Our Experience

OUR PORTFOLIO

Decades of Experience

Process Edge brings diverse experience across a wide range of mineral commodities, having supported mining operations both nationally and internationally. Our team has worked with clients in gold, copper, iron ore, lithium, nickel, and mineral sands, among others, delivering practical solutions from design through to operations. This breadth of exposure enables us to tailor our approach to the specific technical and operational requirements of each mineral type and geographic region, ensuring effective and efficient outcomes for our clients.

Operational Readiness Project

Scope:

Develop and Implement the Operational Readiness Protocols for a Greenfields project in the Goldfields. This included,

  • Readiness Planning & Governance
  • Systems & Process Integration
  • Workforce Enablement
  • Asset Management & Maintenance Readiness
  • Risk & Safety Assurance
  • Progress Tracking & Readiness Reviews

Success:

Through this comprehensive approach, the project was able to capitalise on the accelerated ramp-up, whilst reducing risk, and ensure the operation was equipped for immediate and sustained success.

Value:

Bridging the gap between construction and operations and ensuring that the plant could start up safely, efficiently, and on time, and was able to meet its performance targets from the outset.

Lithium Plant Commissioning & Ramp Up

Scope:

Establish a team of 84 personnel consisting of management, trades, operators and technicians to commission, operate and maintain a newly constructed lithium operation in the goldfields.

Success:

Achieved nameplate production within two weeks of operation and increased from 100% to 160% of nameplate production capacity with zero LTIs throughout entire operational period. Maintained operational budget well below forecast.

Value:

Showcase operation for both the EPCM and the client, resulting in additional projects and customers. Very high staff retention and reduced operational costs, delivering higher than forecast returns for the client.

Increased Production Audit

Scope:

Complete an asset operational audit to determine the condition of an in-service coal handling plant for a major WA coal mining operation. Determine the plant capability and develop maintenance strategies to support an increased throughput from 2.7MTPA to 5MTPA.

Success:

Plant audit completed with equipment condition profiles documented and a plan developed to address current plant maintenance requirements.

Value:

Plant capability identified and integrated into the product delivery chain to establish the new operational strategy required to achieve the increased tonnage throughput target of 5Mtpa. Maintenance shutdown drivers identified, and the maintenance strategy moved to a primary maintenance driven shut down cycle to deliver increased availability while minimising the asset life cycle costs.
The development of a resource profile for the Coal Handling Plant to identify the resources required to perform the maintenance planning and execution functions effectively.

Plant Recommissioning & Restart

Scope:

Establish a team of 90 personnel consisting of management, trades, operators and technicians for the recommissioning and return to operation of a nickel processing facility located in the North of Western Australia.

Success:

Although the operation had been poorly shutdown and maintained going into and during the care and maintenance phase, production was achieved in time to meet the clients’ shipping requirements.

Value:

The client was able to capitalise on the rapid rise of the nickel price achieving a timely ROI

Offshore Commissioning & Restart

Scope:

Commission and operate processing facilities in Central Asia and Northern Europe.

Success:

Both facilities successfully met production targets despite challenging commissioning and ramp-up phases due to extreme weather, necessitating rapid and innovative solutions to previously unseen industry issues.
Commissioned a new plant and recommissioned an older one to revitalize Norway’s largest magnetite operation, contributing to economic growth and employment in Northern Norway. Enabled the client to secure multiple off-take agreements.

Value:

Developed and trained a workforce of hundreds of foreign nationals, new to the industry, in the operational and maintenance requirements of a magnetite and coal handling preparation plant, delivering lasting value to the client and advancing both countries mining sectors.

RESOURCES WE SERVICE

We cover all Resources

At ProcessEdge, we specialise in driving excellence across the ore & mineral processing industry.  Our mission is to optimise plant equipment and processes to improve efficiency, productivity, safety and sustainability. Additionally,

Companies We Work With

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At ProcessEdge, we specialise in driving excellence across the ore & mineral processing industry.

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