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Ferroalloy processing plants
BATEMAN is a leader in the design and construction of processing facilities for the production of
ferroalloys. It has the largest reference list for this type of project in Southern Africa.
BATEMAN Engineering NV - Ferroalloys Track Record...BATEMAN’s Ferroalloy know-how includes:
BATEMAN offers a full spectrum of project management and support services including bankable
documents, process development, design and detail engineering, procurement, manufacture,
equipment supply, erection and commissioning.
Projects and contracts can be carried out on a turnkey, managed contract or partnering basis.
BATEMAN has a track record of sharing or absorbing project risks with its clients according to their needs.
BATEMAN’s capabilities extend across all engineering disciplines.
As part of Bateman Project Holdings Limited, it can also tap into the full resources of the BATEMAN group.
Ferroalloys PDF Brochure - Ferrous-metals Services
Processing technologies
Turnkey plants
Engineering, construction and project management
Feed pretreatment
AC and DC furnaces
Raw-materials and product handling
Environmental control
Finance facilitation
Engineering Project Services
Engineering & Project Services
Finance & Contracts
- Technologies
Processing ferrous metals
From concept to commissioning of ferrousmetals processing plants, BATEMAN provides all
of the capabilities required.Ferroalloy Processing Services
Feasibility studies
Consulting
Ore-body, production and market evaluation
Project management From project inception through design and construction to commissioning
Maintenance Retrofits, rebuilds, audits and staff training
Comprehensive spares and after-sales back-up.
BATEMAN has more than eight decades of experience in nearly 70 countries on over 3 000 successful projects.
Ferroalloy Processing Finance & Contracts
Optimal, cost-effective, financial packages for projects of all sizes
BATEMAN structures, negotiates and secures financial packages to support projects globally
More than 20 years experience on how to manage,
expedite and coordinate this complex and time
consuming process
Familiarity with international financing institutions supported by personal relationships.
Flexible contract structuring for projects large and small
Turnkey, reimbursable, EPCM, lump-sum, fixed fee or any combination to suit client needs
Joint ventures on projects
Build, own, operate (BOO) and transfer (BOOT).
Ferroalloy Processing Technologies & Engineered Systems
All of the systems required to process ferrous metals
Raw-materials stockpiling, handling and off loading
Raw-materials batching, weighing and blending
Pelletising, sintering and preheating of furnace feed
Alternating- (AC) and direct-current (DC) furnaces
Liquid metal and slag handling
Alloy preparation and packaging and slag disposal
Gas cleaning and water treatment to preserve the environment.
These systems are provided either from BATEMAN’s
in-house and licensed range of
technologies and equipment or by selecting the most appropriate equipment
from other suppliers.
Ferroalloy Processing Bulk handling of raw materials and product
BATEMAN supplies open and closed stockyard systems to store, blend, homogenise and reclaim bulk
particulate materials.
Proven in-house, Gustav Schade and Rahco equipment
Licences augmented with in-house expertise
Three decades of experience in the design, project management and supply
of bucketwheel
reclaimers and stackers; luffing, slewing luffing and circular stackers;
portal-scraper,
bridge-scraper, circular-bridge-scraper, portalbridge- scraper reclaimers
and transfer cars.
Conveying
BATEMAN supplies facilities to convey feed materials in bulk to ferrous-metal process plants, to handle
the product from the furnaces and to discard waste materials.
Potential conveying routes are identified and optimised
In-house conveyor-design facilities are utilised
A close association is maintained with specialist mining, environmental and conveyordynamics consultants.
BATEMAN supplies feeding and screening systems.
Batching, weighing and blending raw materials
Feeding material into the furnaces
Handling material between conveyors and processes
Automatic and manual systems
Rugged well-proven equipment.
BATEMAN
apron feeders – installed below bulk storage or transfer facilities
for demanding duties.
Mass or tunnel flow is applied to move stockpiled material.
BATEMAN
plough feeders – reclaim abrasive, sticky or dry materials through
a slot onto a conveyor
running beneath the stockpile, long storage bin or silo.
BATEMAN
pan and grizzly vibrating feeders – customised heavy-duty brute-force
vibration assists material
in the hoppers to overcome the clogging effect of moisture,
temperature, grain size and retention time, and facilitates flow.
BATEMAN
conventional screens – supplied as linear motion, horizontal and multi-slope
units with single- or
double-deck brute force design.
BATEMAN
modular screens – comprise multiple small screens operating together
for high throughputs
of large screens while retaining the advantages of smaller screens.
Ferroalloy Processing Raw-material pretreatment
Weighing, batching & blending
BATEMAN installs flexible and automatic systems for the weighing, batching and blending of various ore types,
fluxes and reductants prior to their introduction into the furnaces.These systems ensure that:
a consistent grade of product is produced despite fluctuations in the composition of the raw materials
batches of different alloys (e.g. high carbon FeMn
or FeSiMn) may be produced by changing the raw
material feed to the furnaces.
Pelletising and sintering plants
Several of these plants, jointly designed with Outokumpu
and incorporating certain core Outokumpu
equipment, have been installed by BATEMAN
at large ferrochrome furnaces in the past few years
and are well proven.
This pretreatment process:
improves chromium recoveries by 15 %
results in 25 % less energy consumption in the furnaces.
Travelling grate-type sintering machines
This equipment is used to beneficiate carbonate ores in the manganese and steel industries.
The sintered ore fed to the furnaces:
adds to the burden resistance, improving the rate of reaction
does not fracture during processing
reduces power consumption by 10 %.
Preheating the furnace mix using off-gas
Systems in which the raw material is preheated by burning furnace off-gases in shaft-type reactors above
AC furnaces processing chromium ores, designed by Outokumpu, have been installed successfully by
BATEMAN.These systems:
This system:
facilitates the smelting of fine ores
has been proven for chromite ores.
Rotary kilns
Under licence to Electrotherm of India, BATEMAN can supply and install rotary
kilns for the
solid-state prereduction of oxide lumpy ores and pellets.
Ferroalloy Processing Arc-furnace processing
Direct-current furnaces
DC plasma-arc furnaces are an attractive means for processing fine material often produced during
mining and comminution of friable materials.
Finely dispersed materials may be processed effectively
High recoveries are typical of DC-plasma furnace operations
Low electrode consumption
Low-cost reductants may be used
High-purity products may be obtained from small reaction vessels
High rates of reaction permit low furnace-residence times
Accurate processing because the feed rate and power can be controlled independently
The power input is limited only by the electrode
size and is independent of electrical conductivity
of the processed materials
High-intensity copper cooling panels permit freezelining operation to prolong lining life
Less flicker is transmitted to the electrical-supply grid.
DC-furnace technology has been used to process ilmenite,
chromite, nickel-laterite ores,
ferrochrome, ferronickel, base-metals, including zinc, steel-plant dust
and copper, and cobalt slag.
Alternating-current furnaces
Large BATEMAN AC furnaces have been installed on most of the major new ferroalloy processing
plants built in the past decade in Southern Africa, ensuring low-cost production.
BATEMAN focuses on innovative equipment and the enhancement of key technology components
to sustain more severe operating conditions. These core technologies are supported by innovative designs
for the furnace feed system, roof, shell, refractory lining and water-cooling, off-gas and electrical
systems, including single and multiple transformer configurations.
Electrode columns for medium and large furnaces using both graphite and Söderberg electrodes
Unique electrically-driven slipping devices for electrode columns
Electrical power systems for furnaces with single and multiple transformer configurations
Improved roof and electrode seals, and gas cleaning
Refractory freeze linings with improved lining management
Shell- and hearth-cooling systems
Integrated intelligent furnace-control systems
Improved control and furnace-monitoring systems ensure quality products
Operator-training software.
Ferroalloy Processing Taphole technologies
Hydraulic taphole guns and drills
Over 200 installations have demonstrated extended tapping block and enhanced furnace campaign
lives.
Overhead rail-mounted systems with combined carriages for gun and drill
Bateman Titaco taphole gun and drill
These systems are designed specifically for furnaces processing ferroalloys.
Rail-mounted mudgun and drills suspended side-by-side on single electrically-driven
carriages
Ferroalloy Processing Product & slag handling
Product & slag handling
BATEMAN supplies leading edge liquid-solid processes for the safe and effective handling of molten materials.
Liquid metals may be solidified into particles from small to large using a variety of processes.Product handling
Atomisation
Molten metal is sprayed through a nozzle into different media to produce particles of the required shape
ranging from 10 µm to 100 µm.BATEMAN supplies well proven technologies, including:
Ferroalloy Processing Slag handling
Slag granulation
BATEMAN supplies slag-granulation systems using water or water and air as granulation media.
BATEMAN Stillwater granulators Granules are formed during the molten metal’s freefall
in a closed vessel into a waterjet and quenched in a cyclonic water bath.
Compact and highly economical closed-circuit system
Handles flows up to 1,5 t/min
Minimal steam generation
BATEMAN Unifield granulators
In this launder slag-granulation process, an upper stream
of water disperses the liquid metal during
freefall and a lower stream quenches the granules. Granulation is achieved
in the waterjets before the
granules reach the bottom of the sloping launder from where they are discharged
to a dewatering system.
Continual or batch flows of up to 3 t/min
Launder normally discharges into dewatering ponds
High-tonnage slag granulators
These are used in the production of blast furnace and Corex slag and LD
(Linz-Donawitz) converter slag.
More than 50 are in operation worldwide.
Any flow rate but flows usually exceed 3 t/min
BATEMAN granulators
In these open-tank slag granulators, granules are produced at the point
where the freefalling molten slag
and the waterjet meet at the quenching-pond surface.
Slag flows in the order of 2 t/min
Extremely clean, safe and quiet.
Other slag-handling systems
BATEMAN supplies:
Systems for crushing and milling slags
Pelletising equipment to ensure that slag fines do not harm the environment
Manual slag water casting and disposal systems
Slag dumps designed and constructed to ensure environmental compliance
Product packing and dispatch
The range of equipment supplied includes:
Rail and road outloading stations
Automatic product samplers
Container loading systems
Product bagging and drumming systems.
Environmental control
Gas cleaning
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 handled equally effectively
Economic with low energy and spares cost
High dust collection efficiencies
Gas temperatures up to 450 °C with optional pre-cooling
Optimum availability with minimal maintenance.
BATEMAN
baghouses clean large volumes of hot gas from furnaces where the
fumes and dust must be
collected dry. Designs include pressure, suction, top or bottom entry.
Low cost per cubic metre of air
High efficiency
Long filter-bag life
Reverse air-flow cleaning maintains filter efficiency
Handle gas up to 230 °C with radiant or forced draught pre-coolers
Optional cyclone pre-cleaning.
BATEMAN
reverse-pulse bagfilters enable dust collection at high filter rates
with collection efficiencies
of about 99,99 %. The filter bags are cleaned by venturi-injected reverse
pulses.
High efficiencies under variable operating conditions
Reverse-pulse action maintains the filtration efficiency
Economical collection of dust
Easy inspections by personnel
Filter-bag replacement from the bagfilter’s clean-air side.
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.
Low maintenance
Low water consumption
Internal linings that are corrosion and abrasion resistant.
BATEMAN-Simatek particulate- and dry-scrubbing technology, in which low-pressure
pulses
clean the individual filterbags, is proven in many applications, filtering
airborne particles as well
as removing heavy metals and acidic gases, such as HCl, SOx and HF.
Easy to operate
Low capital, operational and maintenance costs.
BATEMAN installs systems to remove particulate solids from effluent streams and to clarify and
chemically treat water for recirculation to the plant:
Ferrous
Metals & Industrial Processes
More information can be obtained on the main
BATEMAN
Engineering NV Website
SAMANCOR Metalloys metal from slag recovery, Meyerton, RSA
The Hernic Ferrochrome plant near Brits, RSA, during startup.
A modular air-pulsed metal separator ready for export.
Ferroalloys Home | Bateman Engineering NV | Ferroalloy Processing Track Record | Project Management | Contact us
PGM - Platinum Group Metals and Base Metal Processing technologies / Diamond extraction processing and equipment / Coal mining processing equipment and engineering technology / Gold extraction and mining technology and engineering equipment / Modular Engineering Processing Plants / Jigging equipment / Alternating current AC Furnace and Smelting technology / Direct current DC Furnace and smelting technology / Post taphole services and handling systems and technology / Ferromineral / Diagnostic systems for process plants / Environmental Control Process engineering pollution control of toxix harmful stack emissions and waste products /
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Links to other Bateman Engineering Web Sites -
P G M Platinum Group Metals processing - PGM & Base Metals, BATEMAN Engineering NV has designed, engineered, procured and construction-managed process facilities for most primary platinum group metal (PGM) producers worldwide: Rasimone, Potgietersrust, Impala UG2 and EMPR, Hartley, Western Platinum, Stillwater and Anglo's Waterval, Modikwa and PMR projects. We are also the only independent contractor to have successfully installed all types of PGM process plants: concentrators, smelters and precious metals refineries / Ferrous Metals & Industrial Processes - BATEMAN Engineering is a leader in the design and construction of processing facilities for the production of ferroalloys. It has the largest reference list for this type of project in Southern Africa / Coal Mining Equipment - From coal face to coal loading, BATEMAN Engineering tackles any coal-processing assignments - from mine evaluation, sampling and testing, process feasibility and economic-viability studies, through to the design, engineering, procurement, management, construction and commissioning. BATEMAN Engineering NV optimises the recovery of coal for the least possible cost / Gold Mining Process Plants and Equipment - From ore to bullion and fine gold, BATEMAN tackles any gold-processing assignment - from preliminary test work and studies to bankable documents, raising project funding and complete turnkey projects, covering all the processes needed for the effective recovery of gold / Modular Engineering Process Plants - BATEMAN is the world leader in modular engineered transportable process plants for mining and minerals processing applications. The concept was developed by BATEMAN nearly three decades ago and has progressed steadily ever since. As new technology was proven this has been added to the range of modules made available to clients. Most of these plants have been used for diamond recovery, but the range has been expanded steadily to cover other minerals processing applications. / Jigging - Bateman Engineering has established a leading position in the world using APIC Jigs to recover metal from slag / AC Furnaces smelting technology - BATEMAN Engineering NV’s state-of-the-art alternating current (AC) smelting-process technology is supplied with most of the references being in ferroalloy applications. Know-how includes pre-treatment of ores, pollution control, power supplies, raw material and product handling, metal casting, sludge treatment and handling and remelting of fines / DC Furnaces smelting technology - BATEMAN has designed, built and commissioned plants or executed feasibility studies for numerous ferrous and nonferrous pyrometallurgical processes utilising AC and DC furnaces. These include smelting of ferrochrome, ferrosilicon, ferromanganese, ilmenite, and recovery of metals such as zinc and cobalt from waste dusts and slags / Water and Wastewate - BATEMAN Engineering designs, supplies, installs and commissions technical solutions in industrial water and wastewater plants. BATEMAN Engineering offers enhanced water-treatment systems and environmental services worldwide. BATEMAN Engineering 's international technology links with leading global technology partners ensure the availability of state-of-the-art process technologies. BATEMAN Engineering's water processing expertise includes: Potable-water treatment, Sewage treatment, Sludge dewatering, Industrial effluent treatment, Boiler feed-water treatment, Industrial process-water treatment, Integrated and optimised systems, BATEMAN Engineering technologies used in water and waste-water treatment applications include: Clarification, Thickening, Sludge dewatering, Filtration, Softening, Demineralisation, Ion-exchange processes, Evaporation / Crystallisation Membrane technologies, Aerobic and Anaerobic digestion, High-rate anaerobic digestion, Detoxification / Neutralisation / Bulk Materials Handling Conveyor Design & construction / Pneumatic conveying systems / Specialised Engineering Equipment BATEMAN Engineering offers its customers in minerals processing, cement, food and other industries, complete processing technology systems backed up by spares and services. The product portfolio features all the key types of equipment, from feeders, to mills and crushers, screens, separators, flotation plants and thickeners, specialised conveyors and elevators, iron, steel and non-ferrous processing technology and expert control systems. The range available enables clients to select the best solution to optimise their processes / Taphole - BATEMAN Engineering NV and MINTEK have formed a partnership, called Post Taphole Services, to pool their 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 / Ferrominerals - BATEMAN Engineering NV’s process and applied engineering capabilities bring a range of solutions for the processing of ferrous and industrial minerals. A sound track record has been established over many years. There has been a particular focus on heavy-minerals, iron-ore pelletising and steel-processing plants and projects. / Diagnostic Systems for Process Plants / Environmental Pollution Control Systems - Air pollution control is provided through the supply of electrostatic precipitators, fabric filters, dust-removal systems including wet and dry scrubbers, bag filters and ceramic filtration systems for hot gas (up to 1000°C) and liquid applications - The markets served are cement, mining and minerals processing, metallurgy, food, petrochemical, power and general industry. Technologies continue to be explored to expand the present BATEMAN Engineering's range and markets as well as developing the existing technologies for new applications. Electrostatic precipitators, Reverse-flow baghouses, Reverse-pulse bagfilters, Cartridge filters, High-efficiency cyclones, Low-energy scrubbers, Dynamic scrubbers, Venturi scrubbers, Ceramic filters. / BATEMAN AFRICA is a BEE compliant company serving Industry in South Africa.
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