Ferrometals process plants – track record
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information)
Construction of Titania Smelter Plant for CYMG in China
Construction of the 85,000 t/yr TiO2 slag smelting plant designed by Bateman Engineering, together with the local Kunming Design Institute, for the Chinese Yunnan Metallurgical Group (CYMG) is well underway.
Ferroalloy processing expertise showcased at INFACON XI
Bateman Engineering showcased its ferroalloy processing expertise at INFACON XI, the international ferroalloys congress, held this year from 18 – 21 February, 2007 in New Delhi, India.
New
furnace feed system for Tubatse Ferrochrome
Bateman Engineering has upgraded the furnace feed system at Billiton's
Tubatse Ferrochrome plant in Steelpoort, Mpumalanga, RSA. The previous
feed system comprised a number of conveyors feeding through the furnace
roof directly into the furnace, while the new feed system consists
of a conveyor feeding raw material to a new storage bin at a rate
of 150 t/h.
BATEMAN
rebuilds Transalloys No. 3 Furnace in 105 days
Highveld Steel and Vanadium Corporation commissioned its Transalloys
Furnace No. 3 at Witbank, South Africa in October 2005, following
a successful BATEMAN mini-rebuild that took just 105 days.
US$50m
contract for IFM's pelletising and sintering plant
BATEMAN has been awarded the lump-sum turnkey
(LSTK) contract to design and build a 400,000 t/yr pelletising and
sintering plant using Outokumpu's chromite-ore pelletising and sintering
technology for part of the new US$250-million International Ferro
Metals (IFM) ferrochrome plant.
Definitive
feasibility study for Shevchenko project
BATEMAN has been contracted by Oriel Resources plc for the definitive
feasibility study (DFS) on a ferronickel-process plant for the Shevchenko
project in Kazakhstan.
BATEMAN
joins forces with COMETVA SA to market the latest technology in electrode
columns for AC furnaces
BATEMAN has signed a collaboration agreement with COMETVA SA, providing
clients of both companies the option of utilising the new hydraulic
electrode-clamping device from BATEMAN, together with forged copper
electrode components, sold under the brand COFOR, from COMETVA SA.
This agreement therefore provides the industry with access, through
a single source, to the latest technology and improvements in electrode
columns.
Bateman
electrode column for UMSL, India
BATEMAN has been awarded a contract to supply an electrode column
to Utkal Manufacturing & Services Ltd (UMSL) in India for their
new 27 MVA submerged-arc, high-carbon ferrochrome furnace.
New
furnace electrode-clamping device offers improved process control
BATEMAN's new electrode-clamping device for furnace installations
offers the ferroalloy industry significant benefits, including no
lubrication required after installation and minimal maintenance; low
operator involvement; minimal wear on moving parts and much faster
slipping rates for better process control, compared to the previous
electro-mechanical drive units. An order for the new device has already
been received from an international client.
DC-smelting
study on nickel ore from Shevchenko, Kazakhstan
BATEMAN was contracted by Mintek to provide the engineering input
to a prefeasibility study for Oriel Resources plc on a ferronickel-process
plant for the Shevchenko project in Kazakhstan. The study was completed
successfully.
Ferrometals'
Furnace 4 upgraded to 60 MVA
BATEMAN has completed an upgrade of Ferrometals' Furnace 4 (F4) in
Witbank, RSA, for Newsam Pty Ltd (a joint venture between Samancor
and Poschrome) to increase the furnace's production capacity from
100 000 t/yr of ferrochrome to 125 000 t/yr.
SA
Ferrochrome exceeds criteria in performance tests
The newly installed furnaces and sintering plant at SA Ferrochrome
exceeded performance and design criteria in performance tests recently
completed by BATEMAN. In addition, following commissioning, monthly
targets were increased constantly.
BATEMAN upgrades ferrochrome furnace for Crometals
BATEMAN has completed the lump-sum turnkey upgrade of Furnace No.
5 at Samancor’s site in Witbank, RSA, and has increased its ferrochrome
output by 25 % to 125 000 t/yr of metal. Simultaneously, the cost
per ton of ferrochrome produced was reduced by improving the efficiency
of the furnace.
SA Chrome’s Ferrochrome Smelter
The new greenfields smelter, pelletising and sintering plant for
SA Chrome and Alloys Limited has been commissioned as a lump-sum turnkey
project by BATEMAN at Boshoek, some 20 km north of Rustenburg, North
West Province, RSA. The first metal was tapped only 15 months from
the receipt of the order.The plant has a design capacity of 235 000
t/yr of saleable charge ferrochrome from a blended feed of lumpy chromite
and chrome concentrate.
Ferroalloy processing
BATEMAN, through its subsidiary Bateman Titaco (Pty) Ltd, is a leader
in the design and construction of processing facilities for the production
of ferroalloys. With the largest reference list for this type of project
in Southern Africa, its ferroalloy processing know-how includes smelting,
upgrading of ore, pollution control, raw-materials handling, metal
casting, product handling, smelter utilities, sludge treatment, handling
and remelting of fines and extracting metal from slag.
BATEMAN’s well proven alternating current (AC) smelting process
has been installed on some of the latest and largest ferroalloy plants
worldwide with the lowest production costs, e.g. Hernic, Assmang Chrome
and SA Chrome.
First
tap of ferrochrome at SA Chrome
SA Chrome’s first furnace at the Boshoek site near Rustenburg,
RSA, was fired up on 9 June 2002, with the first tap of charge ferrochrome
being tapped on 13 June. By mid July, less than one month later, when
100 taps of metal had produced 2 800 t of saleable product, the furnace
had already been ramped up to a power consumption of 48 MW.
Safety on track at SA Chrome
On 28 February 2002, the site personnel installing the R700M turnkey
ferrochrome smelter for SA Chrome at the Boshoek site near Rustenburg,
RSA, celebrated the significant achievement of half-a-million manhours
without a lost-time injury.
New
ferrochrome smelter for Assmang
A consortium of Bateman Titaco and Outokumpu Engineering
Contractors Oy has supplied a new smelter at Assmang Chrome Division's
Machadodorp Works, Mpumulanga, RSA. The plant uses the latest technology
in agglomeration, sintering and preheating of the feed ore supplied
to the furnace, resulting in improved chromium recovery and a lower
consumption of kilowatt hours per tonne of metal produced. Furnace
stability and ease of operation during smelting are also enhanced.
TEMCO’s
ferromanganese furnace in Tasmania
The Tasmanian Electro Metallurgical Company (TEMCO),
which is part of Samancor, South Africa and located near Georgetown
in Tasmania, has awarded Bateman Titaco a US$1,8M turnkey contract
to refurbish its No1 furnace. The objective of the project is to increase
the operation period between relines.
SA
Chrome's ferrochrome smelter contract
Bateman Titaco has been awarded a lump-sum turnkey
contract by SA Chrome and Alloys Limited for its new smelter, pelletising
and sintering plant at Boshoek, some 20 km north of Rustenburg, North
West Province, RSA. The plant will be designed to produce 235 000t/yr
of saleable charge ferrochrome from a blended feed of lumpy chromite
and chrome concentrate. Importantly, Bateman Titaco was instrumental
in preparing the bankable feasibility study for the project and also
facilitated the off-take agreement for the ferrochrome product. These
aspects ensured that the client was able to raise the necessary equity
and loan finance for the project.
The
Hernic Ferrochrome project
Bateman Titaco Limited has engineered, supplied and constructed one
of the most sophisticated charge-chrome producing plants in the world
for Hernic Ferrochrome(Pty) Ltd. he state-of-the-art technology together
with the benefits of large-scale production have enabled Hernic to
improve its competition have advantage by improving the stability
of its furnace operation, increasing chrome recovery and saving energy.
Technology gives Hernic Ferrochrome the edge
Titaco Projects, a BATEMAN subsidiary, is currently engineering,
supplying and constructing one of the most sophisticated charge chrome
producing plants in the world for Hernic Ferrochrome (Pty) Ltd. The
process technology used combines Outokumpu’s ore sintering and
furnace charge preheating processes with a large closed type submerged
ore smelter designed by Titaco in collaboration with Hernic, Outokumpu
and Tanabe Corporation. It will be the largest furnace of this type
in South Africa.
Extracting value from ferro-alloy plant waste
Titaco Projects Limited, a BATEMAN subsidiary, has a complete waste
management system available to enable ferro-alloy plants to comply
with all environmental regulations. This will not only protect the
environment, but could extract value from those process streams previously
considered to be waste material.
Titaco
expands Hernic ferro-chrome production
Titaco Projects Limited, a BATEMAN subsidiary, has
been awarded a 200M turnkey contract by Hernic Ferrochrome for a third
charge chrome furnace near Brits, RSA. This will double Hernic’s
production capacity to 260 000 t/yr and place it within the top five
global producers of ferro-chrome (FeCr) and, more importantly, at
the forefront of low cost production by virtue of a new but proven
ore pre-treatment process.
