Handling Molten Materials Safely and Effectively
BATEMAN and MINTEK have formed a partnership, called Post Taphole
Services, to pool heir expertise and experience in the processing of
molten materials from the tapholes of furnaces. The combined capabilities
make this partnership a world leader in liquid-solidification processes,
providing complete process plants with the most up-to-date technology
for the safe and effective handling of molten materials.
SOLIDIFICATION PROCESS
The comprehensive range of processes available from Post Taphole Services
for solidifying liquid metals produces particles ranging from the smallest
(atomisation) through granulation to larger lumps (blobulation) to ingots
(pig-casting).
ATOMISATION
Molten masses of metal may be dispersed into small droplets using a
variety of means such as praying under pressure through a nozzle into
different media, by pouring onto a rotating disc and by ultrasound.
The means selected will depend upon the material to be processed and
the size (from a mean of about 10 µm to 100 mm) and shape of the solidified
particles required.
Post Taphole Services offers pressure, ultrasonic and centrifugal atomisation
in water, hydrocarbons, gas and air, MINTEK Splatterjet and powder metallurgy.
It provides a full range of capacities and product sizes, with its principals
having an impressive track record in the supply and installation of
a wide range of flexible technologies. BATEMAN also represents Atomising
Systems Limited (ASL) of Sheffield UK for the ASL-Atomisation systems
in sub-Saharan Africa, maintaining the high standards set by ASL and
required by industry. ASL has successfully complete over 100 atomisation
projects in more than 29 countries, often repeat business from the same
clients.
A BATEMAN Stillwater 1 tonne/min copper / nickel matte granulator
at Mineração Serra da Fortaleza, Brazil.
MATTE GRANULATION
Systems are supplied which safely granulate molten mattes. They ensure
that the mattes are introduced into the granulation jets in a manner
which avoids the sudden generation of energy and maintains the correct
temperatures, pressures and conditions in the granulation bath. The
technology was originally developed in association with Stillwater and
Unifield. The knowledge base is expanded by infusion of the latest production-plant
data to ensure that new plants embody the most up-to-date matte-granulation
technology and can operate safely and free of trouble.
The range of products supplied includes BATEMAN granulators and BATEMAN
Stillwater granulators. The equipment offered primarily uses water as
the granulation medium, but where water supplies are limited units can
be supplied using a combination of air and water. The particles produced
are generally in excess of 1 mm in size, but this depends on the process.
Mattes which have been granulated include flash-furnace, electric-arc
furnace and converter-platinum, platinum / alladium and copper / nickel
mattes.
SLAG GRANULATION
All slag-granulation applications are covered in the product range.
The equipment offered primarily uses water as the granulation medium,
but, where water supplies are limited, units can be supplied which use
a combination of air and water. Particles in excess of 1 m min size
are generally produced, out this depends on the process applied. The
range of products supplied includes BATEMAN granulators, BATEMAN Unifield
granulators, BATEMAN Stillwater granulators and high-tonnage slag granulators.
Slag granulation
Blast-furnace slag granulator, Iscor, Vanderbijlpark, RSA.
METAL-LUMP PRODUCTION
The metal-lump production systems produce solid particles of different
sizes with sufficiently high densities to effectively eliminate the
risk of thermal popping when used in melting processes. Large lumps
of metal are generated, with very few fines, to facilitate the bulk
handling of the product. his s achieved by gently uniting a co-current
stream of water with a stream of liquid metal / alloy so that he surface
tension of the molten metal / alloy serves to break it into large lumps
as it solidifies.
The range of products supplied includes the BATEMAN INCOL Lumpenalloy
process, the MINTEK Blobulator and the S-Gran. It has processed pig
iron, mild steel, ferronickel and ferrochrome (high-, medium- and low-carbon),
charge chrome, nickel, stainless steel (300 and 400 series), ferrosilicon
(75 % silicon metal), ferromanganese (medium- and low-carbon) and certain
high-carbon grades and silicon manganese. The products are typically
6 to 10 mm thick and 20 to 0mm across and suited to bulk handling. They
are heavy enough to fall rapidly through a molten-slag layer yet small
enough to dissolve quickly and reproducibly.
PIG AND INGOT CASTING
The BATEMAN pig- and ingot-casting machines produce products of a reliable
shape, weight and quality to suit individual customer requirements.
The single strand pig-casting machines have been used to successfully
produce ingots of aluminium, copper, bronze, zinc, lead, ferroaluminium,
cobalt, iron, mild and alloyed steels. The ingot-casting machine was
specifically designed to produce ferromanganese ingots of the appropriate
size and is well suited for all slow cooling processes.
A 145 kg/min cobalt-ingot caster at Chambishi Metals PLC Zambia.
PARTICULATE METAL AND SLAG DEWATERING
A full range of technologies is available for the effective dewatering
of atomised, granulated and lump metals, mattes and slags to enable
them to be safely disposed of without contaminating the environment.
The product range includes BATEMAN Unifield static-dewatering systems,
BATEMAN dewatering-bin and -pond systems and bunkers, NBA dewatering
drums, rake or spiral classifiers, magnetic separators and vacuum filters.
A BATEMAN matte dewatering-bin and -bunker system at Mineração Serra
da Fortaleza, Brasil.
Bateman Titaco taphole clay gun and drill, Advalloy, Meyerton, RSA.
TAPHOLE EQUIPMENT
The range of taphole systems available include those which have been
developed in-house as well as other specialised systems for all types
of smelting furnaces in the ferrous, non-ferrous and ferroalloy industries.
The equipment meets all functional needs and tapping platform designs
and handles process-related demands such as long tapping times and regular
metal, matte or slag flows. It is simple, rigid, functional, reliable
and maintenance free. Repeatable positioning on the taphole is assured
because of its high power.
The systems include hydraulic-taphole guns and drills and the Bateman
Titaco taphole gun and drill.
Post Taphole Services maintains the high standards required by industry
and has successfully completed twenty five turnkey projects and twenty
one service contracts, both in Southern Africa and abroad, often repeat
business from the same clients.
For more information, kindly contact Dave Norval, General Manager,
Post Taphole Services, on +27-11-201-2300 or email posttaphole@batemanengineering.com.
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