Barbara Mulcahy - Lead Process Engineer

B.Eng. Chemical (Minerals Processing), University of Stellenbosch, South Africa, 1994
Post Graduate Diploma in Engineering (Extractive Metallurgy), University of Stellenbosch, South Africa, 1996
Management Development Programme, University of Stellenbosch Business School, South Africa, 1995
Professional Affiliations
Professional Engineer, ECSA, Reg No 20010377
Member : South African Institute Mining & Metallurgy Reg No 700867
Member : Mine Metallurgical Managers’ Association Reg No SUB-01311
Summary of Experience  
17 Years experience in the consulting, projects and research sectors, predominantly in minerals processing and some
hydrometallurgical projects. Consulting projects include client representation for scoping, pre-feasibility and bankable
feasibility studies; process design and project development; alignment with project engineering companies and discipline
engineers; 3rd party reviews and investor reviews of projects/processes and test work program management and data
interpretation. Commodities include base metals, gold, uranium, heavy mineral sands, platinum group metals and coal
Projects Process Engineer for various minerals processing projects ranging from scoping studies, test work reviews,
feasibility studies, control budget estimates, detailed engineering and execution metallurgical projects. Projects
included mainly platinum process plants, mineral sands mining and beneficiation plants, base metals and gold plants.
Research metallurgical projects include scouting test work, laboratory and pilot plant test work, plant audits and
optimization studies. Co-ordinated and operated pilot plants for mineral sands upgrading and separation, flotation
plants and gravity separation plants.
Relevant Experience  
Metallicon Process Consulting. Lead Process Engineer (2006-present)
• Greenfields platinum concentrator – owner’s team for development of a new concentrator feasibility study in
South Africa.
• Various commodities – general process consulting for test work, process design development.
• Graphite project – Test work management and process design for scoping study for a greenfields graphite
scoping study project in Mozambique.
• Greenfields Uranium project owner’s team – process manager for owner’s team for development of a
uranium processing plant in Namibia.
• Various projects – base metal concentrators pre-feasibility studies.
• Iron Ore due diligence and investor review.
• Greenfields Copper project owner’s team – options study, order of magnitude estimate, pre-feasibility study,
bankable feasibility studies, engineering company tender management, test work review, trade off studies;
co-ordination with engineering companies for project development and process engineering.
• Scoping study for greenfields coal project.
• Third party and Investor reviews – copper concentrator and base metals refinery.
• Metallurgical project assistance for development of P&ID’s for copper/nickel refinery.
• Heavy minerals sands project – bankable feasibility review; test work co-ordination and flowsheet
development, project process engineer for feasibility study.
• Uranium plant – options study for gold slimes dam retreatment for uranium extraction and gold recovery.
• Platinum group metals - various studies for concentrators; upgrading for increased throughput; 3rd party
reviews; client representation for test work management and bankable feasibility studies; co-ordination with
engineering companies for project development and process engineering.
• Chrome tailings retreatment for platinum group metals recovery.
Hatch, Johannesburg, South Africa. Senior Process Engineer (2001-2006)
• Lead Process Engineer for greenfields heavy minerals sands project – definitive estimate and detailed
engineering design; flowsheet development; liaison with discipline engineers.
• Senior Process Engineer for gold projects – supervising testwork and feasibility study for flotation and
bioleaching of refractory gold ore; study for gravity concentration for hard sulphide ore.
• Process Engineer for copper and magnetite concentrator – supervising testwork for upstream classifier and
control budget estimate (CBE) project.
• Process Engineer for a number of platinum projects – includes amongst others: CBE and detailed
engineering for Reagent Plant, CBE’s for Mobile platinum concentrator and various concentrator upgrades,
detailed engineering, execution and commissioning of a Tailings Retreatment Plant followed by a later
upgrade thereof, CBE for various slag milling and flotation plants, UG2 plant optimization studies,
decommissioned UG2 plant restart study.

Konkola Copper Mines, Anglo Technical Division, South Africa. Process Engineer (2000-2001)
• Process Engineer at Head Office for the refurbishment programme of the copper operations in Zambia. This
included concentrators and tailings leach plant and the metallurgical and analytical laboratory.

Hatch, Johannesburg, South Africa. Process Engineer. (1998-2000)
• Process Engineer for numerous projects in the metallurgical industry, namely CBE and detailed engineering
for upgrading of a gold Reclamation Plant, detailed engineering for a Merensky Plant, CBE and feasibility
studies for Copper Secondary Milling plant and flotation plant upgrade as well as magnetite recovery, plant
audits for UG2 plant.

Mintek, Randburg, South Africa. Senior Engineer. (1997-1997)
• Research process engineer for various industrial minerals’ projects, including Gypsum flowsheet
developments; heavy mineral sands pilot plant – gravity and mineral separation for flowsheet development
and production of marketing samples; beachsands (calcium carbonate for cement) pilot plant; fluorspar
flowsheet developments and plant audits; andalusite testwork. Laboratory testwork for diamond and gold
beneficiation projects. Laboratory and Pilot plant testwork for chrome recovery from MG6 ores as well as
old chromite dumps. Various other physical separation projects.

Professional Development  
JKSimMet - Minerals Processing Simulation, JKTech visit to South Africa
SPIN selling course - Mintek
Project Management - Mintek
Consultant Powerhouse - Hatch
Dale Carnegie - Hatch
English, Afrikaans  
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