Through process and plant analysis, Ex Mente rapidly starts adding value to clients’ operations, by applying our process engineering experience and expertise. EMPROBE is a thorough investigation of the facility that addresses process, infrastructure and operational aspects. We deliver detailed process and plant data, information and in-depth knowledge. This information adds value to the process and can also be used as an input into modelling, simulation, control, and design projects.
Process modelling and simulation is at the heart of what we do. We combine chemistry, mathematics and software to develop computer-based models that we can use to study metallurgical processes and improve our understanding. The insight that we derive from modelling and simulation is what enables us to move process performance forward.
Ex Mente specialises in the development of computational process models to mimic the behaviour of an existing or conceptual process. Models can be used effectively during feasibility studies, process design, plant optimisation, economic evaluation of projects and control system design. Ex Mente can provide our clients with a customised thermochemical model of their unique process. Clients now have access to manipulate process parameters and view results within minutes through a web browser.
Managing process data is a critical task for any operation. The most important by-product of any industrial plant is data. Our process-level information systems assist operational and process personnel to harness the large volumes of data produced, turning it into valuable information, and ultimately insight that can improve performance.
Ex Mente has developed a framework for process-level information systems to assist our clients in effectively capturing the vast volumes of data produced on their plants. This data is valuable if it is harnessed to gain insights into the process to allow for continuous process improvements. EMPLIS is also a vital link that enables advanced control systems to utilise not only continuously monitored data but also data from discrete activities that occur on the plant (e.g. taps, inspections, sample taking, analyses, etc.). Each system is customised to our clients’ specific needs to give them a competitive advantage.
Multiphysics modelling and simulation (FED, DEM, CFD). EMPHYS can be used to enhance process understanding and equipment design and to gain insight where conventional experimental techniques are limited.
A number of multiphysics modelling and simulation techniques are available for assisting our clients to gain greater insight into their operations. The Finite Element Method (FEM) is used for modelling heat transfer and the subsequent stresses, strains and displacements of pyrometallurgical systems. Computational Fluid Dynamics (CFD) provides insight into fluid flow, heat and mass transfer of processes or systems. Finally, the Discrete Element Method (DEM) is a tool for modelling interactions between granular particles and their surroundings and is used to model particle movement, interactions and trajectories within static and dynamic environments.
Multiphysics modelling supplements our process modelling capabilities and provides our clients with a deeper understanding of the process kinetics and equipment performance.
Optimising process control has the potential to improve operational performance significantly. Automated real-time monitoring and control of a process can reduce variability, improve recovery and yield, and ultimately enhance profitability. Our optimising control systems are based on sound process and control understanding, and can make a significant contribution to improving challenging metallurgical processes.
Ex Mente focuses on the development of control systems that manipulate processes on the chemical or metallurgical level. These systems encapsulate process knowledge obtained from plant data, operators, engineers and literature. This is a unique approach because traditional control methods are focused on monitoring and controlling of equipment, which leaves many decisions up to the operators. EMOpt control systems are not able to replace an operator or process engineer, but can handle the tasks where an automated system can yield superior results. The result could be tighter control of certain process parameters that can make it possible to operate the process closer to its limits, increasing throughput and improving utilisation of the equipment.
Training is a key step in the implementation of any new technology solution. This is important to close the gap between process documentation and the actual operational process. Personnel requires enough knowledge of how their tasks affect the bigger processes to enable them to make correct judgements when dealing with non-standard situations. EMEQUIP is a training service that provides the necessary information to allow personnel to apply theoretical concepts in practice.
An additional benefit of good documentation and training is improved continuity. Personnel will be able to refresh their knowledge on how to use the system by quick and easy access to system documentation.
An integral part of the EMProcessSolution is building a mutually beneficial partnership. One way in which we do this is by providing continuous maintenance and support. The support and maintenance service components include system support and access to all updates that become available during this period. You also have access to our extensive knowledge and experience, almost like having an extra metallurgical or chemical engineering expert. Our engineers will do regular operational assessments to see if there is any additional room for improvement on the operation and will make recommendations accordingly. This is the true value of EMProcessSolution™.
The support contracts range from 3 to 10 years.