Mining Plant Engineering & Process Design

Our engineering department translates mineralogical ore characteristics into robust, cost-effective flowsheet designs tailored to the specific gold geology of East Africa.

From Run-of-Mine (ROM) primary crushing through fine grinding classification, agitation leaching, carbon adsorption, elution, and electrowinning, our engineers model every stage for maximum gold recovery, energy efficiency, and operational uptime.

All engineering documentation is prepared in accordance with international quality standards (ISO 9001:2015) and environmental containment frameworks (ISO 14001:2015).

Engineering Disciplines: 4 Core Fields (Process, Mechanical, Civil & Electrical)
Standard Framework: ISO 9001 / 14001 (Certified Quality & Environmental Design)
Circuit Specialization: CIP / CIL / Gravity (Refractory & Free-Milling Gold Ores)
Statutory Approval: NEMA & Mining Act (Full Regulatory Prequalification)

3D CAD process flow and piping layout of gold mineral processing plant

3D Process & Mechanical CAD

Coordinated process, mechanical, electrical and structural design deliverables

3D Isometric CAD model of turnkey gold mineral processing plant showing ball mill grinding, hydrocyclones, and CIL agitation tank farm.

Technical Imagery & Field Records

Visual Assets & Field Records — Mining Plant Engineering & Process Design

Inspect high-resolution mechanical assemblies, 3D CAD flowsheets, on-site construction rigging, and diagnostic testing apparatus. Click any record to zoom up to 2.5x with full pixel clarity.

Process Design

3D Plant Process & Piping Layout

Comprehensive 3D mechanical CAD model integrating ball mill grinding circuits, slurry pipe racks, interstage carbon screens, and CIL tank farm foundations.

Record #01 Click to zoom & inspect

Field Execution

As-Built Operating Plant Structure

Field implementation of engineered gold processing facility at Bondo, Siaya County (NEMA/PR/SYA/002) featuring primary grinding and CIL tanks.

Record #02 Click to zoom & inspect

Electrical Design

MCC & Electrical Automation Loop

Motor Control Center (MCC) panels, frequency drives, and automated sensor loops controlling slurry feed rates and agitator motor loads.

Record #03 Click to zoom & inspect

Piping & Mechanical

Piping & Slurry Manifolds

High-density slurry pipework, chemical-resistant lined fittings, and automated valve manifolds for cyanide slurry reticulation.

Record #04 Click to zoom & inspect

Technical Scope & Certified Deliverables

Turnkey engineering and process design for gold mineral processing facilities, Carbon-in-Pulp (CIP), Carbon-in-Leach (CIL), and gravity concentration circuits across East Africa.

Process & Metallurgical Deliverables

Process Design Criteria (PDC)ISO 9001
Defines ore throughput (tpd), mineral recovery targets, slurry densities, and retention times.
Process Flow Diagrams (PFD)ISA-5.1
Comprehensive mass, slurry volume, water balance, and reagent consumption flowsheet.
Piping & Instrumentation Diagrams (P&ID)ANSI/ISA
Complete piping line lists, valve schedules, and instrumentation interlock loops.

Mechanical & Structural Deliverables

Equipment General Arrangement (GA)BS 8888
Detailed 3D models and orthogonal drawings for crushers, mills, screens, and tank farms.
Dynamic Foundation EngineeringEurocode 2 / ACI 318
Structural concrete design absorbing vibrational harmonics from rotary ball mills.
Structural Steelwork & Pipe RacksBS 5950 / AISC
Fabrication drawings for access walkways, stair towers, crane gantries, and pipe supports.

Electrical, Control & HSE Deliverables

Single Line Diagrams (SLD) & MCC LayoutsIEC 60364
Plant power distribution, motor protection, transformer sizing, and grounding grids.
Functional Control Philosophy & PLC LogicIEC 61131
Automated interlocks for slurry pump sequencing, emergency e-stops, and cyanide dosing.
Environmental Impact & Containment DossierNEMA / ISO 14001
Spill bunding, cyanide destruction circuit design, and tailings containment specifications.

Core Competency Register

Process Flow Diagrams (PFD) and Mass/Water Balance Modeling
Piping & Instrumentation Diagrams (P&IDs) with ISA-standard symbology
3D Plant Equipment General Arrangement (GA) and Piping Layouts
Mechanical equipment datasheets, sizing calculations & duty specifications
Civil and structural foundation design for heavy dynamic grinding mills
High-voltage electrical switchgear, MCC panels and PLC automation loops
Environmental containment, tailings dam design and cyanide detoxification
Controlled drawing revisions, engineering transmittals and as-built records

Phase-by-Phase Execution Pathway

Every stage produces auditable records and signoff gates so the project advances on verified empirical data rather than assumptions.

Phase 01

Design Basis & Metallurgical Review

Establish definitive ore characteristics, throughput requirements, and site constraints.

Key Deliverables:

Design Basis Memorandum
Ore Sizing Curve
Process Flowsheet Selection

Signoff Gate: Signed Design Basis Agreement

Phase 02

Front-End Engineering Design (FEED)

Develop complete PFDs, P&IDs, equipment sizing datasheets, and civil layout blueprints.

Key Deliverables:

Approved P&IDs
3D Plant GA Model
Mechanical Equipment Specifications

Signoff Gate: FEED Approval Gate & Transmittal

Phase 03

Detailed Engineering & Fabrication Packages

Issue certified fabrication drawings, structural steel bills of quantities, and electrical schematics.

Key Deliverables:

Issued for Construction (IFC) Drawings
Structural Steel Fabrication Packs
Cable Schedules

Signoff Gate: IFC Release Dossier

Phase 04

Site Support & As-Built Verification

Provide on-site engineering supervision during erection and capture all as-built modifications.

Key Deliverables:

Technical Query Responses
Site Instruction Records
Final As-Built Drawing Archive

Signoff Gate: Engineering Handover Certificate

Design Criteria & Technical Parameters

Key engineering tolerances, process capacities, and design standards applicable to this scope.

Engineering Parameter	Standard Design Criteria	Application & Notes
Plant Ore Throughput Capacity	50 – 2,500 tpd (customized per project)	Scalable modular CIL and gravity circuit layouts
Target Grind Size (P80)	74 µm (80% passing 200 mesh)	Matched with ball mill power and cyclone classification
Leach Residence Time	24 – 36 hours continuous agitation	Calculated from laboratory cyanide leaching kinetics
Structural Steel Wind & Seismic Rating	Zone 4 / 160 km/h wind load	Engineered for Rift Valley and East African terrain

Registered Engineering Standards & Review Boundary

All engineering deliverables are produced under the supervision of registered professional engineers and comply with statutory NEMA, EPRA, and Mining Act requirements.

Frequently Answered Engineering Questions

Direct technical guidance regarding specifications, implementation, and regulatory compliance.

What information is needed to begin engineering a new gold processing plant?

We require ore mineralogy reports, head grade assays, metallurgical leach test results (or bulk samples for testing), target daily throughput (tpd), water and power availability data, and site topographical surveys.

Can Green Ngoria customize designs for refractory vs free-milling gold ores?

Yes. Free-milling ores utilize high-efficiency gravity concentrators and direct cyanidation, whereas refractory ores incorporate intensive fine grinding, chemical pre-oxidation, and tailored CIL carbon circuits.

Are Green Ngoria engineering drawings accepted by regulatory bodies like NEMA?

Yes. Our engineering packages have successfully secured statutory NEMA approvals (including Ref: NEMA/PR/SYA/002) and local county building authorizations.

Tell us what you need built, processed or supplied

Send the scope, quantities and delivery location and the enquiry reaches the right division. For an installed circuit, a technical plant assessment is the faster route.

Customer care & enquiries

Director lines & emails: Leadership Profiles →

Tatu City, Kijani Ridge, Nairobi, Kenya