Processing ferrous ores

n Turnkey plants
n Engineering & construction
n Project management
n Finance facilitation
n Technologies
n Materials handling
n Beneficiation
n Waste disposal

– ferrous ore process plants that work

Project services
Facilitated finance
n Screening n Gravity separation
Technologies n Feeding n Pelletising
n Stockpiling n Scrubbing n Sintering
n Conveying n Jigging n Out-loading

Ore transport Crushing

o Road o Cone crusher
o Rail o Ball mill
o Conveyors

Secondary
Mine ROM & tertiary
stockpile ore systems

Stacking Reclaiming Scalping & screening

o Luffing o Harrow o Grizzly
o Slewing o Bucket-wheel o Vibrating screens
o Circular o Portal o Scrubbers
o Magnetic separation

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 Beneficiation
o Jigs
o DMS
o Spirals
o WHIMS

Conveying
products
o Belt
o Pipe
Lump Environmental
control
ore o Baghouse Processing
o Scrubber
furnace

Semi fine
or Product
fine ore stockpiling

Export
Very port
fine Stacking and
ore reclaiming

Load-out
o Train
Beneficiation o Ship
o Flotation o Road
o Scrubbing
o Thickening

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Processing ferrous ores
Project services Facilitating project
B ATEMAN provides all of the capabilities needed to
bring a ferrous-ore-processing plant into production,
finance
from concept to commissioning.

n Feasibility studies
n Preparation of bankable documents
n Flexible contract structuring for projects large and
small
n Turnkey, reimbursable, EPCM, lump-sum, fixed fee or
any combination to suit client needs
n Joint ventures on projects may be formed
n Consulting services
n Exploration, sampling, production and security
n Full spectrum project-management services
n From project inception through design and
construction to commissioning
n Maintenance services
n Retrofits, refits, audits and staff training
n Comprehensive spares and after-sales back-up services.

BATEMAN has more than eight decades of experience in

nearly 70 countries on over 3 000 successful projects.
B ATEMAN facilitates the optimal, most cost-effective,
financial packages for projects of all sizes.
Structuring, negotiating and securing financial packages to
support international projects is a service which has been
provided to clients for more than 20 years.
Understanding how to manage, expedite and
coordinate this complex and time-consuming
process, is assisted by BATEMAN’s familiarity
with international financing institutions and its
established personal relationships with them.

Zisco’s iron-ore handling facilities at Ripple Creek, Zimbabwe.
Technologies
B ATEMAN provides all of the technologies
required to process ferrous ores, either from
its in-house and licensed range or by selecting
the most appropriate equipment from other
suppliers.
These include technologies for conveying
raw materials and products to, around and out of
the plant, stockpiling, crushing, feeding and
screening, beneficiating and disposing of waste
material.

Conveyor and
luffing stacker
at Saldanha
Bay, RSA,
handling
9 000 t/h of
iron ore.

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Technologies
Bulk handling of
raw materials and
product
Stockpiling
S tackers and reclaimers from BATEMAN,
GUSTAV SCHADE and RAHCO are supplied
to store, blend, homogenise and reclaim bulk
particulate materials in stockpiles and dumps.
Licences are augmented with proven in-house
expertise.
Successful solutions are based on a thorough
understanding of the criteria affecting flow. In-
house facilities enable the determination of the
behaviour of materials to assist in designing The parallel blending stockpiles at Zisco’s Redcliff site with luffing stacker,
efficient and effective stockyard systems. single-harrow-bridge reclaimer and transfer car.
BATEMAN has nearly three decades of
experience in the design, project management and
supply of bucket-wheel reclaimers and stackers;
luffing, slewing-luffing and circular stackers;
Environmentally friendly
portal-scraper, bridge-scraper, circular-bridge- conveyor systems
scraper, portal-bridge-scraper reclaimers and
transfer cars.
T he BATEMAN JPC (Japan Pipe Conveyor) conveys material
securely within a pipe formed by a longitudinally-rolled belt
and negotiates tight horizontal and vertical curves.
Conveying n Minimal environmental pollution
o Dust generation and spillage do not occur along the length

B ATEMAN tackles any assignment to convey

bulk materials from mine production facilities
to process plants to out-loading at rail and port
of the pipe
o The number of costly, potentially dust generating, transfer
points is minimised
terminals. n Contamination of the enclosed product is prevented
Potential conveying routes are identified and n Belt inclines 50 % steeper than conventional belt conveyors
optimised, supported by in-house conveyor-design n Well-proven worldwide.
facilities and a close association with specialist
mining, environmental and conveyor-dynamics
consultants.

Belt-conveyor systems

B ATEMAN’s overland and long curved-

overland belt conveyors include curved,
regenerative downhill and high-lift troughed belt-
conveyor systems.
n Convey to over 11 000 t/h
n Belt speeds over 6,5 m/sec
n Amongst the longest in the world
n Can regenerate over 800 kW of power
n Designed to ISO and CEMA standards.

Zisco’s 15,6 km single flight curved-overland conveyor transports 500 t/h of

blended iron ore, Zimbabwe.

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Feeding and screening
BATEMAN pan and grizzly
B ATEMAN supplies rugged well-proven equipment to move and
screen material onto conveyors and between processes.
vibrating feeders
BATEMAN apron feeders
BATEMAN
apron
feeder.
Flight
overlap
minimises
spillage.

I nstalled below bulk storage or transfer facilities, apron

feeders are used for demanding materials-handling
duties. They apply mass or funnel flow to move
stockpiled material.
n Infinitely variable feed rates
n High impact carrying capability
n Guaranteed extraction of sticky materials
n Flexible local or remote control
n Heavy-duty frames and rugged short-pitch flights
n Feed decks with positive or negative slopes up to 25°
reduce space requirements
n Moving parts available worldwide off-the-shelf
n Minimal scheduled maintenance.
More than 500 BATEMAN grizzly feeders ensure the
smooth feeding of materials such as iron ore, quartz,
limestone, kimberlite, and coal.
C ustomised heavy-duty brute-force vibration assists
material in the hoppers to overcome the clogging effect
of moisture, temperature, grain size, retention time, etc. and
facilitates flow.
n Robust construction
n Fully lined grizzly-bar support members and side plates
n Rubber impact liners on the feed tray
n Cast manganese grizzly bars.

BATEMAN modular screens

BATEMAN plough feeders
T hese tough and reliable feeders reclaim abrasive,
sticky or dry materials through a slot onto a conveyor
B ATEMAN modular screens comprise multiple small
screens operating together. They handle the high
throughputs of large screens while retaining the advantages
running beneath the stockpile, long storage bin or silo. of smaller screens.
n Capacities range from < 50 t/h up to 1 000 t/h n Low dynamic loads, mass and head room
n Lump sizes up to 300 mm n Reduced power consumption
n No rat-holing or piping and easier control of materials n Standard interchangeable modules
which tend to pack or arch. n Significantly reduced operating noise.
n The reclaim rate is easily set and maintained
n Low headroom requirement
n Simple maintenance.

BATEMAN conventional
screens
H igh-performance conventional screens are
supplied as linear motion, horizontal and multi-
slope units.
n Single- or double-deck brute force design
n Simple amplitude adjustment to suit processed
product
n Rugged and compact construction minimises
downtime and in-situ repairs.
BATEMAN conventional screens.

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Beneficiation technology
Scrubbing
B ATEMAN roller-supported scrubbers are ideal for a
variety of heavy-duty scrubbing applications.
n Power consumption from 22 kW to 350 kW
Gravity separation
B ATEMAN supplies dense-media-separation (DMS)
and spirals plants.
In the past three decades BATEMAN has supplied
over 300 large permanent and transportable modular
DMS plants fitted with individual cyclones handling up
to about 200 t/h of material.
n Factory assembled and tested prior to despatch
n Easy operation and maintenance
n Mobile units easy to move and re-erect
n Technical back-up
n Reliable spares service.

BATEMAN drum scrubbers are driven by solid polyurethane

wheels, reducing capital costs by up to 30 %.

n Shell diameters between 0,8 and 3,0 m and lengths

between 1,5 and 6,0 m.
n Variable peripheral speed
n Fully reversible
n Low capital and maintenance costs
n Short delivery and installation time.

BATEMAN DMS systems are proven for chrome and platinum-group-

Jigging metals and ferrous ores and industrial and precious minerals.

T he BATEMAN Apic jig is an underbed air-pulsed jig

which separates particles of different density in a
homogeneous bed of solid material, effectively producing
Thickening
clean and valuable products from raw materials.
n Processes both fine and coarse material
n Produces sinks, middlings and floats
B ATEMAN Ultrasep is a versatile thickener with no
moving parts and utilising a unique internal dilution
and mixing system to facilitate the particle-binding and
n Wide range of feed and discharge rates settling process. A reliable database enables sizing of
n Large plants from 100 t/h upwards Ultraseps for wide ranging applications to within 90 %
n Modules from 15 t/h to 200 t/h accuracy. Site-specific sizing is done using Ultrasep
n Very low operating costs pilot plants.
n No consumption of heavy media. n Optimised underflow density and overflow clarity
n Low flocculant
consumption
n Quick startup and
stabilisation
n Small footprint
minimises plant size
n Standard sizes from
0,5 m to 12 m diameter
n Capital cost as low as
50 % of conventional
thickeners.

BATEMAN Ultraseps are

An Apic jig at an iron-ore mine, RSA. proven for mill-circuit
thickening, countercurrent
decantation, slag treatment,
dewatering and water
recovery, etc.

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Processing Ferrous Ores
Pelletising and sintering
B ATEMAN supplies pelletising drums and energy efficient,
steel-belt sintering furnaces, to dry, preheat and sinter
pellets for the hard and porous structure required for
processing in smelters.
Environmental control
Electrostatic precipitators efficiently collect either
solid or liquid particles suspended in air. BATEMAN
is licensed to supply the ELEX range of electrostatic
precipitators. Wet and dry dusts are handled
effectively.

Out-loading BATEMAN baghouses clean large volumes of hot gas

from furnaces and other process applications where

B ATEMAN is a leader in rapid rail-loading systems

comprising load-out stations and train movers, custom
designed to meet the client’s specified requirements,
the fumes and dust must be collected dry.

BATEMAN reverse-pulse bagfilters enable dust

standards and reliability.
BATEMAN load-out stations feature flask-loading systems to
load particulate materials into moving trains.
n Load at rates up to 8 000 t/h
n Random arrangement of train wagons
n Handle many different products
n Loading accuracies meet statutory requirements
n Allow variations in particle size and bulk density.
collection at high filter rates with collection
efficiencies of about 99,99 %.
BATEMAN wet scrubbers are versatile, ranging from
static, low-energy scrubbers for fixed dust-control
volumes to hi-tech variable-volume venturi scrubbers
for complex-process applications with gas
temperatures up to 750 °C.

BATEMAN
load-out station
with a capacity
of 2 500 t/h at
Richards Bay,
RSA, handles
coking coal,
fertilisers,
sulphur and
potash with
densities from
0,7 to 1,4 g/ml.

BATEMAN dynamic scrubbers and high-efficiency

cyclones.

Bateman BV
Haaksbergweg 59, 1101 BR Amsterdam, Netherlands
Offices in Africa, the Americas, Australasia and Eurasia

For more information on

ferrous ores services contact ...
Tel: +27–11–345–5000 Fax: +27–11–455–6446
Email: engtech@batemanbv.com
or visit our website at www.batemanbv.com

– process plants that work

Alan Langbridge Design
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