Centre of excellence provides internationally acclaimed leaching solutions

Bateman Engineering’s Centre of Excellence for Leaching provides the minerals resources industry with access to technology packages and historical proven designs for both primary and secondary copper leaching, complemented by leading expertise in the complete range of non-ferrous metal recovery processes.

As one of the world leaders in leaching technologies, Bateman Engineering has an impressive track record covering nickel, copper, zinc, cobalt, gold and uranium. For example, Bateman Engineering was a joint venture partner in the Sepon Copper Project that was internationally acclaimed with an Engineering Excellence Award from Engineering Australia. This achievement underscored the ability of Bateman Engineering to provide innovative solutions for its clients’ needs, solutions which in many cases have made previously uneconomic projects viable.

The copper technology packages provided by Bateman Engineering cover development, testing and marketing of the technologies for which Bateman Engineering has long term strategic agreements with the patent holders. These technologies include Galvanox™, the Sepon Process, incorporating total pressure oxidisation of sulphides, and the Mount Gordon Ferric Sulphate Leaching Process.

Galvanox™ is a process in which galvanically assisted atmospheric leaching of copper from chalcopyrite (CuFeS₂) occurs in a ferric / ferrous sulphate medium. The Sepon Process comprises the acidified ferric leaching of secondary copper minerals, followed by conventional solvent extraction and electrowinning incorporating a pressure oxidation circuit. This circuit generates the required sulphuric acid and ferric sulphate reagents from a pyrite flotation concentrate. The Mount Gordon Process involves the low pressure and temperature autoclave oxidation of chalcocite ore in a ferric sulphate medium, followed by conventional solvent extraction and electrowinning.

In addition, Bateman Engineering has an established record of applying proven processes, including tank, biological, heap and medium and high pressure leaching, to process ore, concentrate and smelter mattes.

The company’s experience in tank leaching processes covers cyanide and ammonia, alkali, acid, nickel / cobalt / PGM matte, zinc oxide ore and copper / cobalt oxide ore leaching. For example, the award winning Skorpion Zinc project in Namibia uses an atmospheric leaching process followed by solvent extraction and electrowinning.
For medium pressure leaching, Bateman Engineering has a strong process group experienced in autoclave design. This experience has been used to process high grade sulphide ore, concentrates and converter mattes. The company’s most recently installed autoclaves, designed to operate at 200 ˚C and 2.3 MPa, were recently commissioned at Uranium One’s Dominion Reefs project in South Africa for uranium leaching.

With regard to high pressure leaching, Bateman Engineering was a joint venture partner in the implementation of the Bulong laterite nickel project in which the leach process utilised a titanium clad autoclave designed to operate at 240 ˚C and 4.7 MPa.

The biological leaching technologies in which the Group is experienced include processes from BRGM, Mintek, Bactech and Goldfields. Examples of Bateman Engineering projects include Beaconsfield Gold in Australia, Penoles Copper demonstration plant in Mexico and Kasese Cobalt in Uganda.

Bateman Engineering’s experience in the design of base metal heap leaching covers varying environments from low to high elevation and arid to tropical climates. Projects are taken from interpretation and management of column testwork programmes through to scale up and construction of heap leaching projects. The track record includes Accha Zinc in Peru, Muliashi Copper in Zambia and Nifty Copper in Australia.

Bateman Engineering has also worked with a number of emerging leach technologies such as thiosulphate leaching, the Albion process, Activox, Intec, Platsol, and CESL.

Services are comprehensive covering: scoping studies; bench top and pilot scale testwork management, supervision and interpretation; prefeasibility and feasibility studies; support for detailed design, procurement and construction teams; conceptual flowsheet development to accommodate resources and reserves; preparation of technology supply, basic engineering and front end engineering packages; metallurgical support to existing leach operations; and process optimisation.

Proprietary software is used to assist in developing effective solutions for the clients, including programs such as Metsim® for process simulation and HSC chemistry thermodynamic analysis.
Bateman Engineering also has leading expertise in the entire range of non-ferrous metal recovery processes covering: materials handling; comminution, including crushing, grinding and milling; flotation – flash, conventional, tank and column cells; solvent extraction, including the supply of Bateman Reverse Flow Mixer Settlers™; electrowinning; smelting and roasting.

For further information, please contact John Turney, General Manager, Leaching, Bateman Engineering, on +61-8-9366-4900 or email john.turney@batemanengineering.com.au.

Bateman Engineering’s Centre of Excellence for Leaching recently participated at Expomin 2008, the leading mining trade fair in Latin America. With more than 900 companies represented at Expomin and over 60,000 attendees at the exhibition, Bateman Engineering showcased its expertise and services in providing technology driven leaching packages.

Linus Sylwestrzak’s presentation at the fair’s technical sessions highlighted Bateman Engineering’s ability to develop, test and market the Galvanox™ and Sepon Copper Processes, as well as other proven processes including tank, biological, heap and medium and high pressure leaching. The company’s competence to complement these leaching technologies with Bateman Reverse Flow Mixer Settlers™ and electrowinning processes was also highlighted. For a copy of the presentation please see www.batemanengineering.com or contact enquiries@batemanengineering.com.au.

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