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Telephone: +1 (314) 878 – 0123
Email: info@peccg.com

PEC Consulting Group LLC
10123 Corporate Square
Saint Louis, Missouri 63132 USA




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PEC Consulting Group LLC, the consulting arm of PENTA Engineering Corp., is recognized worldwide for providing engineering and consulting services to the industrial minerals industry. Our extensive experience comprises limestone, cement, lime, gypsum, sands, aggregates and other non-metallic minerals.

Services

PEC Consulting Group has the capacity to develop complete projects from concept to commissioning for Greenfield Plants Projects and Plant expansions. Our services cover:

  • Scoping Studies.
  • Conceptual and Economic Study, including plant and mine design.
  • Project Schedule Development, CAPEX Studies and OPEX Studies.
  • Economic Studies, Market Studies and Financial Studies.
  • Pre Feasibility and Bankable Feasibility Studies for new plants and plant expansions.
  • Investigation and evaluation of raw materials.
  • Sampling and evaluation of mineral deposits.
  • Geological studies Mine and quarry planning.
  • Environmental emissions assessment and selection of control technologies for particulate matter.
  • Operations improvement.
  • Flow diagram development.
  • Selection of process equipment and evaluation of existing equipment.
  • Due Diligence for Acquisitions.
  • Mergers and Acquisitions.
  • Process Audits and productivity improvements.
  • Maintenance and Reliability Audits.
  • Operations evaluation and operators training.
  • Development of Bid Documents for Main Process Equipment.
  • Contract Negotiation.
  • Closure of Contracts.
  • Auxiliary Equipment Selection Assistance and Material handling.
  • Contractor Selection Assistance.
  • Quality Assurance / Quality Control Monitoring.
  • Procurement & Expediting Assistance.
  • Site Advisory Services.
  • Commissioning and Start-up Assistance.

Industrial Minerals Consultants

PENTA has been providing consulting services to the industrial minerals industry for over 28 years. Our consultants have extensive experience in the following Industries:

  • Cement.
  • Clays.
  • Diatomaceous Earths.
  • Feldspar.
  • Frac Sands (Proppant Sands).
  • Ground Calcium Carbonate.
  • Gypsum.
  • Industrial Sands.
  • Kaolin.
  • Lime.
  • Limestone and Dolomite.
  • Perlite.
  • Precipitated Calcium Carbonate.
  • Pozzolans.
  • Refractory Clays.
  • Salts.
  • Silica Sands.
  • Wollastonite.

Clients List

  • US Silica.
  • Pioneer Natural Resources.
  • Cutler Magner.
  • Florida Crushed Stone.
  • Florida Rock Industries.
  • Salt River Materials Group
  • United States Lime & Minerals, Inc.
  • …among others

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Development of a minerals processing facility is complex and requires extensive planning and due diligence. The focus generally goes into the technology to be utilized and the engineering for the project…Read More

PEC Consulting is uniquely qualified to provide comprehensive consulting services on raw materials for the cement industry.

In addition to exploration and geology, mining and mine planning, we use our vast knowledge of the process for cement manufacturing to develop the pre-blending strategy that enhances raw material resources to maximize reserves and lower costs.

Our consulting services cover:

  • Exploration, sampling and testing.
  • Geological mapping.
  • Mine layouts & planning.
  • Raw mix design.
  • Implementation plan.

Raw Materials Utilization Package

We can prepare a Raw Materials Utilization Package with a long-term for “averaging” the quality over a long period; increasing the life of the limestone deposit – the largest asset of a cement plant.

Exploration & Geology

Geology is a natural occurrence that must be assessed. Mining and Raw Mix Design can be adapted to suit the product mix and maximize the utilization of the geological reserves.

If required, we design an exploration program to assess the mining reserve quantity, quality and mineability, develop and oversee the drilling campaign and sampling program. The Scope may include:

  • Identification of mineral resource.
  • Exploration program design and management.
  • Sampling protocols.
  • Analytical data analysis.
  • Geological mapping and modeling.
  • Resource and reserve assessment.
  • Geological mapping quality gradations.
  • Guidelines for hydrogeological studies (if required).

Mine Planning

Limestone deposits should be planned for a minimum of 30 years. Choosing “sweet spots” in the short term will deprive the plant of required quality limestone in later years.

We provide mine modeling support to many customers in cement, lime, coal and industrial minerals. Our mining engineering staff has many years of hands-on operational experience in surface and underground mining. Our mine planning services include:

  • Conceptual, pre-feasibility and feasibility studies.
  • Surface, underground or transition from surface to underground planning.
  • Mine development schedules.
  • Selection of mining equipment.
  • Capex estimates.
  • Operating cost estimates.
  • Transportation and logistics assessment.

Raw Mix Design and Blending Strategy

Our expertise with the preparation of the raw mix guarantees a high-quality product; the overall strategy increases the life of the limestone deposit. We do the following:

  • Evaluate the limestone chemistry.
  • Identify the additive raw materials.
  • Evaluate the overburden as an additive.
  • Prepare the optimum raw mix for quality and economics.
  • Average the quality across the deposits to extend the mine life.
  • Provide inputs to the mine plan to extend mine life.
  • Define the pre-blending strategy.

Implementation Program

We work closely with our clients to develop an implementation program of the mining and blending plans and provide training and follow-up audits if required.


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Frac Transloading4PEC Consulting is experienced in all aspects of cement distribution

PEC Consulting provides solutions for the full development of rail to truck remote cement terminals.  Our consulting services meet the specific needs of our clients to help develop the facility from concept through implementation.  The objective is to obtain optimal logistics and efficient dispatch.

We provide the following services:

  • Technical Feasibility Studies for the development of cement terminals.
  • Evaluation of potential sites and property acquisition
  • Permitting
  • Investigation of potential transportation systems
  • Rail, truck, and barge logistics analysis
  • Capital and operating costs analysis
  • Conceptual through detailed design of the terminal and equipment

Basically, there are three different systems for transloading depending on requirements based on the “length of use” and “throughput”.  The systems could be:

Direct Rail – Truck: lowest CapEx; High OpEx

– Rail – Flat Storage – Truck: Medium CapEx; Medium OpEx (no demurrage)

– Rail – Silos – Truck: Highest CapEx; Very low OpEx

 

 

PEC Consulting is experienced in all aspects of cement distribution.

airview 1Areas of expertise for cement import terminals include comprehensive studies for cost-effective solutions for the distribution of cement to a satellite market. Our knowledgeable staff has performed many studies for the development of cement distribution terminals to fit our clients’ requirements. One of them, the cement transfer terminal with modular rail unloader, automated truck load-out and weight scale system, minimizes construction costs and installation time. Other designs, like the one appropriate for navigable rivers uses river cells for proper draft for the ship or barge.

airview w bargeWe perform studies for cement distribution systems with logistics costs in mind. Regardless of the design, all the components of the cement terminal, including the storage facility and conveying system, will be laid out to obtain optimal logistics and efficient ship loading. Consideration is also provided for the environment —  a dust collector and a simple and complete de-dusting circuit is included in the design.  Our services include:

  • Feasibility and Technical Studies for Distribution Networks
  • Investigation of potential rail, river, or ocean transportation systems
  • Logistical analysis of industrial distribution
  • Technology comparison of equipment tenders
  • Conceptual through detailed design of the cement terminal and equipment
  • Capital cost and operating cost estimates
  • Logistical cost studies and overall project economics of alternatives

Learn more about Cement Distribution Logistics – click on the following publications:Port of Cleveland Ohio cement silos

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We have extensive experience in assisting mining companies with cost-effective solutions to supply lime products for metallurgical operations. Some Copper and Gold Mining operations have benefited from the installation of a lime plant within their mine/concentrator facilities for which we provided consultancy services.

We are proud to have provided these services to:

  • BARRICK GOLD CORPORATION / PASCUA LAMA PROJECT, ARGENTINA & CHILE
  • MINERA ALUMBRERA LIMITED, ARGENTINA
  • MINERA CHINALCO PERU S.A., PERU
  • NEWMONT / CIA DE MINAS BUENAVENTURA: YANACOCHA GOLD OPERATION, PERU
  • SOCIEDAD CONTRACTUAL MINERA BYT / CAL CHILE, CHILE
  • SOUTH AMERICAN GOLD AND COPPER / MINERA CAL NORTE S.A., QUELON CHILE
  • SOUTHERN PERU COPPER CORPORATION, PERU

Projects

To download a representative list of projects, please click here.

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Frac Transloading1Hydraulic fracture drilling operations have expanded in recent years, as a result, companies involved in the oil and gas energy sectors have focused their attention on the cost and complexities related to the logistics and cost of Frac Sand supply to the vicinity of the drilling operations.

Frac Sand production is not always near to the gas and oil fields. If distances exceed 100 miles, it’s more economical to transport by rail, in this case transloading operations at the location of the oil wells play an important role in the availability and reliability of Frac Sand supply.

Transloading terminals require efficient access and distribution capacity to optimize their commercial viability and growth potential. PEC Consulting Group is experienced in transloading terminals that efficiently and effectively optimize logistic costs.

Frac Transloading4

Transloading Systems

Basically there are 3 different systems for transloading, depending on requirements based on the “length of use” and “throughput”. The systems could be:

  • Rail – Truck : Lowest CapEx; High OpEx
  • Rail – Warehouse – Truck : Medium CapEx; Medium OpEx (no-demurrage)
  • Rail – Silo – Truck : Highest CapEx; Very Low OpEx

photo-gallery07

PEC Consulting is experienced in studies for the development of transloading terminals. We have served clients with feasibility studies, evaluation of potential sites, property acquisition, permitting and rail & truck logistics analysis.

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Structural Pathology

We have expertise in both concrete and steel structural pathology. We offer highly detailed analyses of behaviors of structures subjected to any kind of loading conditions including physical and/or chemical attack, allowing precise diagnostics and retrofits solution techniques for the best repair method. A structural pathology diagnosis comprises:

  • Detailed analysis based on realistic 3D Structural Numerical Models to simulate the structural problem.
  • Consideration of all loads and load combinations acting on the structure and foundation during construction and operation.
  • Consideration of the real boundary conditions (supports, load and displacement locations, etc.).
  • Evaluation of possible soil-foundation structure interaction effects.
  • Analysis and consideration of construction and maintenance conditions.

As a preventive and maintenance & reliability measure, we perform methodical analysis of the structural components of your facility. The breadth of knowledge of our Consultants in the Structural field allows us to provide a practical assessment of structural deficiencies, solutions and recommendations to prevent and repair imminent problems.

Because buildings, storages (silos, etc.) and equipment foundation systems are a major investment in a minerals processing facility, a structural evaluation provides a cost-effective solution to plant maintenance. It also prevents the risk of injury and life loss to plant personnel and it increases the plant’s reliability and life of the facility.

To learn more about this subject, click on this published article: Evaluation of Buildings and Structures for Heavy Industrial Plants

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Cement Plant Pyroprocessing and Comminution

PEC Consulting offers customized in-plant training to enhance and broaden your operating staff’s understanding of the plant’s process and operations. The results are a well-trained and knowledgeable workforce which will help reduce operating and maintenance costs and increase production and overall system efficiency.

One of the goals of our program is to create a system to transfer technology, whereby

  • Best practices learned in one plant are effectively transferred to other plants
  • Operating results are benchmarked against similar plants

Our tutorials offer the following advantages:

  • Customized to the specific design of your plant and to meet your goals
  • Developed together with plant management and with feedback from operators
  • Conducted by experienced instructors

A training program is developed ahead of the plant visit to tailor it to the type of facility and training needs. An experienced instructor will then visit the plant to gather equipment data, become acquainted with the operations of the plant, and observe operating techniques. Following a meeting with the plant’s management team, the instructor will prepare a customized training manual specific to the plant’s operations. Once the manual is complete, the instructor will schedule training sessions.

Our experienced instructors are on the cutting edge of technology including plant optimization, modifications, and expansion projects. They have held various positions: Chief Chemist, Process Engineer, Production Manager, etc.

The personnel who will most benefit from this type of training are: Control Room Operators, Process Engineers, Shift Foremen, Shift Personnel, Laboratory, mine managers, and other key personnel.

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Cement Distribution Terminals and Logistics

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PEC Consulting is experienced in all aspects of cement distribution.

As plants become larger in capacity and distances to market increase, the economics of the distribution chain becomes critical to the financial success of a cement manufacturing facility. The design and operation of transporting, storing, and distributing is extremely important.

The distribution system components, such as types of storage and materials handling equipment, have an effect on the economics of the operation.

Logistical calculations of various options will show the capacity of the ship unloading facility, storage facility, and the size of reclaiming and truck load-out systems. The same applies when distributing from rail to truck.

Logistics for importing cement are very important in calculating the competitive position of imports versus local production. The following is taken into consideration calculations: dock occupancy with relation to the capacity of the ship unloader, required size of the ships, unloading time per ship, throughput of the terminal with the corresponding number of trucks, size of the storage facility, etc.

PEC Consulting offers comprehensive studies for cost-effective solutions for the distribution of cement to a satellite market. Our knowledgeable staff has designed many cement distribution terminals to fit our clients’ requirements. One of them, the cement transfer terminal with modular rail unloader, automated truck load-out and weight scale system, minimizes construction costs and installation time. Other designs, like the one appropriate for navigable rivers uses river cells for proper draft for the ship or barge.

We perform studies for cement distribution systems with logistics costs in mind. Furthermore, we have the know-how to design a system that will meet the specific needs of our clients. Regardless of the design, all the components of the distribution terminal, including the storage facility and conveying system, will be laid out to obtain optimal flow of cement and efficient ship loading. Consideration is also provided for the environment and a dust collector and a simple and complete de-dusting circuit is included in the design.

To download a representative list of projects, please click here.

Learn more about Distribution Logistics – click on the following publications:

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Throughout the years, we have been approached by law firms, government agencies, and insurance companies asking to provide a specialized Consultant to serve as an expert witness and help resolve conflicts.

Our knowledgeable professionals in cement, lime, and industrial minerals are highly qualified to offer expert witness support. Based on education and experience, an expert will be selected according to the industry and specialty field for which his testimony is required.

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When raw materials availability, funding, schedule or other factors do not support the implementation of a full clinker/cement manufacturing facility at a location, a Satellite Cement Grinding Plant could be a strategic alternative solution.

Additives used in blended cements, such as pozzolan or slag, may not be available at the location of the clinker plant. As an economic measure, many cement companies have opted to ship clinker to satellite grinding facilities for the supplementation of readily available additives at the location of the grinding plant.

In the manufacturing of Cement, clinker grinding is an important process in obtaining a high quality product.  As the main requirement is to obtain a consistent fineness of the ground clinker, there are important factors to be considered such as, for example, the feed rate of clinker into the finish mill in an open circuit system, the addition of gypsum to control the setting properties of cement, temperature control, etc. Our team of Process Consultants is knowledgeable in all aspects of cement grinding process requirements. For many years, they have worked together on many projects which called for mechanical, process, structural and electrical engineering for the installation of new finish mills, selection of equipment, construction bid packages, construction management, commissioning, and start-up assistance.

PEC Consulting can do a study to install or upgrade a clinker grinding plant — complete with a packing plant and material handling equipment, including the economics of the project. The efficiency of a cement grinding plant is always a consideration, giving special attention to power consumption, the high performance of equipment, and quality of the end product.

We carry out scoping studies, pre-feasibility and full feasibility studies and can determine if the implementation of a satellite grinding plant is a recommended economic option for your cement operation.

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Comparative Properties of Bituminous Coal and Petroleum Coke as Fuels in Cement Kilns

Bituminous coal has been in use as fuel in cement kilns for a long time. With coal costs continuously rising, cement plants have been looking for alternative less expensive fuels. Petroleum coke presents a viable alternative because of its lower cost since it is a byproduct of the refining process. It has a high heat value and low ash content, which favor its use in cement kilns. However, petroleum coke presents some challenges, such as high sulfur content and poor grindability, compounded by the need to grind it finer due to a low volatile content.

Comparative-Properties-of-Coal-and-Petcoke

The following table provides a comparison between bituminous coal and petroleum coke with respect to their characteristics and operational and emission aspects. The comparison is on a very broad basis and an evaluation is required for each specific coal and petcoke origin.


COMPARISON BETWEEN BITUMINOUS COAL AND PETROLEUM COKE

 

 

Coal

Coke

Comments

Mitigation

Measures

EMISSION

 

SO2 emission: (Depends on % S in fuel and alkali content in the raw mix)

Low

High

Typically Petroleum coke comes with 4 – 7% Sulfur content.

Lime injection.

Alkali balance.

Process strategy.

 

NOx emission:

(Petroleum coke is low in volatiles and the combustion occurs at a higher temperature)

Low

High

High flame temperature in the kiln generates higher thermal NOx

Multi staged combustion technique and SNCR (Selective Non Catalytic Reduction) technology.

 

OPERATION

 

Coating formation and preheater plugging

Low

High

High sulfur increases circulation of volatiles and potentially cause plugging in preheater

Alkali balance and operational strategy

Sulfur bypass

Grinding load

Low

High

Petcoke is hard to grind and needs finer grinding

No remedy

However, lower fuel requirement due to higher heat value.

Raw mix design

Higher ash levels

Low in ash

Raw mix needs to be adjusted for ash absorption

 

SAFETY

 

Fire and explosion hazard

high

low

Low volatile content makes petcoke safer to handle

Inerting systems and explosion vents are required.

CLINKER QUALITY 

 

SO3 content in clinker

low

high

Permissible SO 3 content in clinker limits the use of some petcokes

 

CHARACTERISTICS

 

% Ash Content

14 – 20

0.5 – 1.0

Petroleum coke is superior in heat content due to lower ash content.

 

% Fixed Carbon

55 – 60

82 – 87

Higher carbon content gives higher calorific value (CV).

 

% Sulphur

0.5 – 1.0

4 – 7

Creates emission of SOx and Operational problems.

Please refer to point A1 and B1

Gross C. V. kcal/kg

6000 – 6200

8000 – 8200

With higher calorific value less amount of Petroleum coke is required.

 

Hardness – HGI

The lower the HGI, the harder to grind.

50 – 55

35 – 40

Higher grinding (electrical) energy due to lower HGI.

 

% Volatile matter

22 – 27

7 – 8

Petroleum coke is a slow reactive fuel difficult to burn, making it a less of a fire and explosive hazard.

Special burner for petcoke. High flame momentum kiln burner.

Finer grinding.

Longer retention time in Pre-calciner.

 

 

           

                        

Petroleum coke is a viable alternative fuel to Bituminous Coal provided the challenges associated with it are properly addressed.

The quality of Petroleum coke varies from source to source. Depending on the refining process, various types of Petroleum coke are produced.

To ensure a successful operation, a detailed study based on the characteristics of the raw material and Petroleum coke to be used is required.

Additional investment may be envisaged for incorporating technology that supports use of Petroleum coke as fuel and for controlling environmental emission levels.

The use of petroleum coke may be limited by its high sulfur content. Technological measures such as finer grinding, pre-calciners designed to have a higher retention time, an external combustion chamber before the calciner, a special high-momentum kiln burner, etc. will help to effectively utilize Petroleum coke.

Based on the quality of Petroleum coke, typically a mixed fuel firing is designed. The percentage of Petroleum coke is determined based on quality and operational trials.


This article was contributed by Jagrut Upadhyay, Senior Process Consultant, and Narayana Jayaraman, Director – Technical Services at PEC Consulting Group.

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PEC Consulting Group LLC offers a diverse range of opportunities to seasoned professionals with specialized expertise in industrial minerals. Our Consultants have lengthy experience gained during their careers with major mineral processing and consulting companies throughout the globe. PEC Consulting benefits from the complementary skills of its team of Consultants.

Process Engineer

PEC Consulting Group is seeking a Process Engineer with superior knowledge and experience in the mineral processing industries to participate in the scoping work for the development of industrial minerals facilities; and provide professional consultation services as needed to complete Customers’ assignments.

Primary Responsibilities:

Detailed Process simulations and calculations

  • Preparation of process simulations for different plant configurations.
  • Development of design criteria for new projects.
  • Preparation of process flow diagrams with mass, gas, and heat balances.
  • Preparation of equipment specifications.
  • Development of raw mix designs and recommendation of suitable mixes.
  • Analysis of the operation for waste heat recovery possibilities.
  • Preparation of process equipment bid documents with data sheets.
  • Validation of OEMs’ process data.
  • Provide advice on emission compliance and safety requirements for fuel handling systems.
  • Participate in discussions with OEMs.
  • Preparation of bid evaluation report.
  • Preparation of OpEx with support from other disciplines.

Field work – Feasibility Study, Due Diligence Study, Plant Upgrade, Trouble Shooting

  • Preparation of Questionnaire for specific requirements.
  • Visit plants to observe operation, discuss with plant personnel, and obtain necessary data.
  • Preparation of comprehensive data analysis reports.
  • Obtain information from internet or from sub-consultants. Coordinate with sub consultants.
  • Calculate and collate data for Feasibility Study, Due Diligence Study, Plant Upgrade, Trouble
    Shooting or any other topic.
  • Provide commissioning and start-up assistance.

Reports

  • Preparation of detailed reports based on the analysis. Reports are the main deliverables for PEC
    Consulting and therefore this aspect is specially emphasized.

Requirements

  • Five (5) years’ work experience.
  • Bachelor of Science in Chemical or Mechanical Engineering. A Master’s Degree in an
    engineering science is preferred as well as EIT or P.E. certification.
  • US Residency or US Citizenship is an absolute requirement.
  • Proficient in computer design and drafting software.
  • Proficient in the English language.
  • Familiar with OSHA / MSHA requirements.
  • Domestic and international travel.
  • Commitment to maintaining the Company’s professional image and reputation with error free
    work.

Apply now to join a world-class consulting firm where you can truly make a difference.
E/O/E

 

Principal Consultant

Principal Consultant / PEC Consulting Group LLC/PENTA Engineering Corp.

PENTA Engineering Corp. (“PENTA”) is a global company specializing in the mineral processing industries. PENTA has managed hundreds of projects for the mineral processing industries worldwide, involving Feasibility Studies, new production lines, plant upgrades and modifications. Our group has a considerable amount of experience in developing concepts, troubleshooting, project management, and plant optimization.

PEC Consulting is the consulting arm of PENTA, specializing in high level Consultancy Studies such as: Scoping Studies, Mineral Reserves Evaluations, Economic Feasibility Studies and Conceptual level Plant Design and Operations Studies. Studies for existing operations include: Due Diligence, Plant Operations Analysis and Plant Maintenance and Reliability Programs and Audits.

PEC Consulting is seeking a Senior Minerals Consultant with extensive consulting and operating experience to lead the consulting group as a Principal Consultant.  The Principal Consultant will be based in the Saint Louis, Missouri office.

Core competencies require competency in Feasibility Studies, Due Diligence Studies, Plant Upgrades, Trouble Shooting and preparation of reports.

Primary Responsibilities:

  • Contact existing and prospecting clients to identify potential opportunities, develop detailed scope of Consultancy work and prepare proposals with estimates.
  • Follow up on opportunities and generate business for PEC Consulting.
  • Prepare process simulations for different configurations of mineral processing plants.
  • Develop design criteria for new projects.
  • Direct process design activities through all phases of a project (conceptual design, preliminary design and final design).
  • Prepare process flow sheets with mass and gas flows, equipment specifications, CapEx with support from other disciplines, and questionnaires for specific requirements.
  • Prepare bid documents with data sheets and bid evaluation report.
  • Validates OEM’s process data and participates in discussions with OEMs.
  • Provide advice on emission compliance and safety requirements for fuel handling systems.
  • Familiarity with OSHA / MSHA requirements.
  • Visit plants to observe operations, discuss with plant personnel and obtain necessary data.
  • Prepare Feasibility Reports. A Report is the most important deliverable of PEC Consulting, and therefore this aspect is specially emphasized.
  • Provide commissioning and start-up assistance.
  • Domestic and international travel.

Qualifications:

  • BS in Engineering.
  • Professional Engineer Registration.
  • Minimum 20 years’ engineering and consulting experience in the minerals processing and mining industries.
  • MBA or experience with economic analysis and financing strategies.
  • Strong strategic orientation with ability to think long-term with business awareness, critical analysis & integration of information, and ability to develop an action-oriented plan.
  • Good analytical skills with problem solving and decision-making abilities.
  • Demonstrates leadership skills, strong team building and project management.
  • Excellent verbal and written communication skills.
  • High customer service focus.
  • Commitment to maintaining the company’s professional image and reputation with error free work.
  • United States citizenship or residency (green card holder).

Company Benefits:

  • Comprehensive insurance package: Medical, dental and vision insurance available on first day of employment.
  • 401k with company match.
  • Three weeks’ vacation eligibility upon hire.

Please email your curriculum vitae to: rmerz@penta.net

Refractory Consulting

As a partner with Refractory Consulting, the engineers at REFRA.reSources provide customers solutions to the challenges presented within a continuous pyro-process. The service stands where art, experience and science meet. Proprietary tools facilitate the management of refractory costs and protect against associated collateral costs.

REFRA assesses your facility and analyzes your records and then offers the precise solution for your processing unit. REFRA.reSources provides refractory consulting services, failure analysis, build management, benchmarking, and training.

Visit www.refraresources.com for more information.

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A Plant Maintenance and Reliability Audit identifies aspects that prevent plants from increasing capacity and maximizing productivity. At PEC Consulting, we provide recommendations and action plans to bring each plant to a World Class / Best in Class Maintenance facility. In recent years, reliability engineering concepts have been adopted by process industries with significant improvements in financial performance.

Benefits

For each percentage of availability lost, facilities lose millions of dollars due to low production. However, a small increase in equipment reliability converts into an increase in production and substantial increases in revenue, particularly for those products in strong demand (by the magic of incremental margins). Considering the high capital costs invested in the minerals industries, increasing reliability results in a high return on investment.

What We Do

  • At PEC Consulting, we provide comprehensive Maintenance and Reliability Audits to mineral processing facilities.
  • Analyze Maintenance and Reliability management systems, preventive and predictive systems, organizational structure and staff, methods and procedures.
  • Benchmark and score your maintenance program against industry’s Best Practice standards. Best Practices enhance equipment reliability and realized capacity by avoiding unnecessary production interruptions. Production interruption due to lack of equipment reliability increases a unit’s production cost.
  • We make appropriate recommendations for improvements, with follow-up audits and consulting services to help with the implementation process.
  • Plant Maintenance and Reliability Audits for Cement Plants
  • Plant Maintenance and Reliability Audits for Lime Plants
  • Plant Maintenance and Reliability Audits for Coal Mines
  • Plant Maintenance and Reliability Audits for Industrial Minerals Industries

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We carry out plant efficiency studies, technical audits, bottleneck analysis, trouble shooting and capacity upgrades. Our studies and recommendations improve our Clients’ competitive edge by helping them to achieve better fuel economy and run factors.

What we do:

  • Assess the current operation of the plant.
  • Analyze Key Performance Indicators and benchmark them against our database for similar operations.
  • Identify areas for improvement.
  • Recommend steps to troubleshoot and upgrade the operation.
  • Provide a cost-benefit analysis.

A plant efficiency study translates into improved productivity and higher profit margins. PEC Consulting’s Plant Efficiency Studies include a comprehensive range of studies such as Market Studies, Plant Evaluations, Economic Analysis, Technical Feasibility Studies, Maintenance and Reliability Studies, and Management Consulting.

We have performed a cement plant efficiency study for a company in Texas which called for a field audit of a finish mill. An independent review of data generated during the OEM’s field audit at the client’s plant was performed, while circuit samples obtained from both circuits were obtained for analysis.

In another case, a cement plant energy audit was performed for a client in Kingston, Jamaica. Energy savings were identified and recommendations were made for the implementation of modifications with a simple payback of four years or less.

In addition to the above, we have performed efficiency studies such as analysis of kiln rehabilitation, kiln capacity and fuel efficiency, capacity upgrade, evaluation of plant staff and procedures, assessment of the reliability of plant equipment and readiness for sustained operations, review of process details, utilization of waste heat for power generation, raw materials studies, etc.


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PEC Consulting’s comprehensive valuations take into consideration business assets, historical earnings, market, mining and production methods, maintenance and reliability of the operations, evaluation of plant personnel, management, financials, future projections, etc. We generate a fair and objective valuation, valid for the specific purposes of our client. The finished product is delivered as a comprehensive written report.

We carry out independent valuations of lime plants, cement plants, and for the coal and industrial minerals processing facilities as required for:

  • Financing / collateral.
  • Taxation.
  • Accounting for plant depreciation purposes.
  • Mergers and acquisitions.
  • Insurance coverage.

PEC Consulting is experienced in utilizing several appraisal methods depending on the need of our clients, such as valuations based on:

  • Replacement cost approach.
  • Present value of discounted cash flows.
  • An EBITDA multiple for the industry.
  • Comparable recent acquisitions.

The valuation must take into consideration market growth and stability, raw materials reserves for the predicted life of the facility, and substantial capital investments which may be required due to upcoming environmental or other factors external to the facility.

We are knowledgeable in the industries that we serve and have performed many valuations for mergers and acquisitions, financing, insurance and accounting depreciation purposes. Over the course of the last five years, we have carried out several valuations of cement plants which included an overview of their operating conditions and valuation of assets. Some valuations were required by financial institutions to support the expansion of current cement plants or for the implementation of Greenfield cement manufacturing facilities. Others included the valuation of cement plants for accounting and insurance purposes.

  1. Cement Plant Valuations.
  2. Lime Plant Valuations.
  3. Coal Mine Valuations.
  4. Industrial Minerals Industries Valuations.

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PEC Consulting assesses potential mineral resources and estimates raw materials reserves. Skilled mineral exploration is the key to locating and mining appropriate deposits. The extensive process of mineral exploration starts with sizing the deposit and characterizing the mineral reserves at the site.

We employ several mineral exploration methods depending of the stage of the project, including:

  • Review of existing geological maps and published documentation of the area of interest.
  • Mapping of outcrops, where possible, and data from existing mining operations.
  • Mapping and modeling based on core drilling and sampling.

Our reserve reports are an excellent basis for locating quality reserves, for planning further exploration, and for mine design. Our geologists and mining engineers are involved from the early stages of exploration. They embrace the latest technology when performing geological mapping, core drilling, sampling and modeling. Our expertise extends to geological evaluations and mine planning and the results are given in quality reports.

We perform evaluation of reserves for the:

  • Coal Industry.
  • Cement Industry.
  • Lime Industry.
  • Industrial Minerals.

Our services include:

  • Surface geological exploration.
  • Core drilling programs and management.
  • Raw materials testing (physical and chemical properties).
  • Geological modeling based on geochemistry.
  • Mining Plans.
  • Evaluation of Reserves for Cement Plants.
  • Evaluation of Reserves for Lime Plants.
  • Evaluation of Reserves for Coal Mining.
  • Evaluation of Reserves for Industrial Minerals Industries.

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An analysis of the market is an important component of business strategy. It provides a thorough analysis of the challenges, prospects and competitive activities that you could be facing; it may evaluate the impact of increased production in the market; the competitive positioning – domestic and global –of your firm, provide a supply analysis of required raw materials; provide a general overview of the cost, provide benchmarking, and reveal and assess factors that may influence your business decision.

We have conducted Market Studies for Greenfield projects, including the evaluation of raw materials, bid specifications for major process equipment and capital cost estimates. Other Market Studies have been conducted for Greenfield and Brownfield projects and plant expansion projects for the Mining Industry.

PEC Consulting Market Studies are a rich resource for your business expansion or new acquisition. Typically, the Report delivers a current market analysis, an analysis of the future market potential and potential revenue of your product, and an analysis of the competition.


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All investment decisions should be made following a rigorous Economic Analysis

PEC Consulting’s Economic Analysis includes CAPEX and OPEX calculations, Market Price and modeling of different scenarios to develop a Sensitivity Analysis. This model will determine how the Project’s Net Present Value, Internal Rate of Return and Payback will be affected by variations in CAPEX, OPEX and Market Pricing, which provides the investor with information on the potential risks originating from project variables.

Benefits

An Economic Analysis is a powerful tool used to assess the expected returns from an investment and for the Owner to choose among potential investment opportunities.

What We Do

  • Approach your particular project systematically and evaluate all pros and cons of your potential investment.
  • Address and consider investment and operating costs and risks, and provide a course of action that best benefits your organization. Benefit-cost analysis is one of the most important tools in making sound decisions.
  • Provide a Sensitivity Analysis considering:
    • Operating costs
    • Capital costs
    • Market Price
    • other specific variables which may be of concern to the project
  • Prepare a comprehensive Economic Analysis Report detailing the analytical procedures utilized, and attaching the data used in the analysis.
  • Economic Analysis is utilized in scoping studies, pre-feasibility and feasibility studies; in project options comparative analysis, in facility valuations, due diligence work and in selection of process options.
  • Economic Analysis for Cement Plants.
  • Economic Analysis for Lime Plants.
  • Economic Analysis for Coal Mining.
  • Economic Analysis for Industrial Minerals Industries.

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Our clients are private entities and international financing institutions.  We   provide advice in the form of business and technical reviews to identify potential risks associated with the asset to be acquired.    We identify and assess elements which could affect the future operation of a processing plant or mine from a technical, environmental, economic, and social viewpoint.  The Scope of a Due Diligence Study covers the following:

  • Analysis of the Company ownership; business activities including: financial data, earnings, share price, holdings, growth and general business dealings.
  • Evaluation of the market, capacities, energy usage and fuel sources, logistics, products and services; involvement with local communities, culture and values, commitment to social responsibilities and sustainable development, waste management practices, environmental footprint and concerns, environmental and social impacts; current or future potential negative issues.

Our due diligence covers geologic resources and mining operations. It begins with a Desktop Analysis, followed by fieldwork where an assessment is made of resources and reserves, mineability, equipment selection, productivity, CAPEX and OPEX, the operational organization (team & organization); environmental, safety and security; audit of process systems and equipment.

The Scope of a Technical Mining Due Diligence Study, or Coal Mine Due Diligence Study, will also include the different aspects related to the property such as the geology, hydrogeological, geotechnical, surface terrain and how these physical characteristics impact the reserves, mining plan, mining operations, infrastructure, logistics, environmental issues, safety, etc.

PEC Consulting’s specialized Consultants are involved in the due diligence process starting at project inception and are exceptionally qualified to prepare and deliver a comprehensive Report. The Report will provide company benchmarking against similar operations, an economic analysis, and management review.

Our Mining and Process Consultants are highly experienced professionals with former operational and technical backgrounds working for world class mining organizations.  They have conducted technical due diligence reviews, developed mine and mine access layouts, evaluated and selected mining plans, mining equipment, and provided other mine support to our clients.


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We believe that the experience with our own successful company makes us an excellent consultancy to create an effective plan prepared to serve your particular needs. An independent analysis of your project economics and a strong business plan will not only help you locate the funds you need, but will also clarify your own purpose and serve as a guide for future growth and productivity.

PEC Consulting creates the kind of economic models that banks want as support for financing. Our Feasibility reports provide professional financial projections and address the needs of investors and lenders.

We take into consideration the technical and financial phases of a project for the preparation of a Feasibility Study. An estimate is made of all equipment, systems and energy requirements, a financial analysis is then prepared, including operating and capital costs. A Feasibility Study also gives detailed site logistics and transport requirements.

Our services are interrelated. We see the benefit to our clients when we are awarded the preparation of a conceptual study or a pre-feasibility study prior to that of a Feasibility Study. This preliminary work will be most valuable to determine whether to proceed with project evaluation.

Furthermore, and along the same line of a Feasibility Study, we are qualified to assist our clients from financial organizations with pre-credit feasibility studies, which provide an independent and thorough analysis and verification of the data submitted to our clients by their customers. PEC CONSULTING has performed Conceptual Feasibility Studies, Feasibility Studies, Pre-Feasibility Studies, and Pre-Credit Feasibility Studies, including capital cost estimates in many countries around the world, including recent projects in the United States, Trinidad, Colombia, Peru, Paraguay, Africa, and Kuwait.

We have the expertise to produce the following studies:


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The use of Alternative Fuels, also known as “Co-Processing”, is the use of combustible waste materials as a source of energy in pyro-processing of cement manufacturing plants, lime plants, and in the calcining of other minerals.

Some forms of alternative fuels are:

  • Used tires
  • Plastic waste (bags, bottles etc.)
  • Waste Oils
  • Solvents
  • Saw dust
  • Paint
  • Hazardous Wastes
  • RDF (Refuse Derived Fuels)

Benefits

Conversion to Alternative Fuels benefits the economy of operation by lowering fuel costs. In some cases, a facility that uses Alternative Fuels receives economic compensation for waste elimination (e.g. use of Hazardous Wastes). In addition to energy recovery, there are considerable environmental/green benefits, such as the reduction of emissions and greenhouse gases into the atmosphere by not using natural non-renewable raw materials and fuels such as coal. In certain countries, these savings can be utilized for Carbon Trading credits.

However, because of their inherent characteristics, the implementation of Alternative Fuels present a challenge to use which, if not handled properly, may impact the manufacturing process, product quality, and environmental exposure.

What We Do

At PEC Consulting we provide innovative and thoughtful solutions to help the cement industry and lime industry implement co-processing at their plants and become more cost efficient, which improves their economic competitiveness.

An Alternative Fuels Project will evaluate the characteristics of co-processing and recommend ways to handle and utilize fuels in the pyro-process in the most effective and secure way.

Our scope of work includes:

  • Studies for handling and firing Solid Waste Fuels
  • Studies for handling and firing Liquid Waste Fuels
  • Studies for handling and firing Hazardous Waste Fuels
  • Conceptual studies to use whole or shredded tires
  • Studies to use gas or petroleum coke (petcoke) as replacement fuel
  • Alternative Fuels / Co-Processing Studies for Cement Plants
  • Alternative Fuels / Co-Processing Studies for Lime Plants

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Waste Heat Recovery Systems (WHR) utilize the heat in industrial waste gases for the generation of electrical power. WHR Systems are common in cement and lime plants and other pyroprocess industries where Rotary Kilns are used and the price and reliability of grid power supply make the investment economically feasible.

In developing the concepts for the WHR system, the challenge lies in determining the optimum quantity of waste heat available for power generation and in integrating the WHR system with the cement process. PEC Consulting can assist the client to perform a Feasibility Study to assess the optimum size and configuration of the WHR system and the viability of the project. The study will provide recommendations for an efficient and economical system based on several factors such as the thermal capacity of exhaust gases, size and type of heat exchanger, and desired parameters of the cogeneration system operating conditions.

In some cogeneration systems, the exhaust gas from power generator sets using diesel oil or furnace oil is used as a source of heat for the WHR plant.

Benefits

  • Reduction of electrical power demand from the grid and consequently of the plant’s operating costs.
  • Reliable electrical power supply from waste gases from the kiln and cooler.
  • Reduction of the carbon footprint by conserving the use of fossil fuels and thus helping the environment.

What We Do

  • Assess the realistic quantity of heat that can be recovered taking into account variations in the drying requirements of raw materials and fuel throughout the year. This analysis results in optimum sizing of the WHR system.
  • Determine the energy recovery process to be utilized: The steam Rankine cycle uses water as the thermodynamic medium and is commonly used for generating power from high temperature sources. Depending on the temperature and other situational factors, some plants use the Organic Rankine cycle for generating power, using an organic compound as the thermodynamic medium.
  • Optimize the layout of the boilers and power generation system considering plant footprint space constraints.
  • Provide an effective integration of the WHR equipment with the existing cement plant or industrial facility.
  • • Provide our clients with an assessment of the power potential, a financial analysis with capital and operating cost estimates, and an economic analysis to assess the viability of the project.
  • Technical Feasibility Studies of WHR Systems for Cement Plants.
  • Technical Feasibility Studies of WHR Systems for Lime Plants.

Learn more about WHR; click on the following publication:

Waste Heat Recovery for Power Generation

To download a list or Energy Efficiency/Process Studies, including WHR projects, please click here

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PEC Consulting offers extensive experience to your metallurgical processes and operations. Our team consists of industrial metallurgical experts who are highly qualified and capable to investigate and find solutions to improve your existing operations. We will provide an independent assessment of our findings and recommendations in a thorough and clear report.

We have considerable knowledge in extractive metallurgy. Our workforce has many years experience in the physical and chemical processes for the separation and concentration of raw materials and have provided engineering to cover all aspects of this operation from crushing and grinding the ore to concentrating, smelting, casting, and refining processes.

We have demonstrated leadership when providing material characterization studies for the extraction of metal ores. Minerals deposits are analyzed using state-of-the art microscopy technologies and computer software to identify and determine ore deposits for metals manufacturing.

We have been active participants in projects that involved areas of hydro-metallurgical and pyro-metallurgical treatment of various types of ores for the beneficiation and recovery of copper, gold, silver, platinum, zinc, lead manganese, uranium, vanadium, zirconium, molybdenum, nickel and the rare earths.

Our experts in the field of lead processing have in-depth knowledge in lead production, smelting of lead materials, refining, and material design. Our services have been provided with an understanding of the environmental impact when establishing processing parameters. We have participated in environmental improvement projects, major plant expansions and modifications, including smelters, ductwork, barge unloading facilities and truck loading stations.

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PEC Consulting offers the expertise of its world-class consultants to evaluate the feasibility of projects in the mining industry.  We start with a conceptual study by analyzing the resources and process using our unique knowledge to conceptualize the project and preparing realistic capital and operations costs in order to generate project economic evaluations investors can depend on with high levels of confidence.  The project may advance to a comprehensive, bankable feasibility study which delivers a more in-depth evaluation and financial viability of the project.

Metal Ore Mining

PEC Consulting provides the services needed to determine the viability of new mining projects. We offer our services to the metal industries as gold, lead, copper, silver, zinc and heavy sands mining, including:

  • Analysis of reserves, exploration and minerals testing.
  • Technical feasibility, energy efficiency, and environmental studies.
  • Maintenance and process audits for the optimization of mining operations.
  • Mine planning and design.
  • Implementation of safety plans and procedure.
  • Operational improvement and management consulting.
  • Economic, market, and financial studies.

Metallurgical Processes

PEC Consulting offers extensive experience to your metallurgical processes and operations. Our team consists of industrial metallurgical experts who are highly qualified and capable to investigate and find solutions to improve your existing operations. We will provide an independent assessment of our findings and recommendations in a thorough and clear report.

We have considerable knowledge in extractive metallurgy. Our workforce has many years of experience in the physical and chemical processes for the separation and concentration of raw materials and have provided engineering to cover all aspects of this operation from crushing and grinding the ore to concentrating, smelting, casting, and refining processes.

We have demonstrated leadership when providing material characterization studies for the extraction of metal ores. Minerals deposits are analyzed using state-of-the art microscopy technologies and computer software to identify and determine ore deposits for metals manufacturing.

We have been active participants in projects that involved areas of hydro-metallurgical and pyro-metallurgical treatment of various types of ores for the benefaction and recovery of copper, gold, silver, platinum, zinc, lead manganese, uranium, vanadium, zirconium, molybdenum, nickel and the rare earths.

Our experts in the field of lead processing have in-depth knowledge in lead production, smelting of lead materials, refining, and material design. Our services have been provided with an understanding of the environmental impact when establishing processing parameters. We have participated in environmental improvement projects, major plant expansions and modifications, including smelters, ductwork, barge unloading facilities and truck loading stations.


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