Professional Documents
Culture Documents
TAILINGS
Flash Conventional Tank cells Column cells
SMELTING
CONVERTING
LEACH
ACID PLANTS
IMPURITY REMOVAL
Iron removal Precipitation Cementation
EFFLUENT TREATMENT
ENVIRONMENTAL MANAGEMENT
Bag-houses Scrubbers Electrostatic precipitators
I I I I
Dust- & air-pollution control Toxic emission control Closed-circuit processing Solid waste handling
GAS CLEANING
Cellhouses
Large, fully automated
COPPER ELECTROWINNING
PURIFICATION SX & IX
Pulsed columns Reverse ow mixer-settlers
NICKEL ELECTROWINNING
Alternatively: H2 Reduction
Alternatively: Cobalt Salt Production Undivided cells Divided cells (anode bags) Vacuum degassing CI2 Aqua Regia Other
COBALT ELECTROWINNING
LEACH
PRETREATMENT
Materials Handling
Bateman Engineering has the capability to design and supply materials handling systems to transport PGM-bearing ores and tailings.
J All types of conveyor systems to move ore and tailings to, from and within the processing plant. J Stockpile systems for the efcient, effective and economic stacking, blending and reclaiming of ore and the safe disposal of tailings. J Plants to process tailings and extract coarse material for use as backll.
Comminution
Bateman Engineering designs comminution circuits that take into account the specic requirements of downstream metallurgical processes.
Crushing
We have designed and constructed all forms of crushing systems including inpit, primary, secondary, tertiary and quaternary crushing systems.
Grinding Circuits
Our experience includes the design of large autogenous grinding (AG) and semi-autogenous grinding (SAG) circuits. We have installed a 26 ft (7.0 m) SAG mill at Hartley and have many rod and ball milling references, including Modikwa Platinum and Blue Ridge Platinum projects.
Preconcentration
Physical separation processes can often be used prior to otation to upgrade the otation feed by making use of differences in the physical properties of ore and gangue minerals.
Fine Grinding
We have utilised tower mills, stirred mills and ISA mills for flotation concentrate grinding and are experienced in the operational and maintenance requirements of equipment essential for the development of efficient plant designs.
Gravity Separation
Our experience includes the use of spirals to recover chromite concentrate from PGM flotation feed and the application of jigs to recover metal from slag. We have also investigated the use of centrifugal separators to recover precious metals from milling circuits.
Magnetic Separation
Bateman Engineering has been involved in a number of studies and projects incorporating the use of magnetic separation in the processing of mineral sands, as well as to concentrate PGM from slow-cooled converter matte into a magnetic fraction.
Conveyor transporting the ore from the underground mine to feed the mills, Blue Ridge platinum mine, South Africa.
Flotation
During otation, surface chemistry is applied to selectively recover valuable minerals or gangue materials.
Flash Flotation
In circuits employing multiple stages of milling, flash flotation cells are used to recover liberated mineral species after each stage to prevent overgrinding.
Conventional Flotation
Bateman Engineering has many references of plants using banks of conventional flotation cells and supplies proprietary cells in addition to providing design and installation services.
Flotation cells, Bafokeng Rasimone, RSA.
Tank Cells
Bateman Engineering has completed several large tank cell installations in recent years.
Column Cells
Our experience in the design of flotation circuits includes column and Jameson cells. This includes the pumping of high air content froths associated with fine grinding of concentrates.
Reagent Plants
Bateman Engineering has designed and installed numerous packaged reagent plants, e.g. Impala UG2 plant, Lonmin, Anglo Platinum and Aquarius, either as standalone or as part of concentrator plants.
Bafokeng Rasimone Platinums Ultrasep thickener, South Africa.
Dewatering
Bateman Engineering designs and supplies the unit processes to dewater the otation concentrate and tailings streams, before being transferred to the next process.
Thickeners
Bateman Engineering has wide experience of the use of conventional, high rate, ultra-high rate and paste thickeners to dewater both concentrate and tailings streams.
Vacuum Filters
Our experience extends to drum, disc and belt filters on a wide range of projects.
Filter Presses
Recessed chamber and membrane presses have been used successfully to generate concentrate cake for sale and occasionally even dry tailings for dumping in arid locations. They are also used widely in base- and precious-metal refineries.
Concentrate thickening at Modikwa, South Africa.
The first full scale Bateman PneumoDrier to be used in the platinum industry.
Pyrometallurgy
Pyrometallurgical plants still process a high percentage of all non-ferrous-metal otation concentrates, despite the advent of new hydrometallurgical treatment routes. Bateman Engineering has a number of references in pyrometallurgical plants for PGM operations where nickel is often a by-product.
Smelting
Bateman Engineering has a number of electric-arc furnaceplant references. We have also been exposed to other technologies such as flash smelting, Noranda and Teniente processes, and top, submerged-lance furnaces.
Converter aisle at the Hartley smelter, Zimbabwe.
Converting
As well as Peirce-Smith installations, Bateman Engineering has worked on top-blown rotary converter installations and has been involved in several Ausmelt converting studies.
Peripherals
Bateman Engineering offers proprietary engineered systems: J belt, chain and pneumatic conveyors for furnace feed, sluices, etc J metal, matte and slag tapping and granulation, J off-gas scrubbing, J bag houses, and J electrostatic precipitators. We also have experience on acid plants and drying installations and have an exclusive agreement for Sub-Saharan Africa with Noram Engineering and Constructors, Canada.
Leaching
Hydrometallurgical processes are gradually becoming more favoured than smelting processes for the treatment of PGM ore, concentrate and mattes. Bateman Engineering has wide experience of leaching processes and designs to process ore, concentrate and smelter mattes.
Tank Leaching
We have experience of both acid and alkali leach processes carried out in trains of agitated tanks. In this type of plant, selection of materials is critical.
The largest-to-date Bateman-Elex electrostatic precipitator, Impala Platinum, South Africa.
Medium-Pressure Leaching
Bateman Engineering has a strong process group experienced in autoclave design. This experience has been used to process high-grade sulphide ore, concentrates and converter mattes.
High-Pressure Leaching
Construction of a tank farm at Impala Platinum Limiteds enhanced precious metals renery, South Africa.
Bateman Engineering has been involved in the design of leach processes which utilise titanium-clad autoclaves designed to operate at 240 C and 47 bar.
Emerging Technologies
We have worked on many projects employing heap leaching, including bacterial heap-leach processes. Several bacterial tank-leach plants have been designed and constructed and we also have experience of project investigations using various novel, proprietary, leach processes, such as the Galvanox atmospheric leaching process which could potentially be applied to PGM processing.
Neutralisation
Between leaching and the downstream purification processes, it is often necessary to neutralise the slurry or solution leaving the leach process. This process is often coupled with iron removal and we have extensive experience of such processes using a variety of reagents.
Purication
PGMs can be selectively separated by ion exchange (IX) technologies. Bateman Engineering has wide experience of impurities removal by purication or cementation and classical precipitation techniques.
Other Processes
Bateman Engineering has used solvent extraction, ion exchange and molecular recognition technology (MRT) to remove minor impurities from solution streams before routing the solution to electrowinning circuits. We also have experience at designing organic-removal circuits using various physical separation processes.
Metals Recovery
Trace amounts of metal contaminants may be extracted from large volumes of solution flowing at many bed-volumes per minute, often in a form and concentration worth processing further. I Copper recovery from in-situ mine-leach solutions and refinery bleed streams. I Production of cathode-quality copper from acid minedrainage streams at high flow-rates. I Iron, aluminium, zinc, copper and manganese recovery from acid mine-drainage and waste streams.
Stainless steel and fibreglass vessels in the base metal refinery (BMR), Hartley Platinum Project, Zimbabwe.
Solvent Extraction
BATEMAN has a wealth of solvent-extraction (SX) experience with SX plants in Australia, Africa and the Americas.
Electrowinning
Bateman Engineering designs tankhouses of all sizes, from small heap-leach operations to large scale, automated systems for electrowinning (EW) and electrorening (ER).
Electrolytic Cell
Bateman Engineerings redesigned cells provide an improved catholyte distribution flow pattern around each cathode resulting in improved cathode quality. The design can also accommodate anode bags and / or a close-capture aerosol / gas emission system, providing a safe working environment.
Typical Cobalt EW circuit.
Tankhouse Layout
Our designs provide low-cost operating facilities for both manualand automated-strip plants. Attention to detail in materials handling allows operators to focus on good operational practices that lead to efficient metal production.
PGM Rening
PGMs are found in nature intimately bound with nickel, copper and iron sulphide minerals. It is necessary rst to separate the PGMs from the base metals and then to process the individual PGMs (Pt, Pd, Rh, Ir, Ru, Os) as well as gold.
Base-Metal Refining
Our involvement in PGM refining includes the three largest, primary-platinum refineries in the world, as well as several smaller plants. We have successfully applied leaching, SX, IX, MRT, distillation and precipitation techniques to separate the individual PGMs as well as to remove residual impurities.
The MRT technique, similar in some respects to IX, is widely applicable to PGM refining. Strong-base resin technology for the removal of Fe from Cu electrolyte can also be provided.
Process Modelling
Heat and mass balances that closely simulate plant operation form the basis of successful plant development and operation. Bateman Engineering utilises various simulation programs to perform front-end modelling of chemical and physical processes.
Finite element analysis of a DC furnace lining predicting the thermal gradients and wear pattern.
Dynamic Simulation
SysCAD, the Windows-based package, is used for the dynamic simulation of processes, Metsim models transient-operating conditions, providing upset analysis, surge verification and downstream de-bottlenecking, and Aspen simulates complex chemical processes. When interfaced with actual control hardware, dynamic simulation becomes a time-saving control system for de-bugging and an excellent training tool.
3D CAD model of a CFM furnace roof. 3D CAD rendering of 60 MW twin electrode furnace.
Impala Platinum Reagent Plant Upgrade, RSA Lonmin Upgrade, RSA RKI Consortium PGM Concentrator, RSA Impala BMR, RSA Anglo Platinum PMR Expansion, RSA Impala Minpro Reagent Facility, RSA UG2 Concentrator Expansion, RSA Crocodile River Platinum Concentrator, RSA Western Platinum Renery, RSA Modikwa UG2 Concentrator, RSA Waterval Concentrator Cleaner Circuit, RSA EPMR Phase 2 - Platinum Circuit, RSA Rasimone Concentrator, RSA Potgietersrust Concentrator Expansion, RSA
Impala Platinum Lonmin Aquarius Platinum (Africa) Impala Platinum Anglo Platinum Impala Platinum Impala Platinum Barplats Lonrho Anglo Platinum
2007 2007 2004 2004 2004 2003 2001 2001 2001 1999 & 2001 2000 2000 1999 1998 1997 1997 1996 1996 1994 1994 1991 1989 & 1991 1989
Anglo Platinum Impala Anglo Platinum Anglo American Platinum Impala Platinum Metals Renery Upgrade, Impala Platinum RSA Limited Reneries Hartley Platinum Project, Zimbabwe BHP Minerals & Delta Gold Impala Reneries BMR Small Projects, RSA Impala Stillwater, USA SMC Impala Mineral Processes Smelter, RSA Impala Western Platinum Base Metal Renery, RSA Lonrho Barplats PMR Project, Brakpan, RSA Lefkochrysos Platinum Complex, RSA Phases 1 & 2 SAREF PGM Renery, RSA Rand Mines Lefko (Rand Mines) Anglo Platinum
Concentrate thickener in front of the reagentpreparation and handling plant serves the flotation circuit, Bafokeng Rasimone, South Africa.
Flotation tank circuit at Aquarius Platinums Kroondal chromite-tailings retreatment plant, South Africa.
Hartley Platinum Project: an integrated minerals processing, pyrometallurgical and hydrometallurgical complex, Zimbabwe.
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Global presence
Bateman Engineering N.V. is a technology-driven process engineering and project management house focusing on providing the services and technology required to establish process plants for converting natural resources into marketable products.
Our position as a technology provider and leading project house in our sector is underpinned by our capability to offer differentiated, project-specific process technology solutions: global, well-proven expertise that covers all commodities. Bateman Engineering has a focused niche in developing regions with evolving economies where clients are faced with technical, financial, commercial, political, logistical and cultural difficulties in bringing their ventures to reality. Our track record of more than 3,000 successful projects in many industries covers nearly 70 countries. Bateman Engineering has a global infrastructure serving its markets in Africa, the Americas, Australia, Asia and Europe. Bateman Engineering is an ISO 9001-2000 certified company.
CAD rendering of the reagent plant at Impala Platinums concentrato, South Africa.
Comprehensive services for browneld upgrades and complete, new, process plants include:
J J J J J J J J J Pre- and feasibility studies Testwork design and management Due-diligence studies Control-budget estimates Process developments and audits Facilitation of nance Design and detail engineering Project and contract management Large and small EPCM and LSTK projects
Bateman Engineering provides the technologies and equipment required, either from its in-house and licensed range or by selecting the most appropriate products from other suppliers.
OUR CORE VALUES: ACCOUNTABILITY, CUSTOMER FOCUS, COACHING AND MENTORING, CONTINUOUS IMPROVEMENT AND TEAMWORK
Email: enquiries@Bateman.com Web: www.Bateman.com Or consult our website for contact details of your nearest Bateman Engineering ofce
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