As Consulmet continues its global expansion, Africa remains at the heart of its growth strategy. The company has steadily strengthened its presence across the continent, with the Democratic Republic of Congo (DRC) being one of its focus countries. Compiled by XANDERLEIGH DOOKEY.
Nearly 12 years ago, Consulmet established its first branch in the DRC, laying the foundation for long-term investment and development. Since then, it has expanded its footprint with branches in Lubumbashi, Kolwezi, and Kinshasa, reinforcing its commitment to supporting the region’s mining and industrial sectors.
While growth in Central Africa remains a strong focus for Consulmet, the company is equally committed to expanding and making a meaningful impact across the broader African continent. With successful projects in multiple regions, Consulmet continues to strengthen its presence and contribute to the growth of Africa’s mining and industrial sectors.
The following projects highlight Consulmet’s growing impact and continued dedication to Africa’s advancement.
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Republic of Congo
Consulmet has been awarded the contract for a complete 500 tph Run of Mine (ROM) hematite (Fe2 O3 recovery) processing plant. The project was awarded on a Lump Sum Turnkey (LSTK) basis for the design, supply, transport and mechanical and electrical installation. The plant includes 2-off 150 tph CMET Super High Density DMS modules.
These units are the company’s Mark II models following on-the-mark I model, which was installed in Thabazimbi on an iron ore project in 2022. Together with one of its key suppliers, MAGQUIP, the team developed an efficient Low Intensity Magnetic Separation (LIMS) magnetite removal module ahead of the DMS. Phase 2 of this project will include Spirals and Wet High Intensity Magnetic Separation (WHIMS) and an additional 500 tph stream.
Gabon
In 2024, Consulmet completed a detailed design for a ROM 300 tph manganese processing plant. The plant design included comminution, feed preparation, a fines DMS Cyclone plant and coarse DMS Drum plant as well as all bulk material handling.
Sierra Leone
Consulmet has been contracted to design, fabricate, construct and commission an innovative near infrared (NIR) plant for removal of mainly granite, from diamond-bearing kimberlitic material, for a client in West Africa. The NIR sorters use a combination of colour and NIR spectroscopy to differentiate kimberlite from waste rock. Upfront test work involved developing specific algorithms using images taken of a reference sample set including kimberlite, granite, pegmatite, amphibolite, and dolerite.
The NIR Waste Sorting plant, utilising TOMRA sorters, is designed to efficiently remove granite from the feedstock. The 70-85% granite removal estimate is based on extensive test work conducted at TOMRA’s facility in Germany. However, a more conservative 70% removal rate is used in the design to reduce the risk of removing kimberlite from the granite waste stockpile. Benefits of NIR sorting include upstream concentration of mine feed and reduced wear on the main plant equipment.
The NIR Waste Sorting plant is designed to process ROM kimberlite mineralised material at a rate of 200 tph. As the TOMRA NIR sorters rely on a surface detection technique, adequate surface preparation is vital to the efficiency of the sorters as any surface contamination can lead to misdetection. In this NIR Waste Sorting plant design, this is achieved by two-stage washing prior to sorting. Scope ancillaries include feed stockpiles, raw water supply and process water storage dam, process water pump and distribution, power generation, filtered water and compressed air required by the sorters is also provided.
South Africa
Consulmet recently completed a 500 tph coal stacker reclaimer project in South Africa. Consulmet SA (CSA), a subsidiary of the Consulmet Group, has designed and delivered a purpose-fit 400 tph bulk material handling system for its client, capable of handling 200 kt per month of -50 mm coal. Tailored to meet the Coal Quality Management Plan (CQMP) requirements for coal supply to Eskom, the system features an auto-mechanical sampler for precise stockpile certification and a 270-degree radial stacker that creates three 7 400-ton stockpiles.
The system incorporates a feed hopper sized for a Cat 993 FEL, a stacker feed conveyor, a six-idler payment accuracy belt scale, an auto hammer sampler with a twoway diverter housed in a containerised sample room, and a containerised MCC with an integrated control room. Designed, fabricated, and commissioned in 2024, this solution highlights CSA’s dedication to delivering innovative and reliable material handling systems that addresses the evolving needs of the mining sector.
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Mozambique
Consulmet (Africa) Limited was awarded a contract for a second treatment plant (TP2) at Montepuez Ruby Mining Limitada (MRM) in Mozambique, by the Gemfields Group Limited. The addition of the second plant will triple MRM’s processing capacity from the existing 200 tonnes per hour to 600 tonnes per hour. The contract was signed in October 2023 and is in line to be completed on schedule in May 2025. The contract is a LSTK contract based on the industry standard International Federation of Consulting Engineers (FIDIC) terms.
The latest proven technologies and trends in the process industry have been considered for the recovery of rubies. The bespoke design of the 600 tph treatment plant was carefully tailored to be able to process the high clay content of the ROM. The receiving bin with apron feeder and mineral sizer is designed to cater for two different tipper trucks with very steep valley angles for the low flowability of the material. The inclusion of double scrubbing in series will assist in the attrition of the material, providing as clean a product to the plant as possible.
A 200 tph DMS module has been designed with reconcentration modules and a scavenger plant utilising ultraviolet sorting technology for the final recovery of rubies. Water scarcity necessitated the inclusion of a 46 m diameter thickener and centrifuge module allowing the recirculation of all the effluent reducing the water consumption by approximately 25%. A 460 m overland conveyor will remove the tailings, reducing the OPEX of the plant. All the concentrated material will report to the existing recovery. Energy efficiency and reduced maintenance requirements were at the forefront of the design.
As Consulmet extends its presence across Africa, its focus goes beyond expansion to delivering real impact. By leveraging its expertise, Consulmet is driving efficiency, innovation, and sustainable growth in key regions across Africa.