Process Studies & Design
We characterize the ore, measure its response in the laboratory, and design the processing route around test data, mass balance and project economics.
Define this stage for my project01 / FEEDFeed preparation
04 / PRODUCTFinal product
02 / SEPARATIONMineral separation
03 / RECOVERYProduct recovery
Engineered for continuous productionLAB → PROCESS → PLANT
Mineral processing engineering
Material intelligence,
process power
We integrate engineering design, specialist laboratory testing and data analysis to reduce risk, improve performance and reach stable production.
- Lower risk
- testing on real samples
- Data-led decisions
- assays and mass balance
- Stable production
- commissioning and optimization
02 An integrated path
From material insight,
to stable production.
Every stage completes the input for the next — no gaps and no decision detached from plant reality.
01/ 05
02 An integrated path
From material insight,
to stable production.
01
From material characterization to technology selection
Process Studies & Design
We characterize the ore, measure its response in the laboratory, and design the processing route around test data, mass balance and project economics.
- Mineralogical studies
- Flowsheet and mass balance
- Pilot testing and feasibility
02
Turning the process into buildable documents
Basic & Detailed Engineering
We integrate conceptual, basic and detailed design across equipment, structure, mechanical and electrical disciplines before the plant reaches the jobsite.
- Layout and 3D model
- Equipment and structural design
- Electrical and mechanical documents
03
The right selection before costly procurement
Procurement Engineering
We manage technical specifications, vendor assessment and bid alignment so equipment matches the real feed, capacity and operating conditions.
- Datasheets and RFQs
- Technical vendor evaluation
- Supply quality control
04
Quality control where the plant is built
Construction & Installation Supervision
From civil works to mechanical and electrical installation, we monitor compliance with engineering documents, standards and the project schedule.
- Site and periodic supervision
- Installation and alignment control
- Non-conformance management
05
Bringing the plant to its real capacity
Commissioning & Optimization
We continue through cold and hot commissioning, operator training and bottleneck analysis until production is stable, recovery improves and costs decline.
- Commissioning and training
- Capacity and efficiency improvement
- Operations management
03 Selected projects
Data transformed into
real production.
Selected iron, gold, copper and recycling projects that turned a technical challenge into a measurable execution path.
01/ 04
Akkahour Hematite Concentration
Operations management and development of a magnetic-separation hematite concentration plant, created to reduce raw ore sales and produce a higher-grade iron concentrate.
- Magnetic separation
- Operations management
- 80
- t/h feed capacity
- 50,000
- t/y production
- 01
- Project dossier
03 Selected projects
Data transformed into
real production.
01 / Fin, Hormozgan
Akkahour Hematite Concentration
Operations management and development of a magnetic-separation hematite concentration plant, created to reduce raw ore sales and produce a higher-grade iron concentrate.
- 80
- t/h feed capacity
- 50,000
- t/y production
02 / Joveyn, Razavi Khorasan
Jelambadan Sulphide Gold
A combined flotation and cyanide-leaching process designed after two years of study to recover refractory gold and deliver a higher-value final product.
- 250
- t/day feed capacity
- 2
- years of specialist study
03 / Zarandieh, Markazi
Parandak Copper Cathode
Mineralogical studies plus crushing, leaching, solvent extraction and electrowinning design for copper cathode production in one integrated industrial chain.
- 300
- t/day feed capacity
- 700
- t/y cathode
04 / Armenia
Battery Recycling in Armenia
A spent lead-acid battery recycling chain, from mechanical separation through smelting, refining and waste management with a reduced environmental footprint.
- 5,000
- t/y recycling
- 3,000
- t/y lead production
04 Zarfaravar scientific core
Mineral processing
laboratory capabilities
Testing real samples narrows the gap between engineering assumptions and material behavior — producing a more accurate flowsheet with lower investment risk.
Sample Preparation
Crushing, grinding and sample preparation
Characterization
Sizing, work index and mineralogy
Gravity Separation
Shaking table, jig and gravity tests
Flotation
Laboratory and semi-industrial pilot tests
Leaching
Column, agitation, acid and cyanide tests
Magnetic Separation
High and low intensity, dry and wet
Pyrometallurgy
Thermal tests in box and tube furnaces
Dewatering
Filtration and product behavior assessment
Confidence in every decision
01
Documented methodRecorded test conditions and parameters
02
Scalable resultsFrom testwork to pilot and plant
03
Analytical reportOutputs engineered for process design
05 Start a technical conversation
Your challenge is
where we begin.
Share a few initial details about the material, capacity or production challenge. We route your request to the right process, operations or laboratory specialist.
01
Register the needInitial project information
02
Technical reviewBy the relevant specialist
03
Consultation sessionA defined action path
06 Quick answers
Your question is
probably answered here.
Frequently asked questions are organized around the stage your project is currently in.
01What information is needed to start designing a processing plant?
The mineral type, initial assay results, target capacity, project location, and water and energy constraints are the starting point. If data is incomplete, a sampling and laboratory test program is defined.
02Are your design services limited to process engineering?
No. The scope can integrate conceptual, basic and detailed design for process, equipment, structures, mechanical systems, electrical systems, instrumentation and layout.
03What does a feasibility study deliver?
The deliverables include a proposed flowsheet, mass balance, major equipment selection, water and energy estimates, an investment range and the project technical risks.
07ZFR / TECHNICAL INSIGHTS
Engineering knowledge,
ready for the field.
Seven in-depth guides based on laboratory studies, process design and operating-plant experience.
CommissioningMineral processing plant commissioning: from completion to stable production
Commissioning is not a final construction event. It starts in engineering and moves the plant through controlled stages to repeatable production.
Read the full articleMagnetic separationHematite magnetic separation: field intensity and circuit design
Hematite is more weakly magnetic than magnetite, making liberation, field gradient and washing conditions central to performance.
Read the full article
Gold processingRefractory sulphide gold processing: flotation to cyanide leaching
Gold may be locked within sulphide grains, so a single direct-leach test is not enough to select the process route.
Read the full article
Copper hydrometallurgyCopper cathode production by leaching and SX/EW
SX/EW is a closed solution chain: leach chemistry and phase separation determine the electrolyte that ultimately controls cathode quality.
Read the full article