Cullinan's second BATEMAN Mega twin-stream 200 t/h DMS module being constructed at the factory.

The DMS modules fitted into the space between existing buildings at the Cullinan Mine. The second module is in the foreground.

The second module being erected on site. The two cut-back feed conveyors to this module can be seen in the top left-hand corner of the picture.

A night scene taken from the top of the Bateman-Japan Pipe Conveyor that takes the diamond concentrate to the recovery plant.

The first module, feeding concentrate into the pipe conveyor, is in the centre of the picture, with the second still being installed, positioned behind it.

Cullinan cones plant replaced by DMS circuit

Bateman Engineering has replaced the old cones plant at De Beers' Cullinan Mine near Tswane (formerly Pretoria) with dense-media separation (DMS) circuits to recover diamonds from kimberlite feed. Two new BATEMAN Mega twin-stream DMS modules, each with a capacity of 200 t/h, were supplied to the mine.

Besides the fact that the cones plant was in need of replacement, the installation of a new DMS circuit was motivated by the fact that this newer technology would recover diamonds more efficiently and reduce running costs significantly, primarily as the team required to operate the new plant would be far smaller.

A major constraint of the project was the need to install the new DMS circuits in a space between the existing buildings at the plant, occupied by the four feed conveyors to the cones plant. As the removal of these conveyors would affect the mine production, the project was planned to minimise disruption and be accomplished in the shortest time possible.

The modules were completely built and tested at the manufacturer's yard before delivery to site, with special care being required as the fit was extremely tight with little scope for adjustments once the modules had been delivered.

The project commenced in April 2005, to be carried out in two phases. While the first DMS module was being manufactured, the on-site task was primarily to cut back two of the four feed conveyors to the cones plant so space could be made for the module. The feed conveyors were modified and a pipe conveyor installed to take the concentrate to the final-recovery facility. The module was also linked to the existing tailings system. The first module was in full production in the first quarter of 2006.

During the second phase, the two remaining feed conveyors to the cones plant were cut back, effectively shutting down this plant. Phase one was effectively repeated to install the second DMS module, with the exception that the pipe conveyor already installed also handled the concentrate from this module. The whole upgrade was completed in the second quarter of 2006.

Details of the project may be obtained from Robert Abate, General Manager, Modular Plants

on +27-11-899-2238 or email modular@BatemanEngineering.com or Scott Brebnor, Project Manager on +27-11-899-4960 or email modular@BatemanEngineering.com.

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