Process engineering for mining projects

Maximise the full value of your orebody with Delonix Solutions. Our process engineering team delivers practical, technically robust mineral processing and metallurgical engineering solutions across every stage of the mining project lifecycle. We specialise in transforming geological resources into efficient, sustainable mining operations, supporting clients from concept studies and flowsheet development through to commissioning, optimisation and ongoing plant performance.

Integrated mineral processing and metallurgical engineering services

Delonix Solutions provides integrated process engineering services for mining projects of all sizes and commodities. Our team combines deep technical knowledge with hands-on project delivery, ensuring every mining process design and flowsheet is tailored to orebody, operating context and business drivers.

We support clients with:

Metallurgical testwork planning, management and interpretation to underpin robust process design.

Flowsheet development and equipment selection for new and existing mineral processing plants.

Process plant design, optimisation and debottlenecking to maximise recovery and reduce operating costs.

Advanced methods including diagnostic leaching, modular process plant design and membrane technology for water and reagent recovery

Our approach

We deliver reliable, buildable process engineering designs that maximise mineral recovery, reduce costs and support ESG and sustainability goals for mining companies.

Our integrated services span mechanical, structural, civil, piping, electrical and controls engineering, with advanced capabilities including FEA, DEM, 3D scanning, detailed design, construction drawings and full EPC/EPCM delivery for seamless outcomes.

finite element analysis (FEA) and discrete element method (DEM)

Core capabilities in mining process design and plant optimisation

Crushing & screening

Site-specific circuits for consistent feed, early gangue rejection and improved downstream performance.

Comminution (grinding)

Optimised mill selection and circuit configuration for energy efficiency, throughput and mineral liberation.

Ore sorting

Sensor-based sorting to improve feed grade, reduce energy and reagent consumption, as well as enhance overall plant efficiency.

Gravity separation

Early recovery of high-density minerals for gold, tin, rare earths and other critical minerals.

CIL, elution & electrowinning

Pre-engineered for gold recovery, circuit stability and operational flexibility.

Flotation

Custom reagent schemes and circuit design for base metals, gold, rare earths, graphite and other commodities.

Thickening & filtration

Water recovery and tailings management for environmental compliance and sustainable mining operations.

Solvent extraction (SX)

Circuit design and integration for copper, nickel, uranium and rare earths, supporting hydrometallurgical flowsheets.

Pressure oxidation & leaching

High-pressure and atmospheric leaching for refractory and lateritic ores, enabling efficient extraction of valuable metals.

Pyrometallurgy

High-temperature processes for concentrate treatment, impurity removal and product quality control.

Heap leaching & hydrometallurgy

Cost-effective metal recovery for gold, copper, uranium and more, with a focus on operational reliability.

Radioactive materials handling

Safe processing and regulatory compliance for uranium, rare earths and other challenging ore types.

Our expertise across commodities

Delonix Solutions’ experience spans the following, delivering value across the mining sector:
finite element analysis (FEA) and discrete element method (DEM)

Multi-disciplinary engineering for mining plant design

Process engineering at Delonix Solutions is fully integrated with mechanical, structural, electrical and controls engineering. Our collaborative approach ensures:

Structural support & access:

We design robust structures and access platforms for equipment installation, maintenance and safe operations, reducing downtime and improving safety across the plant.

Mechanical and piping engineering:

Our mechanical and piping designs are aligned with throughput, slurry velocity and materials of construction for long-term reliability and efficient material handling throughout the process plant.

Civil engineering:

We provide civil design for foundations, earthworks, drainage and site infrastructure, supporting stable and compliant plant construction in all mining environments.

Electrical and controls systems:

Our electrical engineering covers power distribution, automation and equipment duty sequencing, while our controls specialists deliver advanced instrumentation and real-time data feedback for stable, responsive plant operation.

Advanced analysis & modelling:

We apply finite element analysis (FEA), discrete element modelling (DEM) and 3D scanning to validate designs, optimise layouts and resolved complex engineering challenges before construction.

Design, drawings & digital delivery:

Our team produces detailed design packages, construction drawings and 3D models to streamline project delivery and support efficient EPC/EPCM execution.

Risk management & compliance:

We manage risk across pressure, heat and chemical handling, ensuring all designs comply with Australian and international standards for safety and environmental performance.

This integration delivery mining plants that are efficient, maintainable and safe, ready for real-world operation and long-term asset value.

  • Process engineering capability statement

Partner with Delonix Solutions, the mining process engineering experts

Choose Delonix Solutions for process engineering that delivers technical certainty, operational reliability and sustainable value. Our team, authority in complex ore types and a commitment to innovation, ESG leadership and mining project success.

Contact Fil Resnik to discuss your mining project, request a process engineering capability statement or book a consultation with our mineral processing experts.

Explore our engineering design services to see how we can support your project from concept to operation.