Waste is our nature's richness

Design and installation of the Recovery and Conversion plants meeting each recovery site demands and environmental challenges to compliance requirements to landscape recovery

 

Revamps existing raw ore production and beneficiation infrastructure. PFI’s beneficiation and smelting plants are designed to process low grade concentrates

​

PFI install its plant at the recovery site. Were there are existing concentrate plants, PFI will upgrade, revamp, renew or installs state of the art operating facilities, production equipment and concentrate plant(s) to process market quality and quantity product required for PFI’s smelter plant Direct Reduction and conversion process.

​

PFI Builds, Owns, Operates and Maintains (BOOM) are designed state of the art modular facilities including beneficiation and smelting plants, meeting ISO9001. The smelting plants are green hydrogen fired and zero carbon. The plant generates, recovers, reconstruct and repurpose its own carbon black, hydrogen, water and electrical power. There is not heat, gas, steam or water out, all systems are contained in the advanced closed loop and tightly coupled modular recovering environmental systems.

​

Plant production and conversions residuals are all recovered and repurposed on site. By products of these green, zero carbon residuals are all converted to commercial  High Grade Concrete, Cement, Dry High Performance Bricks, Construction grade Thermal Bricks, High Performance construction Glass, commercial grade glass, landscape resurface and reconstruction, top soil recovery. These products are all destined for the ; social development programs with our affiliates and strategic alliance and technical partners in the communities and regions within the plants area of commercial and environmental influence. All of these commercial grade products will generate several micro industries supported by  value added services and maintenance contracts on certain infrastructures supporting the smelter plants.

​

The smelters is a driving force for community  development and sustainability. As a major employer, the plant operations takes into consideration the employees and their families well-being. The plants operate on four six hours daily shifts, six days per week, twelve months of the year. The not operating day is dedicated to our AI maintenance system while systems are not power down, furnaces are on idle maintenance mode. The AI system analysis is monitored live on line twenty four seven by our modules manufacturers to ensure no additional production downtime.

​

Production runs are designed to maximize efficiency and security as well as to meet futures market requirements, thus maximizing the operating live of the plant and work force stability. Each plant provides and average of 360 jobs per day for a minimum of twenty years. To retain good performance and quality of life, the plant builds, in adjacent land holdings, a workers village providing housing for each worker and his family, supply stores (owned interdependently by the community), certify comprehensive clinical services and medical support, board certify parochial school with support or in alliance or affiliation to known schools, universities and professional institutions, which will provide, for its employees, family members and other communities in the area of influence of the plants, on going professional, technical or vocational training, whether related or non related to the plant operations.

 

All elements of the plant, including production, delivery, administrative, human resources, commercial or financial operations are lodged in its own specific Blockchain ledger, specifically futures and spot operations will be ledger on smart contracts for secured deliveries and settlements. Employees payroll, insurance, medical, housing, vacation and retirement benefits, performance valuation, training and bonuses will be covered secured by the plant’s issued Blockchain smart contract upon hiring.

 

PFI plants operational and production systems are escalable and vertical integrated to value added production systems. The modular beneficiation plant and the ensuing smelting plant infrastructure supports, up to five processing modules supporting the DRI conversion furnace(s) each rated at 600 Mt/year. Fully automated; certain production controls, operating and maintenance systems are AI level supported but final decision remain all human.

 

Iron Ore tailings and waste

yields 20% - 58% Magnetite to 87% Direct Reduction Iron to 92% Hot Briquette Iron as well as 53% Hematite concentrate to 67% TFe beneficiated feedstock to the DRI process to yield TFe ≥88% ŋFe ≥93%, to granulated iron or feedstock to steel production.

 

Copper Waste

The plants can be integrated as well to yield “A” grade copper; for conversion to 99.99% pure cathode sheets; by incorporating matte conversion process, to yield from 30-70% copper to 98% blister copper pigs or ingots, battery grade Copper cathode

 

Recovery of other Minerlas and Metals waste

​

Precious metals, Bauxite waste, Alumina, Aluminium, Nickel, Cobalt, Zink and certain Rear Earth elements