Advanced process technologies and modular plant solutions provider, Tenova Bateman Technologies, part of Tenova Mining & Minerals, reports it is seeing growing demand for its modular plant technology from African mining sectors other than the traditional user of this technology – the diamond sector.

Current projects in Africa include the design and supply of a modular plant using dense media separation (DMS) technology for an iron-ore producer, while there are a number of opportunities under discussion with copper, coal and gold producers, amongst others.

“We have successfully broadened our modu- lar plant technology offering from our traditional focus on DMS for diamond processing to provide modular solutions, incorporating complete flow sheets, for processing a range of commodities. We use different processing technologies, such as solvent extraction, ion exchange, electrowinning or gravity concentration, to design a robust plant that optimises the balance not only between capital expenditure and operating expenditure, but also with regard to process efficiency,“ notes Tenova Bateman Technologies MD Albert du Preez.

For example, “using ultrahigh DMS technology for beneficiating iron-ore, one can increase the densities at which separation can be achieved (above 4.2 g/cm3). This will potentially enable significantly higher yields to be achieved at the same product grades, when compared with jigging technology, owing to the high separation efficiencies that are possible”, explains Du Preez.
The Tenova Bateman Technologies modular plant is being supplied complete with feed, product and waste handling arrangements.

The modular plant concept is particularly suited to the mining environment in Africa, meeting the needs of both the major mining houses and the junior players mining smaller deposits, both of whom are looking for a quick return on investment in this volatile climate, adds Du Preez.

“The quickest way to deploy a processing facility is the modular way, which makes them ideal for small- to medium-scale, rapid start-up operations in remote regions, as are typical of Africa’s mineral-rich countries,” explains Du Preez.

An entire modular plant can be supplied within six to eight months, which includes all components, such as the pumps, screens, cyclones, flotation cells, ion exchange (resin-in-pulp, NimCix and fixed-bed columns) and solvent extraction equipment.

In addition, the modular plants are built, erected, precommissioned, disassembled and packed into containers at the factory in South Africa, after which they are trucked to site in Africa, where they are easily reassembled, requiring minimal civil works.

“This is particularly beneficial in remote regions where access for heavy construction equipment and the availability of skilled labour may be challenging.

Further, before the plant leaves for its final destination, it has already been commissioned so there are no surprises on-site,” Du Preez explains.

While about 50% of the modular plants Tenova Bateman Technologies now supplies are for commodities other than diamonds, the diamond industry remains an important market in Africa and globally, notes Du Preez.

As an example, Tenova Bateman Technolo- gies has successfully completed a contract to integrate and supply a second front-end module for a diamond plant, in sub-Saharan Africa. This is just one of a number of project awards from operations in sub-Saharan Africa over the past two years, which include the supply of 110 t/h and 150 t/h modular diamond processing plants.

“The project to supply the second front-end module was completed in March, this year, and has increased the ore-processing capacity from the existing 200 t/h to 400 t/h,” notes Tenova Bateman Technologies’ Modular Plants GM Ockert Kotze.

“The first-stage contract was signed in July last year and was completed on time and within budget. The second-stage contract was signed in August last year, which resulted in the new module having sufficient capacity to process 400 t/h through the ore-receiving bin and apron feeder,” says Kotze.

He states that the 200 t/h scrubber section, with a degrit module, will match the existing 200 t/h scrubber and screening section.

“The scope also includes the in-plant conveyors and the modifications to the existing conveyors and bins, which enable the handling of ore to and from both scrubber sections,” he says.

Further, Kotze notes that the first stage focused on the engineering study, detail, design and procurement of long-lead-time equipment.

“The second stage involved the procurement of the balance of equipment and the fabrication, pre-erection and commissioning of the new module. The fabrication of equipment and structures started well within schedule, as did the pre-erections,” he adds.

In other potential diamond processing projects in Africa, Tenova Bateman Technologies is discussing the possibility of applying the diamond-sorting equipment developed by Bourevestnik Inc of the Russian Federation, for which it has an agency agreement.

This agency agreement gives Tenova Bateman Technologies the capability to offer a comprehensive range of technologies to the diamond industry, covering high and low throughput X-ray sorting and grease recovery technologies, which are applied in fit-for-purpose combinations to meet the client’s specific needs, Kotze notes.

“The X-ray technology offers automated, hands-off diamond recovery systems that recover up to 98% of diamonds, depending on diamond characteristics,” he concludes.