Delivery Excellence

Processing Iron Ore

Bateman Engineering N.V.

Delivering Innovative Solutions to Unlock the Value of Natural Resources

Delivery Excellence

Bateman Engineering
With its more than ninety year heritage as a leading engineering-project house and equipment supplier, Bateman Engineering N.V. serves a range of industries worldwide. Our focus is on delivering innovative solutions to unlock the value of natural resources, through converting them into marketable products. Client access and project management services are provided globally through Batemans network of permanent international offices located in Australia, China, India, Russia, North and South America, Southern Africa, the United Kingdom, and the Netherlands. Services offered include, but are not limited to, process engineering, specialist niche technologies, equipment supply and related services, procurement, project finance facilitation, contracting and project management. Bateman is committed to Delivering Excellence in everything that it does. For more information on Bateman, visit www.bateman.com.

Iron Ore Processing

Bateman provides the full range of capabilities to I Convert run-of-mine (ROM) ore to saleable products. I Integrate engineering and process know-how in development and optimisation of plant designs for iron ore. I Conduct in-house laboratory tests for scoping work. I Deliver processing facilities that meet global environmental standards.
Sishen Expansion Project Phase V, South Africa. The primary crusher is one of the biggest built in recent years.

Batemans state-of-the-art expertise and technologies cover I Process modelling incorporating all aspects of the iron ore processing plant. I Materials handling solutions for conveying, apron feeders, stockyard systems, stacking, reclaiming and load out stations. I Comminution including cone, gyratory and jaw crushers and ball, rod and autogenous grinding mills. I Scalping and screening grizzlies, vibrating screens and scrubbers. I Beneficiation including jigs, dense media separation (DMS), gravity separation, wet and dry magnetic separation, TBS separators and flotation. I Thickening and filtering. I Environmental control air cleaning and waste disposal covering coarse waste and slimes.

Rail load-out station and feed conveyor, Assmangs Khumani mine, South Africa.

Materials handling system, Joda Mines, India.

Bateman Engineering N.V.

Project Services
I Consulting Ore-body, production and market evaluation assesses project viability. I Concept to feasibility, including pilot-plant and test-rig studies to assist in bankable documents. I In-house laboratory for cost-effective and prompt scoping work, as a basis for structuring project definitions. I Project management All phases of the project, from inception through design and construction to commissioning, maximising the success and profitability of the venture. I Comprehensive spares and after-sales back-up Maintenance and refurbishment ensures peak productivity.

Facilitation of Project Finance

Bateman structures, negotiates and secures optimal and cost-effective financial packages for projects of all sizes.
EPCM expansion project for Kumba Resources upgraded Sishen Iron Ores ROM capacity by 24 million t/yr, South Africa.

Flexible Contract Structuring

I Turnkey, reimbursable, EPCM, lump-sum, fixed fee or any combination to suit client needs. I Joint ventures on projects. I Build, own, operate (BOO) and transfer (BOOT) arrangements.

Iron Ore Track Record

Batemans recent iron ore work includes a feasibility study for the mammoth Zogota iron ore deposit in Guinea and the Sishen Expansion Project in South Africa. Bateman is a world leader in jigging.

Processing Technologies
For beneficiation of iron ore, Bateman liaises with suppliers and evaluates equipment to make unbiased selections of the best equipment for the job. For stockpiling, materials handling, environmental protection and waste disposal, Bateman draws upon its comprehensive in-house and licensed range of engineered technologies and selects the most appropriate equipment from all suppliers. I Feed Preparation Plants Run-of-Mine (ROM) ore is prepared for processing by removing unwanted material, eg vegetation, crushed and milled and is classified according to size in circuits comprising washing units, trommel screens, cyclones, crushers, mills, etc. Surge bins can be used to control the feed rate. I Product Recovery Plants Valuable components of the ore feed are separated with a range of screening and separating techniques utilising the different shape, density, magnetic and surface properties of the constituent minerals.
10 m diameter Ultrasep at AVG Minerao SA, Brazil.

Jayaalaxmi Minerals crushing plant under construction, India.

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Delivery Excellence

Bulk Materials Handling

With a thorough understanding of criteria affecting flow, Bateman selects systems which will not be plagued by blockages.

Conveyor systems
I I I I Overland and curved conveyors move up to 6,000 t/h over many kilometres. Pipe conveyors protect the product and the environment from mutual contamination. Hydraulic conveying systems (dilute, medium, dense and boosted dense phase). En-masse (Redler) conveyors and bucket elevators convey materials gently in dust-tight casings. I Aumund pan conveyors convey hot, abrasive materials at over 1,000 C. I Slurry (pipe) conveyor systems.

Overland conveyor at Redcliff, Zisco. This is one of the longest of its kind in the world.

Stockyard systems
I Stacking, homogenising, blending and reclaiming systems to handle feed materials and outloading of the product.

Comminution
Bateman designs efficient comminution systems that take into account the requirements of downstream metallurgical processes.
500 t/h Bateman / Schade single harrow bridge reclaimer at Redcliff, Zisco, Zimbabwe.

Crushing
All forms of crushing systems including in-pit, primary, secondary, tertiary and quaternary crushing systems.

Grinding Circuits
Bateman has the services of a world authority in semi-autogenous grinding (SAG) circuits and is experienced in the design and construction of large autogenous grinding (AG) and SAG circuits. Bateman also has many rod- and ball-milling references.

Southern Middleback Ranges crushing plant, South Australia.

Fine Grinding
Tower mills and ISA mills for flotation-concentrate grinding.

Scalping and Screening

Bateman offers considerable project experience on primary, secondary and tertiary classification processes, consisting of I Screens, cyclones, spirals and shaking tables. I Wet-gravity circuits and water-handling systems. I Dry-mill circuits with feeders, mills and sand traps. I Feed hoppers, surge bins, conveyors, elevators and transfer points.

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Beneficiation
Jigging
Bateman-Apic Jigs offer a cost-effective solution to separating valuable products from waste material, processing and upgrading iron ores to effectively produce clean, saleable products. I Permanent-fixture processing facilities and modular process plants. I Pilot-scale units for process development testing. I J-tube for laboratory-scale testing. Bateman-Apic Jigs incorporate unique features for processing lumpy and fine iron ores.
M9 Apic jig

I Proprietary JigScan control technology enables a consistent pulse shape regardless of feed variations, reducing operator attention and improving control over product quality. I Specially developed fines gate minimises back mixing of fines before discharge. I Adjustable weir gap and weir bar at slot gate improves process performance of gate. I Product extraction system utilises vibrating screen system for increased control over product discharge to increase product recovery.

Dense-Media Separation (DMS)

Widely used and proven in the diamond and coal industries, Batemans DMS plants are also highly effective for iron ore processing. Bateman DMS Plants are available as I Permanent-fixture processing facilities and modular process plants. I Pilot-scale units for process development testing.
Bateman-Apic Jig processing fine iron ores from the Waterberg, South Africa.

Gravity Separation
Gravity separation using a variety of settlers, tables and spiral concentrators.

Jayaalaxmi Minerals jigging plant, India.

Bateman Engineering N.V.

Delivery Excellence

Beneficiation
Magnetic Separation
Bateman applies magnetic separation technologies to minerals with weak and strong magnetic properties, separating those with paramagnetic and diamagnetic characteristics. The range covers I Wet and dry, low-intensity magnetic separation (LIMS). I Wet, high-intensity magnetic separation (WHIMS). I Roll magnetic separators to process weakly magnetic materials. I Induction-roll magnetic separation (IRMS) for cleaning and concentrating dry materials.

3D CAD rendering of Karara FEED project, Australia.

Spirals
Spiral plants can be utilised on their own or in conjunction with TBS Separators for costefficient beneficiation of finer fractions.

TBS Separators
Teetered Bed Separation (TBS) is used to separate fine mineral particles, by size and by specific density.

Flotation
Bateman supplies flotation systems which optimise the process through close control of the solids in suspension, air rates, froth position, etc. I Flash Flotation In circuits employing multiple stages of milling, flash flotation cells recover liberated mineral species after each stage, in order to prevent overgrinding. I Conventional Flotation Design of banks of conventional flotation cells and supply of proprietary cells, in addition to design and installation services.
Spiral columns.

I Tank Cells Bateman has completed several large tank cell installations in recent years. I Column Cells Column and Jameson cells, including pumping of high air content froths associated with fine grinding of concentrates. I Reagent Plants Packaged reagent plants, either as stand-alone or as part of concentrator plants.

BQR Flotation Cells.

Bateman Engineering N.V.

Scrubbing and Thickening

Bateman designs and supplies unit processes to dewater concentrate and tailings streams, before transfer to the next process.

Thickeners
Conventional, high-rate, ultra-high rate and paste thickeners to dewater both concentrate and tailings streams.

Vacuum Filters
Drum, disc and belt filters.

Filter Presses
Recessed chamber and membrane presses to generate concentrate cake for sale and dry tailings.

Continuous Pressure Filters

Horizontal plate pressure filters for both concentrators and refineries.

Pilot plant test facility for thickening system design, Assmang Khumani Iron Ore-BKM project, South Africa.

Screening
Bateman has been involved for over 50 years in sizing and selection of screens for all types of applications in the minerals-processing industry.

Environmental Protection
Bateman designs systems to prevent pollution of the environment.

Air Cleaning
I Bateman Reverse Pulse Bagfilters collect dust at high filter rates with efficiencies of about 99.99 %. I Bateman Wet Scrubbers. I Bateman Electrostatic Precipitators for complex applications to collect suspended solids.

Waste Disposal
I Slimes thickening and clarifying systems to remove particulate solids from effluent streams and clarify and chemically treat water for recirculation to the plant. This reduces overall water consumption and minimises environmental pollution. I Coarse tailings handling systems incorporating decades of design experience on environmentally-friendly installations worldwide.
Reverse pulse bagfilter, Ziscos Redclif complex, Zimbabwe.

Product Quality Assurance

Bateman designs state-of-the-art quality assurance systems to ensure optimal utilisation of orebodies. I Laboratory work. I Sampling systems. I In-line process control systems.
Bateman Roller Supported Scrubber.

Bateman Engineering N.V.

Delivery Excellence

Bateman Test Rig

The Bateman Test Rig offers a facility to test three-stage separation processes and two-stage desliming processes. Complete circuits can be tested as its generic framework permits insertion of all types of minerals separation equipment, eg spirals and gravity separators, upstream classifiers, magnetic separators and wet-separation equipment. I I I I I An open-circuit system rated at 6 t/h, depending on the feed grade. 10 m3 water supply tank to ensure continuous supply of water. 380 V high-tension power supply. Concrete slab to protect surrounding environment. Control equipment housed in a standard container, so the whole rig can be taken easily to site where bulk samples of the material can be tested.

Bateman Pilot Plants

Batemans Pilot Plants are used in feasibility studies to provide a comprehensive assessment of the project flow sheet and develop accurate and reliable capital and operating costs. They are integral for estimating the potential profitability of a project. The pilot plants handle a wide range of supply feeds from 1 t/h to 200 t/h.
Bateman Test Rig.

Sishen Expansion V for Kumba Resources, South Africa. The new jigging plant and thickeners are in the centre back of the photograph, with the ROM reclaimer to the left.

Delivery Excellence
+27 11 899 9111 enquiries@bateman.com
More information is available at www.Bateman.com

Edition 11 Bateman Engineering N.V.