Bateman Engineering technologies for minerals and metals processing

The Bateman Engineering brand name as a leading project house in the natural-resources industry is synonymous with the application of superior processing technology.

This reputation has been achieved over many years during which Bateman Engineering has made strenuous and ongoing efforts to improve its technology base in support of innovative project implementation.

As a result Bateman Engineering offers solutions that resolve specific industry problems based on years of experience in the co-development of process-flow sheets that represent the best possible match with the available financial resources and limit technical and commercial risk. The close association with clients ensures that such developments focus very tightly on real industry requirements to identify technologies with excellent potential for success.

Bateman Engineering technology which has served clients well over the years includes gravity-separation techniques, such as dense-media separation (DMS) and under-bed air pulsation, usually supplied in pre-tested modular plants, for processing diamonds, coal, metallic slag, chromite, platinum-group metals (PGMs) and a variety of other minerals. Density tracers are supplied to optimise DMS processes.
Other niche technologies include the processing of solids and liquids by means of flotation, thickening, clarification and mixing; PGM refining; rebuilds of AC furnaces; solvent extraction (SX) using pulsed columns; overland conveying and drying during pneumatic conveying.
This accumulated process know-how is driven by Bateman Engineering’s process engineers, well supported by a vast database of engineering-design and case-history documentation, methodologies and standard systems. Some of the many project profiles and impressive list of papers prepared by Bateman Engineering personnel may be seen on the website http://www.BatemanEngineering.com.
Innovations for processes, flow sheets and plant modifications are continually developed, not only in-house, but also through joint ventures and alliances with technology providers, vendors, consultants, research institutes, clients and sometimes even with competitors.

Accordingly, a small percentage of Bateman Engineering’s annual turnover is related to the funding of technology development through cooperative agreements with third parties as well as test work and feasibility studies. Cooperation with government development agencies provides further financial support and Bateman Engineering’s international network of contacts enhances the credibility and marketability of these developments. Bateman Engineering also occasionally takes an equity position in technologically-based companies to obtain exclusive rights to the technical development of new processes.

Hydrometallurgical processing includes several novel applications. Bateman Engineering and Mintek jointly market a novel resin-in-pulp (RIP) approach for the metallurgical sector, called the MeTRIX (MeTal Recovery through Ion eXchange) process.

A unique two-step process, developed and implemented on behalf of Lane Xang Minerals at the Sepon Copper project in Laos, leaches 90% of the copper from chalcocite and chalcopyrite. Other novel leach processes are being investigated with copper-leach technology developers.

For example, Bateman Engineering has the exclusive rights from the University of British Columbia (UBC) to market, in about 20 countries, its novel Galvanox technology, which offers several potential advantages over existing copper-leach processes. Thus, atmospheric leaching of primary copper concentrates enables copper recoveries of 98% or greater at 80 °C in as little as four hours.

The Bateman-WesTech Paste-Thickener is ideal for locations where water conservation is a prime need. The system combines the proven paste-thickening technology of PasteThick™ & Associates of the USA with Westech Inc’s thickener drives for high-torque applications. Paste is produced from tailings, assisting in efficient and cost-effective backfilling and surface stacking of mine tailings.

The pyrometallurgical portfolio is also expanding. Competitive operating costs and excellent process efficiencies for smelting ferrochrome and ferronickel have been demonstrated using a combination of pre-heating and improved twin-electrode direct-current (DC) furnaces during feasibility studies with Mintek.

The new electrode column for AC furnaces, featuring a novel holding device, was successfully installed for a major ferroalloy producer in India, a model for both new and refurbished furnaces worldwide. A further enhancement could be the addition of copper cooling elements successfully installed recently in Australia.

In the past few years, the technology portfolio has also been focused strongly on processes supporting sustainable development by ameliorating effluent problems and, whenever possible, also providing additional revenue. These engineered systems and equipment handle solids, slurries, liquids, vapours and gas streams with minimal effluent generation while recycling as much water, energy and reagents as possible.

Other processes recover valuable by products from low-grade solid, solution, slurry and gas streams. A Bateman Engineering speciality is the recovery of valuable products from ferroalloy slag dumps, often done on a toll-treatment basis.

More information on the technologies touched on above may be obtained by contacting Steve Burks, Bateman Chief Technology Officer, on +27-11-899-9111 or email Technology@BatemanEngineering.com.

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