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iron-ore concentrator design

iron-ore concentrator design
CVG Ferrominera Orinoco C.A.
Puerto Ordaz, Venezuela

international team provides fast-track design and engineering services for iron-ore concentrator

C.V.G. Ferrominera Orinoco C.A. (FMO) a Venezuelan government-owned mining company, proposed to build a 12-million-ton-per-year iron-ore concentrator to process a combination of higher-grade natural ore and low-grade taconite ore. Barr was hired to replace another engineering firm a year into the design phase. We had already provided services for the project’s pilot plant, including a feasibility study, preliminary design, capital and operating cost estimates for two alternatives, technical requirements for design/build specifications, and technical evaluations of bids.

Working with an engineering, procurement, and construction management firm from Spain, Barr organized and led a team from five engineering firms to design the iron-ore concentrator. The team of mechanical, electrical, process, civil, structural, and geotechnical engineers and designers developed over 1,400 documents/drawings in approximately 62,000 man hours during an aggressive 18-month schedule. Our team's project work included:

  • Reviewing existing and developing new flowsheets

  • Reviewing and updating equipment specifications and selection

  • Reviewing technical analysis on process development work

  • Developing plant general arrangement drawings

  • Developing detailed design of pumping and piping systems for all process and auxiliary circuits in the plant

  • Developing detailed design of all platework including sumps, tanks, launders, etc.

  • Developing process and instrumentation diagrams (P&ID) for all process control systems

  • Developing functional description for all operating systems to be used for programming control system

  • Designing electrical and instrumentation systems within the plant

  • Reviewing concentrator civil work design by others

  • Designing tailings basin including multiple year deposition, management plan, dam design, pumping, tailings pipeline, pipeline and road alignment, reclaim water pumping and piping systems