Mineral Processing — United Metals

Integrated Technology

Automation Systems for
Comprehensive Control

Our approach integrates sensors, real-time analytics, and intelligent control systems — creating a responsive, self-optimising processing environment. This interconnected system allows for precise control regardless of ore feed variability, ensuring consistent concentrate grades and recovery rates at every shift.

System 01 — Chemistry Control

Advanced pH Monitoring & Control

Precise pH control is essential for optimal flotation selectivity and reagent efficiency. Our solid-state pH sensors continuously monitor slurry conditions across all flotation banks, feeding real-time data to lime dosing control loops. This closed-loop system maintains pH within ±0.05 units of setpoint — far tighter than manual dosing — ensuring peak mineral surface chemistry for copper sulfide, antimony, and tin flotation circuits.

Strategically mounted in-line sensors with annular liquid reference junctions resist abrasion in high-solids slurry environments and minimise plugging, delivering reliable signal without manual cleaning downtime.

Precisely measures pH — optimises Cu, Sb & Sn flotation

Real-Time

Solid-state design — resists abrasion in high-solids environments

Annular reference junctions — minimise plugging risk

Integrated with lime dosing — reduces consumption up to 15%

↓ 15% Lime

System 02 — Visual Analytics

Machine Vision Froth Analysis

Our Machine Vision Froth cameras transform flotation circuit management through real-time froth characterisation — replacing the subjectivity of visual operator inspection with quantified, data-driven process adjustment. High-resolution imaging captures froth texture, bubble size distribution, velocity, and stability parameters at multiple points simultaneously across each flotation bank.

The system integrates with central process servers for comprehensive data analysis and predictive control, dynamically adjusting airflow and reagent dosing in response to froth condition changes before they impact concentrate grade or recovery.

High-resolution imaging — bubble size, velocity & stability analysis

AI Vision

Dynamic airflow & reagent dosing — responds to froth in real time

Server integration — comprehensive data analysis & trending

Predictive froth depth & aeration adjustment — reduces grade variability

Predictive

System 03 — Grade Control

Real-Time Compositional Analysis

Our beneficiation plants deploy a suite of advanced online grade analysis technologies that provide instantaneous elemental composition data without laboratory delays. X-Ray Fluorescence (XRF) stream analysers provide element-by-element assay of concentrate and tailings streams on a 30-second cycle, enabling immediate detection of grade excursions.

Optical absorbance spectroscopy provides continuous electrolyte monitoring in SX/EW circuits, while automated feed grade characterisation drives dynamic reagent dosage adjustments — ensuring the plant always responds to actual ore composition rather than assumed values.

XRF stream analysers — instantaneous elemental assay, 30-sec cycle

XRF

Optical absorbance spectroscopy — continuous electrolyte monitoring

Real-time impurity detection — flags off-spec feed immediately

Concentrate validation — ensures smelter specification compliance

ISO Traceable

XRF

System 04 — Central Nervous System

Integrated SCADA & Advanced Process Control

Our comprehensive SCADA system serves as the central nervous system of every processing plant, unifying data inputs from all sensors, analysers, and control actuators into a single real-time operating picture. Operators visualise and control every stage of the plant — from crushing and grinding through flotation to concentrate thickening and filtration — through an intuitive dashboard.

Advanced Process Control (APC) algorithms run continuously in the background, anticipating process disruptions from ore variability or equipment condition changes and making pre-emptive adjustments — keeping the circuit at optimal performance without manual intervention.

Centralised control dashboard — complete plant visibility in one view

SCADA

Real-time data fusion from all sensors and analysers

Automated flotation circuit control — setpoint maintenance 24/7

Predictive APC algorithms — anticipate and pre-empt disruptions

APC

Processing Methods

Comprehensive
Beneficiation Techniques

United Metals employs a diverse range of beneficiation techniques tailored to optimise mineral recovery for each ore type and deposit character — from low-cost gravity pre-concentration through selective flotation to advanced hydrometallurgical and pyrometallurgical circuits.

Physical Separation

Gravity Concentration

Utilising the natural density differences between minerals, gravity concentration effectively separates valuable minerals from gangue without chemical reagents. Particularly efficient for processing coarse-grained ores such as cassiterite (tin) and chromite, it serves as a critical low-cost pre-enrichment step that reduces the mass of material requiring downstream processing — lowering energy consumption and reagent costs across the circuit.

Equipment deployed includes spiral concentrators, jigs, shaking tables, and dense media cyclones — selected on the basis of particle size distribution and density contrast.

Primary Applications

Cassiterite (Sn)

Chromite (Cr)

Coltan (Nb/Ta)

Hematite (Fe)

Surface Chemistry

Flotation Concentration

An essential method for maximising mineral recovery from sulfide ores such as stibnite (antimony) and chalcopyrite (copper). Selective collectors impart hydrophobicity to target mineral surfaces while depressants suppress gangue minerals — allowing valuable sulfides to attach to air bubbles and float to the froth layer. Our expertise in reagent optimisation and airflow regulation, guided by machine vision froth analysis, enhances selectivity and processing efficiency beyond conventional setpoints.

Froth flotation is our primary recovery technique for the majority of our sulfide concentrate production.

Primary Applications

Stibnite (Sb)

Chalcopyrite (Cu)

Sphalerite (Zn)

Pentlandite (Ni)

Aqueous Metallurgy

Hydrometallurgical Processing

Through advanced leaching and solvent extraction (SX/EW) techniques, we recover valuable metals from oxide ores while minimising environmental impact compared to smelting alternatives. Heap leaching dissolves copper from oxide ore bodies using dilute sulfuric acid; solvent extraction selectively concentrates copper ions; and electrowinning plates pure copper directly onto cathode blanks at 99.99% purity.

Hydrometallurgy is the process route of choice for our Zambian and DRC copper cathode operations — avoiding SO₂ emissions entirely.

Primary Applications

Cuprite/Malachite (Cu)

Azurite (Cu)

Pyrolusite (Mn)

Oxide Ores

High-Temperature Metallurgy

Pyrometallurgical Processing

We employ roasting and smelting to extract metals from refractory sulfide ores where hydrometallurgical routes are not technically or economically viable. Antimony volatilisation smelting in reverberatory furnaces converts stibnite concentrates directly to metal at 98.5–99.5% purity; our copper induction smelting produces blister copper for subsequent electrorefining; and gold doré smelting consolidates precipitate from CIL or Merrill-Crowe circuits.

Advanced mercury capture and scrubbing systems in antimony roasting circuits ensure zero uncontrolled atmospheric release.

Primary Applications

Stibnite → Sb Metal

Chalcopyrite → Blister Cu

Gold Precipitate

Refractory Ores

Mineral Capabilities

Diverse Mineral
Processing Portfolio

United Metals operates specialised processing solutions for a wide range of oxide and sulfide minerals — from cassiterite tin through coltan niobium-tantalum to copper, nickel, zinc, and antimony. Each mineral type benefits from a purpose-matched process route.

⬡ Oxide Minerals — 9 Species

◆ Sulfide Minerals — 4 Species

Tin

Cassiterite

SnO₂

Extracted Metal: Tin

Gravity · Flotation

Copper

Cuprite

Cu₂O

Extracted Metal: Copper

Heap Leach · SX/EW

Copper

Malachite

Cu₂(CO₃)(OH)₂

Extracted Metal: Copper

Acid Leach · SX/EW

Copper

Azurite

Cu₃(CO₃)₂(OH)₂

Extracted Metal: Copper

Acid Leach · SX/EW

Chromium

Chromite

FeCr₂O₄

Extracted Metal: Chromium

Gravity · Magnetic

Niobium

Coltan

(Fe,Mn)(Nb,Ta)₂O₆

Extracted Metals: Nb & Ta

Gravity · Dense Media

Iron

Hematite

Fe₂O₃

Extracted Metal: Iron

Gravity · Magnetic

Iron

Magnetite

Fe₃O₄

Extracted Metal: Iron

Magnetic Separation

Manganese

Pyrolusite

MnO₂

Extracted Metal: Manganese

Hydromet · Leaching

Copper

Chalcopyrite

CuFeS₂

Extracted Metal: Copper

Froth Flotation

Nickel

Pentlandite

(Ni,Fe)₉S₈

Extracted Metal: Nickel

Selective Flotation

Zinc

Sphalerite

ZnS

Extracted Metal: Zinc

Differential Flotation

Antimony

Stibnite

Sb₂S₃

Extracted Metal: Antimony

Flotation · Smelting

ESG in Processing

Sustainability
Commitment

At the Heart of
Every Process

At United Metals, sustainability is embedded at the design stage of every processing circuit — not bolted on as an afterthought. Our mineral processing methodologies are optimised simultaneously for metal recovery and environmental performance, recognising that these objectives are complementary rather than competing.

From advanced tailings management to circular economy metal recovery, our processing operations are governed by the same ISO 14001 certified environmental management framework that covers our mining and smelting activities.

ISO 14001 Certified

Environmental management across all processing operations

Resource Efficiency & Waste Reduction

Minimising waste at every processing stage through advanced tailings management and smart water systems.

Advanced Tailings Management — dry storage, paste tailings, and reprocessing for additional metal recovery

Water Conservation — closed-loop recycling systems and smart water management

Environmental Impact Mitigation

Identifying and mitigating environmental risks before they materialise through rigorous assessment and advanced filtration.

Comprehensive ESIAs — Environmental and Social Impact Assessments with strategic management plans

Membrane Filtration — reduces waste and optimises extraction processes

Circular Economy & Metal Recovery

Recovering metals from secondary sources reduces dependency on primary mining and unlocks value from historical waste streams.

Recycling and recovering metals from secondary sources and tailings stockpiles

Reprocessing historical waste dumps using modern beneficiation technology

Stakeholder Engagement & Transparency

Open, accountable communication with all stakeholders ensures our processing operations maintain community trust and regulatory confidence.

Open communication with local communities and regulatory authorities

NGO partnerships for independent environmental monitoring

Sustainable Technology Adoption

Continuous investment in eco-friendly processing innovations reduces our operational footprint at every stage of beneficiation and refining.

Air-cooled drilling rigs — eliminates water consumption in site drilling operations

Sonic drilling — reduced water consumption vs conventional rotary methods

VFD drives on all major rotating equipment — up to 40% energy saving vs direct-on-line

Renewable-powered water treatment and process utilities

Global Processing Footprint

Operating Across
7 Territories

United Metals operates processing facilities across Africa, Asia, and Latin America — each delivering specialised beneficiation and metallurgical solutions matched to local ore characteristics and market requirements.

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Africa

Zambia

SX/EW copper cathode production. Copperbelt processing infrastructure.

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Africa

Zimbabwe

Antimony flotation, copper processing, gold doré. Great Dyke operations.

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Africa

Tanzania

Gold CIL/CIP processing and polymetallic beneficiation.

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Africa

DR Congo

Copper cathode electrorefinery and coltan gravity separation.

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Africa

Sierra Leone

Mineral sands, rutile, ilmenite gravity and electrostatic separation.

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Asia

India

Antimony smelting and refining. Export logistics processing hub.

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Latin America

Mexico

Silver-lead-zinc differential flotation concentrator.

Partner With Us

World-Class
Beneficiation Services

United Metals continues to redefine the mineral processing industry with innovative solutions that maximise efficiency, sustainability, and profitability. Partner with us for world-class mineral beneficiation services tailored to your operational needs and ore characteristics.

Contact us today to learn more about our automation capabilities and how our integrated processing systems can improve your recovery rates, reduce your reagent costs, and deliver consistent concentrate grades.

Discuss Your Project Smelting & Refining → Business Model

Processed Mineral Products

Antimony Concentrates

Flotation · Stibnite feed

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Copper Concentrates

Flotation · Chalcopyrite feed

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Tin Concentrates

Gravity · Cassiterite feed

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Copper Cathodes