Greenfield & brownfield
Two Ways into a Plant
A new plant is settled on test data before capital is committed. An existing plant starts with measurement, not a proposal — the constraint is found before anything is bought.
Greenfield Project
From Concept to Commissioning. From Feed to Value.
We develop integrated process and engineering solutions for new industrial plants, starting with feed characterisation and technology selection and progressing through plant design, project implementation and commissioning. Every critical decision is driven by process performance, technical feasibility and project economics.
- Feed Characterisation & TestworkEvaluate feed properties, composition and variability to establish process requirements, recovery potential and product objectives.
- Process Development & Technology SelectionDevelop process flowsheets, mass balances and equipment concepts to identify the most suitable technical solution.
- Feasibility, Basic Engineering & CAPEXEstablish plant configuration, utility requirements, preliminary equipment specifications, capital cost estimates and project feasibility.
- Detailed Engineering & DesignTranslate the selected process into coordinated engineering deliverables covering plant layout, mechanical, structural, piping, electrical and instrumentation interfaces, with 3D modelling where applicable.
- Procurement & Project ImplementationSupport equipment procurement, technical bid evaluation, vendor coordination, construction interfaces and project execution.
- Commissioning, Performance Testing & Ramp-UpSupport plant commissioning, process stabilisation, performance evaluation and ramp-up towards agreed operating and product specifications.
Brownfield Modification
An Existing Plant That Isn't Meeting Its Numbers
We improve the performance of operating plants through plant audits, debottlenecking and modification engineering, from the first circuit survey to shutdown execution and post-upgrade verification. The work starts as a measurement exercise, not a proposal — the constraint is found before anything is bought.
- Plant Audit & Circuit SurveyReview the operating plant, its equipment and its records to establish actual throughput, recovery, product quality and downtime against design.
- Mass Balance ReconciliationSample and measure the circuit to build a reconciled mass and water balance that shows where material, value and capacity are being lost.
- Bottleneck IdentificationPinpoint the equipment, transfer points and process steps that limit capacity, recovery or reliability, and quantify the gain from removing each one.
- Modification & Retrofit DesignEngineer the changes to fit the existing layout, structures and utilities, from equipment replacement to circuit reconfiguration and new transfer arrangements.
- Shutdown-Window PlanningSequence fabrication, installation and tie-ins so that the work fits planned shutdowns and keeps lost production to a minimum.
- Post-Upgrade VerificationMeasure the modified plant against the agreed targets for throughput, recovery and product quality, and support the stabilisation of the new operation.
Greenfield · examples
10 referencesNew Plants and New Circuits
20261,000 TPAFeasibility report for setting up a boron carbide plantBoron carbideMINCHEM Impex India Pvt. Ltd. · IndiaOngoing
2025150 TPHConceptual study and pre-feasibility for crushing, screening & beneficiation of the Baghwari-Khirkhori copper blockCopperInnourbia Solutions Pvt. Ltd. · IndiaCompleted
20251,000 lt/daySetting up a pilot demonstration plant for recovery of gallium from Bayer liquorGalliumJNARDDC · IndiaOngoing
2025200 TPHCrushing & dry screening plant on EPC basis, 200 TPH input capacityBauxiteSierra Minerals Holdings Ltd. · Sierra LeoneOngoing
20251,200 TPHOwner's engineer, concept to commissioning, for a 1,200 TPH bauxite beneficiation plant with infrastructure & port developmentBauxiteSierra Minerals Holdings Ltd. · Sierra LeoneCompleted
2025150 TPHConceptual study and pre-feasibility for crushing, screening & beneficiation of the Oranga Revatipur graphite & vanadium blockGraphite & vanadium oreInnourbia Solutions Pvt. Ltd. · IndiaCompleted
2024700 TPHConceptual study and pre-feasibility for crushing, screening & beneficiation of the Bhanta magnetite blockIron oreInnourbia Solutions Pvt. Ltd. · IndiaCompleted
20241,200 TPHDetail engineering of a 1,200 TPH bauxite beneficiation plant with infrastructure development and river pumping stationBauxiteSierra Minerals Holdings Ltd. · Sierra LeoneOngoing
20231,200 TPHCAPEX engineering of a 1,200 TPH bauxite beneficiation plant with infrastructure developmentBauxiteSierra Minerals Holdings Ltd. · Sierra LeoneCompleted
202010,000 TPDBasic engineering package for a new 10,000 TPD copper concentrator at Rakha and Chapri-Sidheswar mines, Hindustan Copper LimitedCopper orePMRC Pvt. Ltd. · IndiaCompleted
Brownfield · examples
10 referencesExisting Plants, Modified and Optimised
20264.5 MTPADebottlenecking and Augmentation of Washery 2 from 2.5 MTPA to 3.5 MTPA and Washery 3 from 4.5 MTPA to 5 MTPA, through M N DasturCoalTata Steel Limited · IndiaOngoing
2025—Test work for iron ore tailing dewateringIron oreMarampa Mines Limited · Sierra LeoneCompleted
20241,200 TPHDesign engineering to replace the primary crushing and screening system at Meramandali, producing −6 mm coal at 1,200 TPHCoalTata Steel · IndiaCompleted
2023450 TPHBall mill grinding circuit optimisation for an existing 450 TPH fresh feed iron ore beneficiation plantIron oreMarampa Mines Limited · Sierra LeoneCompleted
2022900 TPHDetail engineering (technology structure, conveyor, sumps, agitator tank, flow distributor) for modification of the washing circuit, CSW plant, Dalli Mines, Bhilai Steel PlantIron oreBSBK Limited · IndiaCompleted
2021500 TPHDesign engineering to replace the secondary crushing and screening system at Meramandali, producing −6 mm coal at 500 TPHCoalTata Steel · IndiaCompleted
202112 MTPAAssessment of the iron ore beneficiation plant, tailing management concept and process audit for capacity enhancement from 8 to 12 MTPA, AM/NS DabunaIron oreArcelorMittal · IndiaCompleted
202112 MTPAChecking of process design documents for the TEFR of a 3 × 4 MTPA grinding & desliming system at Thakurani Mines (8 to 12 MTPA)Iron oreArcelorMittal · IndiaCompleted
2021200 TPHConceptual design engineering of a slurry sump and feeding hopper for the new feed system of a 200 TPH iron ore slime beneficiation unit, Dalli RajharaIron oreBSBK Limited · IndiaCompleted
2021900 TPHBasic engineering for modification of the washing circuit, CSW plant, Dalli Mines, Bhilai Steel PlantIron oreBSBK Limited · IndiaCompleted
Chain
CLICK TO INSPECTEngineering the Journey from Resource to Value
Every KGS project follows one connected path, from understanding the feed material to creating lasting value on the plant. Each stage is engineered with the next in mind, so that process, recovery and product decisions work together.
Feed
Understand the Resource
We start by understanding the feed material, its composition, mineralogy and variability. This establishes the basis for selecting the right process, assessing recovery potential and evaluating project feasibility.
Scope at this stage
- Feed characterisation
- Sampling and assay
- Mineralogy
- Variability assessment
- Recoverable-value assessment
One engineering partner. From process concept to project execution.
Next step
Contact KGS →Talk to KGS about Your Feed, Your Plant, or Your Numbers.