Projects
36’Ø x 19.5’, 13.5 MW SAG MILL
22’Ø x 34’, 8.5 MW BALL MILL
SUPPLIED INTO NAMIBIA
- Ore type: Uranium
- Throughput: 1400-1800 t/h
- Final Grind: 300-350 µm
- Each mill supplied with a dedicated VVVF drive including chilled water supply circuits.
- Supply included liner handler, thunderbolt and monorails.
- This was the largest SG iron girth gear ever manufactured in the world at the time.
- Supplied and delivered by NCPI.
- Mills supplied in a fast delivery time and one of the reasons an order was placed on NCPI.
- Full installation and commissioning with NCPI labour and specialist completed by NCPI.
- Mills operating successfully for 9 years.
- Mills maintained and supported by NCPI since commissioning.
36’Ø x 17.5’, 18 MW SAG MILL
SUPPLIED INTO AUSTRALIA
- Ore Type: Gold
- Throughput: 500 t/h
- Final Grind: 150 µm
- Dual Drive slow speed synchronous motors directly coupled to pinions including VVVF drive.
- 4 – pad self-aligning bearings.
- Designed and supplied, delivered to site & installation supervision.
32’Ø x 20’, 11.5 MW SAG MILL
SUPPLIED INTO IVORY COAST
- Ore Type: Gold
- Throughput: 500 t/h
- Final Grind: 115 µm
- The mill was delivered within 28 weeks ex works from order date.
- The shell manufactured in 3 x 120-degree segments.
- NCPI designed, supplied and undertook installation supervision for this project.
TWO 32’Ø x 14’, 6 MW SAG MILLS
SUPPLIED INTO DRC
- Ore Type: Copper
- Throughput: 440 t/h
- Final Grind: 150 µm
- Original components reached end of life and required replacement.
- Design of new structural components allowed for higher charge levels to draw maximum power.
- Shell & heads were manufactured to fit into the existing civil foundation which included the trunnion bearings, gearbox’s, girth gears/pinions.
- Design and supply of new discharge arrangements and complete scats return circuit.
THREE 30’Ø x 15’, 7.4 MW SAG MILLS
SUPPLIED INTO LIBERIA
- Ore Type: Iron
- Throughput: 1042 t/h
- Final Grind: 600 µm
- Liberia experiences a tropical rainforest climate, with a monthly average rainfall peaking at 308mm. The large mill components were refurbished, on site, under these challenging conditions.
- NCPI refurbished the client’s existing mills which were stored under poor conditions for 10+ years,
- NCPI re-engineered these mills to international standards, providing long term support, including spares and supervision for the mill installation.
- NCPI are committed to strict safety protocols, thus earning several safety awards from the end user during the site-based refurbishment and installation contract.
28’Ø’ x 18’, 7 MW SAG MILL
20’Ø x 32’, 7 MW BALL MILL
SUPPLIED INTO EGYPT
- Ore Type: Gold
- Throughput: 625 t/h
- Final Grind: 150 µm
- SAG and ball mill carrying an interchangeable drive train.
- 650 TPH Mill Supply & Installation.
- Supply included for a 7 Axis Liner Handler & Thunderbolt system.
- Temperatures in this area regularly approach 50º. The design of the lubrication and cooling systems were supplied to accommodate these challenging conditions.
26’Ø x 28’, 9MW SAG MILL
SUPPLIED INTO BURKINA FASO
- Ore Type: Gold
- Throughput: 625 t/h
- Final Grind: 75 µm
- NCPI was selected to supply a 26’Ø x 28’, 9MW SAG mill for the Bomboré Gold Project expansion in Burkina Faso, reinforcing our ongoing partnership with the client and our reputation as a trusted provider of grinding mill solutions.
- NCPI successfully managed the global sourcing, engineering, and shipment of over 1,250 tons of equipment, achieving delivery of all critical components within 25 weeks through meticulous planning and experienced project management.
- From initial engineering to final dispatch, the project was executed to meet stringent technical benchmarks, reflecting NCPI’s dedication to delivering robust, high-performance solutions tailored to modern mining demands.
- The SAG mill is set to play a pivotal role in the Bomboré Gold Project’s continued success—demonstrating NCPI’s ongoing commitment to supporting sustainable and productive mining operations worldwide.
Read the full blog here
26’Ø x 11.5’, 4.5 MW SAG MILL
15’Ø x 21’, 4.5 MW BALL MILL
SUPPLIED INTO ZIMBABWE
NCPI engaged with the client to supply a complete 4.5 MW ball mill system for a mining operation in Zimbabwe. The scope of the project involved integrating several existing components provided by the client, which included a SAG mill shell, two ball mill heads, and a single drive motor.
Despite challenging logistical and site conditions, NCPI successfully re-engineered and redesigned all remaining mill components to ensure full compatibility and interchangeability with the client’s existing mill infrastructure across their plant network. This strategy allowed for streamlined maintenance and operational flexibility.
Key design and supply features included:
- Dual-drive configuration: Featuring slow-speed, high-efficiency synchronous motors directly coupled to the pinions, supported by VVVF (Variable Voltage Variable Frequency) drive systems for enhanced control and energy efficiency.
- Support system: Four-pad self-aligning bearing arrangement, designed to handle dynamic loads and thermal expansion while maintaining optimal alignment and extended bearing life.
- Flexibility in design: All newly manufactured mill parts were engineered to match or exceed the performance specifications of the existing equipment, with full interchangeability ensured across the mill group.
- Project delivery: NCPI was responsible for the full design, supply, and delivery of all mill components to site, as well as providing installation supervision to ensure seamless integration and commissioning.
24’Ø x 38’, 12 MW BALL MILL
SUPPLIED INTO GUINEA
- Ore Type: Gold
- Throughput: 832 t/h
- Final Grind: 75 µm
- Trunnion-supported with two self-aligning bearing pads.
- Equipped with a self-disengaging barring coupling to mitigate lock charge risk.
- Comprehensive road survey conducted; the mill was transported over 2,500 km across three countries to reach the installation site.
TWO 24’Ø x 36’, 12 MW BALL MILLS
SUPPLIED INTO KAZAKHSTAN
NCPI successfully delivered two high-capacity 24’ x 36’ ball mills, each rated at 12 MW, for a gold ore processing facility in Kazakhstan. The plant is designed for a throughput of 650 TPH, achieving a final grind size of 71 microns.
This project supply featured one of the world’s few shell-supported mill installations, with each mill shell fabricated and delivered in six 180-degree segments.
Mill Configuration: Shell-supported ball mills designed for heavy-duty gold ore grinding applications, with high power density and robust structural integrity.
Drive System: Refurbishment and integration of the client’s existing dual-pinion drive systems, preserving investment in legacy equipment while ensuring compatibility with new mill design and performance specifications.
Process Performance: Each mill is capable of processing 650 t/h of gold-bearing ore with a target grind of 71 µm, delivering efficient liberation and downstream recovery.
Comprehensive Delivery Scope: NCPI managed the complete lifecycle of the project — from detailed engineering and procurement to delivery, on-site installation, and commissioning. This project showcases NCPI’s ability to execute complex, large-scale mill installations under challenging technical and logistical conditions, while incorporating existing client assets to optimize value and reduce capital expenditure.
24’Ø x 18.5’, 4.7 MW BALL MILL
SUPPLIED INTO AUSTRALIA
- Ore Type: Gold
- Throughput: 270 t/h
- Final Grind: 212 µm
- This mill was specifically designed to incorporate a Variable Voltage Variable Frequency (VVVF) drive system, enabling precise and efficient speed control to optimize grinding performance and energy consumption.
- NCPI’s scope of work encompassed the complete design, engineering, and manufacturing of the mill, followed by logistics management for delivery to site. NCPI also provided installation supervision, ensuring compliance with engineering standards and seamless integration with site infrastructure.
- The project was successfully installed, commissioned, and brought into operation under NCPI’s guidance, meeting all performance and schedule expectations.
22’Ø x 43’, 10 MW BALL MILL
SUPPLIED INTO KAZAKHSTAN
- Ore Type: Gold
- Throughput: 380 t/h
- Final Grind: 75 µm
- NCPI re-engineered and repurposed an existing mill to meet the client’s updated operational requirements. The project was completed and delivered in just 28 weeks, marking one of the fastest turnarounds of its kind. This successful delivery brought the total number of mills supplied to this client by NCPI to 13 units—a testament to the ongoing partnership and trust in NCPI’s capabilities.
- The refurbishment was carried out under harsh winter conditions, with key work completed in sub-zero temperatures and snow.
- This project highlights NCPI’s adaptability, resilience, and proven ability to deliver complex engineering solutions in challenging environments—anywhere in the world.
22’Ø x 18’, 3.5 MW SAG MILL
SUPPLIED INTO KAZAKHSTAN
- Ore Type: Gold
- Throughput: 90 t/h
- Final Grind: 75 µm
- The SAG mill was supplied new within 31 weeks from order placement.
- NCPI supplied mill installation supervision services for the mill installation which was completed during Covid 19 travel restrictions.
- NCPI assisted the commissioning, with integration between the mill VSD, PLC and plant SCADA supplied by the end user.
21’Ø x 35.5’, 7.7 MW BALL MILL
SUPPLIED INTO CÔTE D’IVOIRE
- Ore Type: Gold
- Throughput: 500 t/h
- Final Grind: 106 µm
- The mechanical installation was completed in 18 weeks including full commissioning assistance from NCPI.
- This is the first water-cooled VSD for a milling application installed by WEG in Africa.
- The ball mill weighs over 1,000 tons fully charged, including the rotating assembly, grinding media and ore.
20’Ø x 30’, 6.5 MW BALL MILL
16’Ø x 22’, 2.8 MW BALL MILL
SUPPLIED INTO PERU
- This project marked NCPI’s first entry into the South American market.
- Situated at an altitude of 4,500 metres above sea level, the site presented unique engineering challenges—particularly for the mill drive system. The high-altitude environment required careful adaptation of the drive design to ensure reliable performance under reduced atmospheric pressure and cooling efficiency.
- NCPI was responsible for the complete design, supply, installation supervision, and commissioning of the mill, successfully delivering the project in line with the client’s specifications and environmental requirements.
20’Ø x 27’, 5.2 MW BALL MILL
20’Ø x 30.5’, 5.2 MW BALL MILL
SUPPLIED INTO SOUTH AFRICA
- Ore Type: PGM
- Throughput: 610 t/h
- Final Grind: 125 µm
- NCPI has supplied a total of 4 mills to this specific site to date.
- Critical spares of newly installed NCPI mills are fully interchangeable with existing 20ft mills on site, manufactured by another OEM.
- 450 Ton Crawler crane established on site over 9 days to lift 120-ton mill shells into place, including integral mill heads.
- Designed, supplied and installation completed by NCPI.
20’Ø x 13.5’, 2.3 MW SAG MILL
16.5’Ø x 30’, 3.8 MW BALL MILL
SUPPLIED INTO CUBA
- Ore Type: Lead-Zinc
- Throughput: 136 t/h
- Final Grind: 53 µm
- NCPI delivered a comprehensive primary crushing and material handling solution, including the installation of a Metso C140 jaw crusher, load-out conveyor, stacker conveyor, and load-out station. The scope also included the design and installation of a 160-metre-long, 1050mm-wide mill feed conveyor to ensure efficient material transfer to downstream processing.
- As part of the project, NCPI also supplied a complete scats crushing station with all associated conveyors, enabling effective handling and reprocessing of oversize material.
- In a sustainable and cost-effective approach, the SAG and pebble crushing circuit—originally from the Lisheen Mine in Ireland—was fully refurbished and integrated into the new plant layout, demonstrating NCPI’s ability to deliver customized solutions by repurposing high-value equipment.
18’Ø x 31’, 4.5 MW SAG MILL
SUPPLIED INTO GUINEA
- Ore Type: Gold
- Throughput: 125 t/h
- Final Grind: 75 µm
- The mill was delivered within an accelerated delivery time of 30 weeks due to NCPI having existing designs for the mill.
- NCPI was contracted to provide the logistics for the mill components from manufacturing works worldwide. A charter vessel was contracted for the mill shells and various mill components from South Africa for delivery directly to Guinea.
- The mill manufacture, installation and commissioning was completed in 14 months to meet the first gold date of Q2 2023. The mill commissioning included full integration between the mill VSD, mill control panel and plant SCADA.
18’Ø x 26’, 4.5 MW BALL MILL
SUPPLIED INTO AUSTRALIA
- Ore Type: Gold
- Throughput: 1252 t/h
- Final Grind: 120 µm
- NCPI supplied a mill shell in two 360-degree cans, complete with integral heads for enhanced structural integrity and simplified installation. The mill was delivered with a single-stage gearbox and barring drive, providing robust and reliable operational control.
- Despite global travel restrictions during the peak of the COVID-19 pandemic, the mill was successfully commissioned remotely, showcasing NCPI’s ability to adapt and deliver under unprecedented conditions.
- The project was delivered in just 24 weeks, aligning precisely with the client’s commissioning schedule and ensuring zero delay to the broader project timeline.
18’Ø x 25.5’, 4.5 MW BALL MILL
SUPPLIED INTO SOUTH AFRICA
- Ore Type: Platinum
- Throughput: 87.5 t/h
- Final Grind: 75 µm
- NCPI designed and supplied a fully Variable Speed Drive (VSD) controlled mill, eliminating the need for inching during start-up and allowing for smooth, controlled operation across a range of speeds.
- The mill features a 2-pad, self-aligning bearing system engineered by NCPI to ensure optimal load distribution and extended bearing life. Additionally, a fully motorised feed chute with cross-travel capability was included, enabling precise positioning and improved maintenance access.
- As part of the delivery, NCPI provided a comprehensive capital and commissioning spares package, which included:
- Girth gear and pinion
- Trunnion bearings
- Main drive gearbox and bearings
- Barring gearbox
- Load cells
- Instrumentation and commissioning spares
- This complete supply solution underscores NCPI’s commitment to long-term equipment performance, reliability, and client support.
17’Ø x 25’, 3.2 MW BALL MILL
SUPPLIED INTO BURKINA FASO
- Ore Type: Gold
- Throughput: 651 t/h
- Final Grind: 125 µm
- NCPI supplied the mill complete with a Variable Voltage Variable Frequency (VVVF) Variable Speed Drive for the main drive motor, enabling precise speed control and enhanced operational efficiency.
- The mill was equipped with an NCPI-designed, 2-pad self-aligning bearing system, engineered to ensure optimal load distribution and reliable long-term performance.
- NCPI was responsible for the full scope of work, including design, manufacturing, delivery to site, installation supervision, and successful project completion.
17.5’Ø x 23’, 2.3 MW BALL MILL
SUPPLIED INTO LIBERIA
- Ore Type: Gold
- Throughput: 146 t/h
- Final Grind: 75 µm
- NCPI played a critical role in supporting the development of Liberia’s first modern gold mine, operating in a region with limited infrastructure.
- NCPI was contracted to provide the design, supply, logistical coordination, and delivery of mill components sourced from multiple manufacturing sites worldwide. All components were consolidated in South Africa before being transported to the project site in Liberia.
- Despite the significant challenges posed by the Ebola outbreak in 2013–2014, NCPI successfully completed the mill installation and commissioning on schedule, demonstrating resilience and commitment to project timelines under adverse conditions.
16’Ø x 32’, 3.4 MW BALL MILL
SUPPLIED INTO NAMIBIA
- NCPI undertook this interesting project and successfully executed the replacement drop – in of a complete shell assembly with heads. This change out was completed within 8 days.
- The mill shell & head assembly were placed onto 500ton rotators prior to the change out and all steel liners were pre- installed.
- The final weight of the assembled mill was 230T. A 750T crane was used to lift this beauty into place.
16.5’Ø HEAD AND TRUNNION SUPPLIED INTO ALASKA
- The original integral heads reached end-of-life due to critical lubrication failure. NCPI engineered a solution by splitting the heads into 180-degree segments and supplying a separate trunnion to facilitate installation.
- The old trunnion was carefully cut out and removed on site. Detailed designs were developed based on precise, on-site measurements to ensure a perfect fit.
- The project was delivered 20 weeks ex works and completed 4 weeks ahead of schedule, demonstrating NCPI’s commitment to timely and high-quality execution.
