost and comparing to the project plan
- Checking required spare parts
- Checking equipment consumables
Electrical Engineering Department
A summary of the capabilities of this section includes:
- Preparation of Electrical design Criteria
- Preparation of electrical power calculation
- Electrical motors selection
- Electrical Single Line Diagram
- Cable calculation
- Preparing Electrical consumer list
- Electrical panels Single line diagram
- Design and calculations regarding the selection of LV and MV cables
- Engineering studies for plant electrical networks
- Conducting short circuit network studies
- Perform relay calculations
- Lighting design and calculations
- Preparation and design of single line drawings of electrical panels at different voltage levels.
- Installation supervision of all LV drives and motors
- Advice on LV drives and motors
- Prepare Spare Part for drives and motors
- Design, calculation, implementation and testing of ground and lightning systems in accordance with valid standards
- Design, calculation and implementation of capacitive bank, battery and charger
- Calculations and selection of diesel generators
Control and Instrumentation Engineering Department
A summary of the capabilities and services of the control and instrumentation department is as follows:
- Design and consulting in the selection of automation systems
- Preparation and presentation of Design Instrumentation and Control Design Criteria
- Selection of sensors and instruments for measuring pressure, temperature, flow, level, density, analyzer and types of instrumentation converters based on the type of use and process used
- Cooperation with process and mechanical engineering departments to complete P & I Diagram
- Design and selection of industrial PLCs in different sizes and types according to the specific conditions of each project
- Design and selection of HMI software based on process needs
Personnel Training for operation and Industrial laboratories
– Operating manual and instructions required for technological type and selected equipment available in the plants
– Main equipment manual and special operation parameters and maintenance instructions to minimize spare parts
– Obtaining optimum parameters for process based on equipment’s capacity to increase equipment lifetime
– Minimizing consumables including chemicals, heat and energy to reduce operation cost as much as possible
– Identify the bottleneck of process and recommendations for increasing capacity by minimum changes in the equipment and piping
– Reagent preparation procedures training including chemicals MSDS
– Training Standard procedures for laboratory analytical methods
– Laboratory supervision including accuracy, precision and procedures review
– Training personnel to work with a variety of laboratory equipment
– Preparation and presentation of repair programs for equipment in the operational process
– Recommendation for laboratory equipment selection based on plant and ore type
– Designing and equipment selection for mineral processing laboratories
– – Training laboratory staff on how to perform tests and extract the required information from the test results
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