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Coal beneficiation From coal face to coal loading, BATEMAN tackles any coal- processing assignment – including mine evaluation, sampling and testing, process feasibility and economic viability studies, through to the engineering, management, construction and commissioning of coal process plants. We can provide the complete technology needed to design and implement cost effective processes which produce marketable products. We are leaders in the beneficiation of coal, and in particular in the application of dense-media technology in difficult coal washing applications.
Coal beneficiation plants BATEMAN offers the full spectrum of project construction services, from the project inception to commissioning of the plant. Maintenance services include retrofits, refits, audits and staff training. Flexible contract structuring accommodates projects large and small, and includes reimbursable, EPCM, lump-sum, fixed fee or any combination to suit client needs. Joint ventures on projects may be formed with independent mining consultancies.
Oakbridge Limited’s 1 500 t/h coal washing module at Saxonvale, Australia, with two stage cyclones and spirals.
Optimum Colliery’s 2 000 t/h low ash coal preparation plant, Middelburg, RSA, with two stage drums.
Zululand Anthracite’s 400 t/h multi-product plant, near Ulundi, RSA, with two stage drum and cyclone.
Taaiboschspruit’s 130 t/h multi-product coal processing plant, Piet Retief, RSA, with single stage drum, cyclone and spiral plants.
Gordonstone Coal’s 1 000 t/h fine coal circuit, Queensland, Australia, with cyclones, Jameson cells and horizontal belt filters.
Design capability
Consulting service
BATEMAN designs processes for the storage and size reduction of run-of-mine coal, the screening of coal to size and wet concentration to clean coal through typically dense-media separation (DMS), spirals or flotation, including de-watering prior to further processing and handling. New fine-coal separation technologies, such as DMS, column flotation cells and Jameson cells can also be offered to increase the overall yield or make special low ash products. Numerous new and upgraded plants have been designed using DMS technology, spiral-separation technology, multi-slope screens and large diameter cyclones. These coal plants have ranged in size from 60 to 2 000 t/h and have reflected different styles of engineering, from computer controlled, multi-modular units to the “minimum but adequate” approach favoured by some mining houses.
The service identifies the potential processing routes which are likely to optimise the yields of marketable products which can be obtained from the coal resource. For example, raw washability data can be processed to estimate product yields needed to derive the capital and operating costs for a specified capacity plant. The service is supported by: I
in-house laboratory facilities and a close association with many external R & D organisations, laboratories and specialist mining and environment consultants.
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the utilisation of in-house developed coal washability simulation computer programmes. These permit a quick but comprehensive analysis of large sets of borehole or bulk sample data. The analyses can be used for: J initial mine feasibility studies to project future plant yields when combined with a geological data base; J investigating equipment performance limits and guarantees during the plant design stage; and J assessing plant acceptance test results to obtain performance efficiencies.
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Goedehoop’s 1 000 t/h drum and cyclone coal preparation plant, Witbank, RSA.
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Coal liberation curves obtained by analysis of a bulk coal sample. 100 r 80 e b m u 60 N n o i t 40 i t r a P
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Relative Density
Actual versus theoretical cyclone efficiency curves for a working DMS plant.
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Coal handling BATEMAN supplies systems for the bulk handling of both run-of-mine and clean coal. These systems include stackers and reclaimers, conveying systems, and rapid train loading systems. Successful solutions for the bulk handling of coal are based on a thorough understanding of the criteria which affect flow. At the BATEMAN laboratories the behaviour of materials is determined to assist in designing efficient and effective systems.
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load with accuracies which meet most countries’ statutory requirements allow for a variation in particle size and bulk density of loaded material. avoid penalties due to overloading and excess axle loading.
Stock yard systems – stackers and reclaimers Over the past two decades BATEMAN has been responsible for the design, project management and supply of many stock pile systems for the stacking, reclaiming, homogenising and blending of coal. BATEMAN / SCHADE equipment is marketed extensively throughout Africa. The BATEMAN rapid load-out station at the National Coal Supply Company in Israel, utilising the BATEMAN flask loading system with automatic learning system to load 60 t hooded coal trucks at a rate of 2 000 t/h.
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The Elbram robot train mover is a BATEMAN development. Elbram advantages include: J constant train speeds from 0 to 14 m/min (clamp and wheel drive) J train speeds from 0,8 to 15 km/h (wheel drive) J standard diesel or electric prime mover J handle rail wagon braking systems (vacuum/air) J move trains of up to 12 000 t J low axle-loadings which comply with the regulations of railway operating systems.
The BATEMAN / SCHADE double harrow bridge reclaimer at Goedehoop Colliery, Witbank, RSA, handles 650 t/h of clean coal.
Train loading systems BATEMAN is a world leader in rapid train-loading systems and offers the best and most cost-effective solution to load-out problems, large or small. Some 20 BATEMAN load-out stations have been installed worldwide in the past two decades to load coal, iron ore and limestone. I
BATEMAN load-out stations are built on a turnkey basis and use the flask-loading system to load coal into moving trains. They are reliable, low maintenance and safe, and: J load at rates up to 8 000 t/h. J handle a random placement of rail wagons of varying capacity and type
BATEMAN provided all of the materials-handling equipment at this Middleburg Mine Services site, including the 4 000 t/h coal rapid load-out station; the ELBRAM robot train mover, seen on the far right of the picture emerging from the load-out bay; and the BATEMAN / SCHADE stacker and reclaimer in the coal yard behind the station and the conveyors.
Coal conveying BATEMAN’s range of conveyors can handle any run-of-mine or clean coal conveying need. The available systems include:
Overland conveyor systems The overland and long curved overland conveyors include curved, regenerative downhill and high lift troughed belt conveyor systems. These systems: J convey from 100 t/h up to 4 000 t/h. J are designed using dynamic analysis and computer simulation to predict and compensate for the performance under all operating conditions. This reduces cost and ensures an effective and efficient conveying system.
Environmentally friendly conveying systems The JPC (pipe conveyor) conveys materials securely within a longitudinally rolled conveyor belt forming a pipe, which can negotiate tight horizontal and vertical curves. It has overcome many of the coal dust and contamination problems commonly encountered with conventional belt conveyor systems. Pollution is limited by: J preventing dust generation and spillage along the length of the pipe J minimizing the number of costly potential dust generating transfer points which can cause coal degradation. With more than 50 units having been installed in South Africa to convey a range of products since 1984, and in excess of 500 world wide, the JPC is well proven.
This curved overland conveyor, which traverses major flood and minor marsh areas, farming land and two major roads, at Majuba Colliery, RSA, was built on a turnkey basis. It has a capacity of 2 280 t/hr, is 6 km long with a 3 km radius and has a width of 1 200 mm.
Two horizontally curved pipe conveyors, each of 350 mm diameter carrying crushed run-of-mine (ROM) coal to the washing plant at the Arthur Taylor Coal Complex near Witbank, RSA. Each conveyor has a capacity of 725 t/h.
A horizontally and vertically curved pipe conveyor at Amcoal’s New Vaal Colliery near Vereeniging, RSA.
Dust Control The most comprehensive range of systems under one roof enables you to select the best and most cost effective solution – from system design, manufacture, erection, commissioning, project management and turnkey installations to after sales service. The range includes I
Bag filters
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Scrubbers
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Cartridge filters
A typical wet scrubber on a coal screening plant.
Our equipment can be found on nearly 2 000 installations – on furnaces, kilns, smelters, driers, boilers, and mills and on mines, minerals processing, chemical and industrial plants. A dust hood mounted over a coal conveyor, with ducting leading to the wet scrubber.
Ash classification The BATEMAN ash-classification plant classifies, selects and extracts waste ash from coal fired power stations to produce high quality pulverised fuel ash (PFA) for use in the extension and improvement of Portland cement. These plants: J handle up to 1 000 000 t/yr of ash J consistently produce PFA of guaranteed quality J improve the profitability of a power facility
The 170 t/h classification plant for the Castle Peak Power Station, Hong Kong.
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are supplied as a total system using BATEMAN licenced technology can be designed in accordance with local labour needs.
BATEMAN has supplied the two largest ashclassification plants in the world.
A cut away drawing of a typical BATEMAN / IBAU ash-classification plant, with the buffer hopper at the top of the centrifugal classifier unit and product silo. Product may be discharged through a number of loading spouts into tankers.
Modular coal process plants BATEMAN’s modular coal processing plants have the capacity to treat between 60 t/h to about 200 t/h of coal. These units can, however, be used in tandem to increase throughput. BATEMAN’s modular units achieve large savings in capital cost and construction time. Based on dense-media technology, these plants are typically composed of de-sliming modules to separate the fine coal, dense-media separation (DMS) modules in which the waste / shale is removed, magnetic recovery modules for the recovery of the magnetite, and coal washing and de-watering modules. Heavy-media drum and air pulsed over-the-bed jig modules for the separation of coal from waste are also available. All BATEMAN’s modular plants are: J easy to transport, move, re-erect operate and maintain J cost effective and reliable J pre-designed modules or custom designed units J configured to specific process requirements J optional PLC (programmable logic controlled) or manual systems J constructed using wear-resistant equipment and materials tailored to the requirements J re-assembled and shop-tested before delivery to facilitate commissioning J erected on site under supervision and commissioned J factory calibrated and checked by field service personnel J supported by an extensive technical back-up and reliable spares service.
BATEMAN’s modular plants are easy to dismantle, transport and re- assemble – it took only two weeks to move this plant from the fabricator’s premises (above), where it was pre-erected, to the colliery (picture below) for re-assembly. This plant is mounted on five separate modules of which the largest is only 16 m long by 3,5 m wide. The steel- and plate-work weigh about 60 t and the structure is 9 m high.
BATEMAN has a track record spanning three decades during which about 210 BATEMAN modular process plants have been supplied to more than 20 countries worldwide.
A BATEMAN pump-fed, modular coal washing plant with a single cyclone. The plant handles 180 t/h of ROM coal and is one of the world’s largest single cyclone modular engineered plants to be used for coal processing. Single-cyclone plants of this size are more cost effective than plants in which several small units are combined, as less duplication of auxiliary equipment like pumps, piping and controls is required.
Support Services All BATEMAN projects and plants are supported by an extensive technical back-up and reliable service. This includes: J J J J J
Feasibility studies and preparation of bankable documents Consulting services on exploration, sampling, production and security Erection supervision, commissioning of plant and training of personnel Factory calibration of modules checked by field service personnel Rapid dispatch service for spares and consumables to any site world-wide.
With a track record in the coal-processing industry which started in 1968/9 and includes large and small coal projects, much of which is repeat business for satisfied clients, BATEMAN optimises the processing and handling of coal with the most up-todate technology. BATEMAN has successfully served large and small coal clients in Australia, Hong Kong, India, Israel, South Africa and USA.
A 150 m diameter BATEMAN / SCHADE circular blending, bridge-scraper reclaimer storing and blending ROM coal at Transvaal Navigation Collieries, Koornfontein, RSA, with a stacking capacity of 1 200 t/h and reclaim capacity of 1 700 t/h.
As mineral processing and materials handling engineers and project managers, BATEMAN has the in-house technology and design capability to handle the largest turnkey projects. Our track record numbers 2 000 successful projects.
Bateman Engineering BV Haaksbergweg 59, 1101 BR Amsterdam, Netherlands
Offices in Africa, the Americas, Australasia and Eurasia
A BATEMAN stacker reclaimer at the Richards Bay Coal Terminal, RSA. The machine has a capacity of 6 000 t/h and a reclaim capacity of 3 500 t/h (average) and handles 50 mm coal.
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– process plants that work
