Mineral processing

As carbon neutrality becomes a global priority, the mining industry, known for its high energy consumption, must shift toward more sustainable practices. Achieving this requires leveraging digital advancements and decarbonization solutions while maintaining project feasibility. Efficient design and process optimization are essential to meeting growing demand for mineral resources, supporting economic growth and fostering responsible mining.

Mineral processing

  1. YOUR CHALLENGES

    • Mineral processing 1

      Designing an optimal mining circuit for maximum efficiency

      You face the complex task of planning and designing mineral processing circuits, crucial steps that determine the efficiency, sustainability and profitability of your operations. Selecting the right technologies is essential for optimizing your operational performance while adhering to stringent environmental regulations. You’re looking for a solution that will increase your plant's flexibility, optimize comminution circuits to lower energy costs and support informed decision-making. Your goal is to strike the perfect balance among recovery rates, product quality and operating costs.

  2. OUR EXPERTISE

    • Mineral processing 2

      Integrated solutions to optimize your mining processes

      As engineering consultants specialized in technology integration, our deep understanding of mining and metallurgical processes allows us to offer innovative and customized solutions at every phase of your projects. We incorporate the most suitable technologies and equipment. Our multidisciplinary approach promotes seamless coordination among all stakeholders.

      We understand that mineral processing challenges can significantly affect your profitability, which is why we focus on anticipating challenges through precise analysis and design. We offer clear and actionable recommendations that keep your operations sustainable by optimizing facility performance, enhancing energy efficiency and complying with environmental standards.

      Geometallurgy, metallurgical testing and process development

      Our advanced expertise in mineralogy and geometallurgy ensures accurate ore characterization and thorough data analysis to develop effective sample selection, metallurgical testing plans and processing schemes. We design plants capable of handling variations by using a multidisciplinary approach (geology, mining, process, environment) to assess geometallurgical models. This reduces technical, economic and environmental risks while improving performance predictions over the life of mine.

      • Multidisciplinary geometallurgical concept development
      • Ore characterization and variability analysis (grade, lithologies, etc.)
      • Geometallurgical modelling and metallurgical testing management to develop customised solutions that optimize overall value and reduce risks
      • Comminution and ore sorting assessments to optimize plant throughput, improve efficiency and maximize project value
      • Sample selection and composite recipe preparation
      • Test program development, management and data analysis
      • Pilot program development and supervision
      • Recovery-grade optimization
      • Process-design basis and circuit development
      • Technology selection based on process and project needs

      Process design, optimization and reporting

      We establish reliable foundations in process design and optimization for mineral processing, providing a crucial framework for all aspects of project development and execution. Our expertise includes designing advanced comminution circuits and mineral separation processes as well as pyrometallurgy and hydrometallurgy. We provide comprehensive solutions that span every project phase—from mine to tailings management—ensuring cost-effectiveness, optimal throughput and maximized recovery.

      • Mine-to-mill assessments and optimization, including energy-efficient technologies
      • Ore sorting and pre-concentration assessments
      • Project cost and sensitivity analyses
      • Throughput analyses
      • Comminution and grinding simulations and modelling
      • Flotation optimization and modelling (including self-heating testing and modelling capabilities)
      • Water and energy balances as well as optimization for process plants, incorporating water recycling to reduce the environmental impacts
      • Equipment and technology selection
      • Operation support studies: performance optimization, audits and expansion studies
      • Digital solutions and process automation to enhance real-time performance, predictive maintenance and operational efficiency in mineral processing operations
      • NI 43-101 and JORC studies, and more

      Expertise in strategic and key minerals and metals

      At BBA, we excel in designing processes for critical metals such as graphite, lithium, nickel and cobalt, as well as key strategic metals, including iron, copper and precious metals. As the demand for materials crucial to the energy transition and modern civilization rises, we lead the way, mastering the entire value chain.

      Our comprehensive expertise encompasses geological exploration, extraction, advanced processing (including secondary transformation and refining) and recycling. Our tailored approach delivers optimized processes that address the unique challenges of complex projects.

      • Development of processing schemes tailored to the unique challenges of each project
      • Operation restart and optimization studies
      • Design studies and safety reviews
      • Basic engineering and detailed design, commissioning, startup and performance testing services
      • Specialized consulting services
      • Implementation of digital transformation and energy optimization studies
      • Solutions designed for decarbonization and integration of renewable energy sources in mineral processing operations
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