Resume - Consulting Process Metallurgist with 30 years experience in the evaluation, desi...

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Resume #72786

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Education:
B.S. Chemical Engineering - 1977 University of Nevada, Reno
M.S. Metallurgical Engineering - 1982 University of Nevada, Reno

Registration:
Registered Professional Chemical Engineer Nevada

Affiliations:
Registered Member - Society of Mining, Metallurgy and Exploration, Inc.

Experience:
2005 – Present Allard Engineering Services
Independent Consultant: Providing engineering and metallurgical consulting services to mining and engineering companies.
* Provided 43-101 audit of metallurgy and process for a gold/silver heap leach project in Mexico.
* Provided process design for gold recovery plant design near Tbilisi, Georgia.
* Provided detailed engineering for 3,000 gpm gold ADR plant in Nevada. Prepared complete process and mechanical construction documents. Engaged and supervised subcontractors preparing detailed civil, structural and electrical designs.
* Provided metallurgical and engineering support as part of owner's project team for development of a 14,000 tpd Cu/Zn project in Mexico. Prepared conceptual engineering and economic analysis of several configurations. Developed capital and operating costs to ± 30% and pro-forma cash flow analysis for Economic Assessment.
* Reviewed 1,000 tph washed concrete sand plant in California. Provided recommendations for sampling and criteria for re-evaluation of project. Supervised testing of samples at an independent lab.
* Prepared conceptual designs for crusher replacement for diamond mine in Canada. Developed process designs for fine diamond recovery project. Prepared conceptual engineering designs for Audit Plant Refit. Provided designs for screen replacement. Provided conceptual engineering designs for feed upgrade by magnetic separation. All projects included general arrangements, flowsheets, mass balances, equipment lists and capital cost estimating.
* Reviewed crushing and screening installations for a borate mine in California. Reviewed compaction plant operation and made recommendations for product quality improvement. Reviewed reactor performance and designed modifications for planned production increase. Provided capital cost estimate for process operations on a unique borate ore. Reviewed magnetic separator plant operation and made recommendations for operations improvement. Provided independent review of unit operations for pilot testing major process modification.
* Provided process design and supervision of detailed engineering for 1,500 tpd gold mill in Mexico.

2000 – 2005 U.S. Borax Inc. – Boron Operations
Principal Research Engineer: Responsible for developing fundamental basis for new processes and technical support to the production department.
* Seconded to Engineering Department to manage project to relocate specialty chemical processes to Boron Operations. Developed process and operating changes resulting in capital cost savings bringing NPV from $13MM to $19MM on $50 MM project. Supervised engineering company during conceptual design, responsible for schedules, budgets and liaison with operations, maintenance, corporate technical and executive managers.
* Pilot tested and developed engineering designs for the installation of two 3,000 gpm Klaren Self Cleaning Heat Exchangers. Managed capital project for detailed design.
* Prepared preliminary engineering studies for determining the technical and economic viability of three major process modifications.
* Created test program to evaluate reactor performance and engineered and installed modifications to the reactor discharge that increased throughput from 75 tph to 140 tph; resulted in $700K in annual operating cost savings, permanently deferred $12 MM capital expenditure and allowed record production rates. Total project capital $150K.
* Designed and installed reactor internals increasing reaction extent from 85% to 99+%. $230,000 in annual recovery savings; $60K capital cost.
* Supervised vendor testing for replacing hammer mills with roll crushers resulting in project approval.
* Prepared production quantities of magnetically upgraded mineral for testing as micronutrient in the New Zealand forestry industry. Developed preliminary designs and estimates for production facility.
* Developed 1-lpm continuous pilot plant for production of boric acid from low-solubility borate minerals using solvent extraction at ambient temperatures and direct precipitation of solid products.
* Developed bench scale process to recover products lost in tails streams utilizing adverse solubility of impurities. Potential to increase overall recovery by 11%, reduce operating costs by $2 MM per year and eliminate boric acid tailings ponds. Potential capital avoidance of $147 MM over life of mine.
* Prepared detailed fabrication and construction drawings for fast-track installation of parallel slurry pump retrofit during planned outage. Installed cost $45K; NPV $792K.
* Developed and field tested method to agglomerate wet coarse gangue using convective cooling and dehydration by precipitation of highly hydrated salt. Potential to eliminate environmental problem and significantly reduce disposal costs. $2 MM cost avoidance.
* Initiated pilot testing of rakeless and paste thickeners for inclusion in Boric Acid Plant expansion. Potential $5 MM reduction in capital cost, $363,000 annual recovery improvement.
* Developed and field tested method to improve counter-current washing of coarse gangue, $125,000/year recovery improvement; $25,000 capital cost.
* Supervised field testing and subsequent commissioning of a foam dust suppression system.
* Managed expansion of Pilot Plant machine shop. Specified and installed mill, lathe, shear, brake, section bender, grinder/notcher etc. On schedule and under budget.

1991 – 2000 Roberts & Schaefer Company:

Sr. Engineering Manager: Responsible for the oversight and direction of the Process Engineering staff of Roberts & Schaefer Company's Western Operation. Responsibilities include day-to-day management of the process department, distribution of technical staff to projects, technical oversight, proposal preparation and marketing of process capabilities.
* Developed in-house mass balance program used on all process projects.
* Developed operating cost analysis program used on all projects.
* Developed crushing/screening design program used on all projects.
Project Manager for: detailed design of: tungsten carbide drying facility; pit dewatering station - for feasibility studies: 600 tph dry manufactured sand facility; 2,000 tpd gold milling facility; 1,250 tpd gold milling facility; 250 tph aggregate facility; 1,250 tph dry sand classification system; 1,350 tph fine crushing facility; 300 tph glass sand beneficiation facility and a 8,500 tpd gold heap leach.
* Managed design team for tungsten carbide drying facility. Supervised process, layout, mechanical, structural, piping and electrical disciplines. Managed budgets and all client communications.
* Designed and supervised testing for crushing, grinding, scrubbing, heap leaching, agglomeration, filtration, agitation leaching, CCD, flotation, carbon adsorption, SX-EW.

Lead Process Engineer for: investigation of coal mine acquisition in Wyoming; design of 2,000 tpd milling and flotation facility in Utah; detailed design of pressure strip retrofit in Ghana; detailed design of adsorption retrofit in Nevada; detailed design of 600 tph aggregate facility in Colorado; due diligence for acquisition of 5,000 ton/yr copper mine in Arizona; investigation of fine crushing, agglomeration and stacking expansion for a gold mine in Mexico; detailed design for Bankable Feasibility Study of 33,000 tonne/yr copper agitation leach, CCD, SX-EW facility in Northern Chile; investigation of 6,000 tonne/day aggregate facility in Puerto Rico, detailed process designs for a 33,000 tpa copper heap leach SX-EW project in Arizona, detailed design of 1,500 tpd slimes treatment facility in California. Designed screening and crushing circuits, pumps, piping, classifiers, cyclones, agglomerators, leach vessels, SX-EW circuits.
* Developed metallurgical test programs that identified a previously unknown copper mineral.
* Developed process approach resulting in successful acquisition and rehabilitation of a copper mine.
* Developed unique process to increase leach recovery of an exotic copper ore.
* Designed hydraulically efficient carbon adsorption baffle plate, resulting in doubled production.
* Developed technical and economic basis for application of several processing techniques, Waterflush crushing prior to ball milling, slimes agglomeration, dry sand classification, banana screen technology, wet pebble crushing, combined high-low grade adsorption, feeding multiple screens with a single feeder.

1989 – 1991 Pegasus Gold Corporation, Zortman Mining Inc.:
Project Engineer: Responsible for development of in-house feasibility study for 34,000-tpd sulfide ore process expansion. Process development encompassed investigation of materials handling, crushing, grinding, agitation leaching, bio-oxidation, chemical oxidation and heap leaching. Accountable for the development of process flowsheets, P&IDs, computer generated simulations, water balance, general arrangements and economic tradeoffs. Developed detailed process designs for 3,500 gpm carbon adsorption system and 4.5 tpd AARL elution circuit. Prepared project cash flow and sensitivity analysis.
* Directed engineering company conducting preliminary engineering based on in-house study.

1988 – 1989 Western States Minerals Corp.-Northumberland Mine:
Process Superintendent: Responsible for daily process operations of 7,000 tpd gold-silver heap leach, laboratory, refinery, 3,000 gpm carbon recovery plant and heaps.
* Supervised the daily activities of 35 people.
* Developed several simple methods to extend leaching into winter months, increasing production.

1986 – 1988 Bateman Engineers, Inc.:
Senior Engineer: Responsible for process design of a 1,500 gpm carbon adsorption plant for a Nevada heap leach. Solely accountable for process investigation and detailed design and commissioning of a gas phase, temperature swing, chlorinated solvent adsorption system. Was commissioning engineer for startup of 1 tph experimental heavy liquid cyclone coal cleaning pilot plant. Prepared feasibility studies for two Nevada gold heap leach projects. Prepared feasibility study for a copper leach SX-EW project in Nevada. Designed scrubbers, heat exchangers, blowers, adsorbers, pumps, piping, reagent addition systems, filters, etc.
* Carbon plant performed from initial startup at 100% availability for over 9 months.
* Solvent recovery system was a complete, one-off process engineering design and installation, which performed to design specifications.

1977 – 1986 Kappes, Cassiday and Associates: (1977 – 1982 part to full time)
Senior Engineer: Provided engineering, technical support and consulting during the early development of gold heap leaching. Responsible for feasibility study and provided subsequent technical assistance during design and construction of a 1,000 tpd gold heap leach project in Spain. Supervised designers preparing detailed design, acted as construction manager for 4,000 tpd gold heap leach in Nevada. Designed, supervised construction, and commissioned carbon recovery plants for seven mines in the Western U.S. Developed feasibility studies or provided process designs for eight precious metals-heap leach projects in Africa, France, Mexico and the United States.
* Participated in the early development of basic heap leach technology.
* Engineered in-house designs for agglomerating, stacking, carbon adsorption, desorption and electrowinning equipment.

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