Turning up the volume on heavy metal: Navigating nickel mining engineering projects with know-how
In mining, nickel mining engineering projects are the quiet achievers.
Nickel is critical to electrification, essential to stainless steel and increasingly central to the energy transition.
At Delonix Solutions, nickel has long been a space to demonstrate engineering and design agility.
Whether across brownfields or greenfields, and through modular or conventional builds, we deliver fit-for-purpose solutions with confidence.
Complex brownfields and constrained footprints are no issues for us. And we thrive on collaborative delivery models.
Our work across First Quantum Minerals' Enterprise project, the Ravensthorpe sulphuric acid plant and the Poseidon Nickel (ASX: POS) study in Western Australia demonstrates the breadth of Delonix Solutions' capability in the nickel space.
From infrastructure redesigns and shutdown-driven improvements to modular systems that mitigate downtime, we've engineered smarter paths to production.
Yes, even when constraints are tight, conditions are challenging and commercial margins narrow, Delonix Solutions always delivers.
Enterprise, North-Western Zambia
2022-2023
Designing for performance in a high-stakes build
As part of First Quantum Minerals' broader nickel strategy, the Enterprise project marked a major new plant construction adjacent to the existing Sentinel copper operations.
Delonix Solutions was engaged for extensive design work across structural, mechanical and piping (SMP) packages, in collaboration with Lycopodium, CPC and other delivery partners.
Our scope included the reclaim tunnel, mill feed area, flotation reagent systems and a secondary pebble crusher mounted on a raised isolation frame.
They were all designed to be installed without the need for traditional concrete foundations.
Because the plant design had to accommodate challenging terrain, aggressive ramp-up timelines and high-capacity throughput, we engineered systems for access, interchangeability and maintainability from the outset.
"We knew from the start that this had to be done fast, but with no compromise in safety or operability," said Delonix Solutions founding executive director Philippe Vatin.
"We delivered a design that was robust, modular and flexible enough to meet the real-time pressures of construction."
Nickel matte pellets. Delonix Solutions supported the Enterprise nickel project with key SMP systems, modular design and fast-tracked delivery for a high-performance process plant. Done in collaboration with Lycopodium and CPC Engineering.
Ravensthorpe, Western Australia
2021
Precision design in sulphuric conditions
First Quantum Minerals' Ravensthorpe operation is home to an integrated atmospheric leach circuit.
Delonix Solutions was engaged to support the structural assessment, repair design and construction management of a large acid leach tank.
This tank, located in the sulphuric acid plant that supports power generation on site, required a detailed refurbishment strategy.
While addressing corrosive environments and safety-critical tolerances through the tank's value-engineered repair designs, we were also involved with on-site support during implementation.
At the same time, Delonix Solutions contributed to early engineering review works at the Shoemaker-Levy crushing station.
This included a conveyor and earthworks study for the 8–11km connection route.
Subsequently, we supported design assessments for the stockpile reclaimer and structural modifications to improve material flow and maintainability across the crushing circuit.
"That acid tank wasn't just about fixing a problem; it was about keeping the power generation running safely," said Mr Vatin.
"The challenge was to repair it without extending shutdown. We worked through every scenario to find a safe and efficient solution."
Poseidon Nickel, Western Australia
Early 2010s
Feasibility studies and early works
We approached Poseidon Nickel's (ASX: POS) restart planning with the same discipline we bring to all nickel mining engineering projects: modular where possible, robust where required.
This was the miner's proposed re-entry into the Western Australian nickel market.
And Delonix Solutions supported with study management and lump sum turnkey (LSTK) design for a 700,000tpa nickel plant and 1.54mtpa gold circuit.
The objective was simple. The site required a low-cost flotation plant, commercially viable at volatile commodity prices.
We provided input on layout, simplicity and modularity: the keys to making the economics stack up.
However, as the market turned and spot prices softened, the project was deferred pending improved conditions.
Nevertheless, the work remains a valuable case study in early-phase engineering. Good design keeps future options open.
"It was a simple plant on paper, but the economics were tight," Mr Vatin said.
"We had to design for today, with optionality for tomorrow. That's how you add value to a study like Poseidon's."
A close-up of a nickel ore sample held at the surface, illustrating the early-stage feasibility and engineering studies delivered by Delonix Solutions for Poseidon Nickel. The design focused on modular, cost-effective flotation and gold circuits to prepare for re-entry into the Western Australian nickel market.
Proven in practice
Delonix Solutions' nickel experience reflects what we do best: resolve, rethink and rework plant systems where others hesitate.
Whether working within shutdown windows at Sentinel or optimising flow geometry across multi-party designs, our role is not always the loudest.
Still, it's often the one that makes a circuit flow better, safer and longer.
In nickel, as in every commodity, our approach remains the same:
Design with care.
Engineer with innovation.
Deliver with speed.
Optimise for performance.
Above all, do it all in a way that respects the plant, the people and the product it was built to deliver.
Don't settle for standard in the industry. Push your nickel mining projects further. Contact Fil Resnik today.
