Mineral & Chemical Processing
Process Development, Engineering & Optimisation
eXcellerate provides specialist support for complex mineral and chemical processing built on decades of practical, end-to-end process engineering expertise and operational experience in international companies.
We work with clients from early concept development through to EPC delivery, commissioning, and operational improvement, with a strong focus on robust, scalable, and efficient processing solutions.
- Nickel
- Potash
- Salt
- Rare earths
- Uranium
- Lithium
- Base metals
- Platinum group metals
- Iron ore
- Others
From Concept to Pilot: Full‑Lifecycle Processing Development
- Structured, risk-based process development, incorporating market analysis, benchmarking, technology maturity assessments, and project-specific evaluations.
- Review of comparable and failed operations to mitigate known failure modes.
- Design and execution of batch testwork, continuous testwork, and pilot plant programs tailored to project objectives and scale-up risk.
- Timely on-site testwork and piloting to capture real operating conditions and generate design-ready data.
- Translation of testwork and pilot findings into design criteria, equipment selection, control philosophies and operating envelopes.
- Integrated operation training, upskilling and knowledge transfer, supporting a smooth transition to owner-operated execution.
- Technical coordination and management of external laboratories, technology providers, equipment vendors, and contractors through design, construction, commissioning, and ramp-up.
Operational Improvement & Processing Optimisation
- Holistic review of existing operations to identify improvement opportunities aligned with client objectives.
- Targeted optimisation of throughput, recovery, product quality, energy efficiency, reagent consumption and operating costs.
- Identification and mitigation of process safety and operability risks, including debottlenecking and reliability improvements.
- Enhancement of process control strategies, instrumentation, and automation to improve stability and operational consistency.
- Assessment and execution support for plant expansions, capacity increases, and integration of new process units within operating facilities.
- Evaluation and development of additional or alternative product streams leveraging existing infrastructure and processing capability.
Case Study: Sulphate of Potash Plant at Mardie
Advance your process design or optimisation program.
