Mining & Metals Services


Mining & Metals Services

Pulpeiro Consulting has experience within the global Mining & Metals industry, specialized in alumina refining, aluminum smelting and casting with broad expertise in project management, technical assessments, lean manufacturing and restructuring. Pulpeiro Consulting delivered worldwide

The key areas of expertise are:

The global industry has started to show some signs of falling productivity in the face of strong competition. The industry’s fundamentals remain challenged in the short to medium term because of slower demand growth and overcapacity in certain commodities.

As industry leaders we work to rebuild profitability, improving productivity is high on the agenda. Why does productivity matter so much? It’s helpful to go back to basics: “doing more with less” is the foundation of improving performance which leads directly to raising shareholder returns. The process to follow requires:

  • Evaluation and audit of plant equipment’s and processes, to detect bottlenecks and operational issues with a negative impact on performance.
  • Delivery of measurable and specific action plans to improve the overall performance of the facility.
  • All-around analysis, covering equipment, materials, processes, procedures and work force.

If safety excellence isn’t clearly defined and aligned throughout an organization, it won’t be achieved.

When working with executive leaders in the creation of their safety excellence strategy, we often begin by determining the existing alignment between different leadership levels

Safety excellence must be described in operational terms and is more than just repeating great results. It is also profound insight into how the results were obtained, with a shared mindset throughout the culture that continuous improvement will always be possible.

Below is described the SAFETY CULTURE to build a mature system through the leadership. The behavioral excellence is the path to follow to achieve the interdependent organization.

Organization is a key component of any successful business, but it’s especially crucial when you’re dealing with environmental compliance issues. How will you keep important information ready for an unannounced site inspection? How will you stay on top of all this data when you’re constantly on the run? To help your environmental compliance processes and stay proactive you might be interested in using an environmental management expertise

Bayer process

The Bayer process is the principal industrial means of refining bauxite to produce alumina (aluminium oxide) and was developed by Carl Josef Bayer. Bauxite, the most important ore of aluminium, contains only 30–60% aluminium oxide (Al2O3), the rest being a mixture of silica, various iron oxides, and titanium dioxide.[1] The aluminium oxide must be purified before it can be refined to aluminium metal.

Aluminium Refining Process- Electrolytic Process

In this process the oxygen in the alumina reacts with the carbon anodes and cathodes forming CO2 and aluminum. The alumina is conveyed from the storage silos and fed into an ore bin centrally located over the cell. The bin then supplies the cell with alumina as required. Cryolite powder (sodium fluoride) and alumina are loaded into the cell.

A low voltage, high amperage DC electrical current is applied to the anode bus bar from where it is transmitted to the anode block, while the aluminum smelting DC bus temperature monitoring is carried out in the control room.

The current passes from the anode block, through the mix of cryolite and alumina into the cathode, and in the process the alumina is reduced, becoming molten aluminum.

The molten aluminum drops to the bottom of the cell from where it is removed by a siphon into a crucible and transported in its molten state to the cast house to undergo the next process.

Lean manufacturing or lean production is a systematic method for the minimization of waste (muda). Lean also takes into account waste created through overburden (muri) and unevenness in workloads (mura). Working from the perspective of the client who consumes a product or service, “value” is any action or process that a customer would be willing to pay for.

Lean manufacturing attempts to make obvious what adds value, through reducing everything else (because it is not adding value). This management philosophy is derived mostly from the Toyota Production System (TPS).

Pulpeiro Consulting would discuss and agree the detailed terms of reference for the assistance required on a case by case basis. A work programme would be developed based upon the identified key objectives and timing of the deliverables.

A typical scope would include:

  1. Diagnosis of key strategic or operational issues.
  2. Analysis & Bench marking.
  3.  Implementation – Solutions to be implemented with staff
  4.  Sustainability – Coaching and mentoring to Change management.
how can we help you?

You can contact us by submitting a business inquiry online.

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