Professional Documents
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Globe
No. 79 1ST QUARTER 2010
John Ferreira, Executive Chairman.
his is the longest single flight conveyor system to be installed to date within Indian territory. It will transport bauxite from the mines to the new 4.5 MTPA alumina plant at a conveying rate of 3,135 t/hr. The system will comprise two single flight conveyors: a 14.5 km long and a 4.5 km long conveyor. The conveyor system has a drop of 250 m, passing through valleys, crossing several rivers and water bodies and several road crossings. In its total span of travel, the conveyor system has 45 crossings.
New Delhi
INDIA
Kolkata
Raigada
he conveyor system will be sourced via Bateman Engineered Technologies, part of the Bateman Engineering Group and a leader in materials handling, with the scope of the project covering design, engineering, manufacturing, supply, erection, testing, commissioning and performance guarantee testing. The contract has a duration of 29 months, at the end of which performance guarantee testing is expected to take place. The design and engineering phase is taking place at Bateman Engineered Technologies facilities in South Africa, with some of the conveyor components sourced from South Africa,
and the rest from reputed manufacturers in India. Bateman Engineering was awarded the contract due to its well established expertise in long distance conveyor technology as well as its competitive pricing. Two technologies were initially considered, overland trough belt conveying and cable belt, with the client selecting the former due to its many advantages in such an inhospitable and remote terrain. In addition, a major advantage of using trough belt conveying continued on page 2
t gives me great pleasure to congratulate three well-known members of the Bateman team on their new appointments within the Bateman Engineering management: Tollie Nel has been appointed Managing Director of our SubSaharan Africa business unit; Thys Greeff has been appointed Group Executive: Project Execution; and Michael Hughes, continued on page 2
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Senior Executive Appointments 3 4 Bateman Beijing Axis A China-Focused Global Procurement House
Worldwide demand for Japan Pipe Conveyors Front-line SHE continues good safety performance
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ACCOUNTABILITY, CUSTOMER FOCUS, COACHING & MENTORING, CONTINUOUS IMPROVEMENT AND TEAMWORK
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ue to the weak market conditions, new work awarded to the Group last year was dominated by smaller studies and maintenance type work. In addition, considerable attention was devoted to closing off our legacy projects. In December 2009, the Moma Minerals Sands Project in Mozambique, which proved to be a highly challenging contract for all concerned, was successfully handed over to the client, Kenmare Resources marking the end of Bateman Engineerings exposure to our legacy projects. The last few months have seen some significant project awards including, from India, a contract for the longest single flight conveyor in that country. In terms of ongoing work, the Midi project to build a 3 million ton uranium heap leach facility for AREVA Resources Namibias Trekkopje project is entering the commissioning stage. The engineering and procurement for the Maxi project is underway to provide
the 36 million t/yr heap leach facility. The provision of sulphuric acid facilities for DMSAs Ambatovy Nickel Project in Madagascar continues on track with construction more than 50 % complete. Other work continues successfully for our global client base, including Debswana in Botswana, TMSA in Brazil (see pages 8 9), Rand Uranium, Foskor and BHP Billiton in South Africa, Hindalco and Tata in India, and Southern Urals Nickels in Russia, amongst others. An important initiative this year is the Bateman Beijing Axis, a joint venture (JV) established between ourselves and THE BEIJING AXIS to leverage off Chinas status as a leading global supply base. We fully expect this JV to yield significant advantages both for Bateman
inally, I would like to thank Eddie du Rand, who left Bateman Engineering at the end of March 2010, for his dedication and commitment to the Group as CEO over the past challenging period. John Ferreira Executive Chairman Bateman Engineering N.V.
Executive Chairman of Bateman Engineering, John Ferreira (fourth from the left, at the Ambatovy Nickel site in Mozambique.
or further information, please contact Abhijit Gupta, Business Development Manager, India, on +91 803 048 5211 or email enquiries@bateman.com.
he multi million rand contract, which was awarded by Clyde Bergemann Africa (Pty) Ltd, covers the design, supply and commissioning of the fly ash handling equipment for six fly ash storage silos. The contract, which will be carried out in two phases, was won against wide opposition, due not only to the competitive pricing but also to Bateman Engineered Technologies niche technology and extensive track record in fly ash handling. The equipment to be supplied includes Bateman-IBAU inverted cones for the silos, Bateman-IBAU aeration pads powered by blowers, as well as Bateman-IBAU control valves and airslides powered by fans to discharge the fly ash from the silos to the conditioners. All the associated piping and valves will also be supplied by Bateman Engineered Technologies and sourced from local, South African suppliers. Bateman Engineered Technologies provided the silo dimensions in accordance with the fly ash handling equipment that will be provided. The silos, which receive fly ash from the power station boilers, each have a storage capacity of 3,700 t, with each airslide discharging at a rate of 220 t/hr to its respective conditioner. The contract commenced in 2010, with Phase 1 (the ash handling equipment for Silos 6, 5 and 4) due for completion in November 2010, with commissioning in February 2011, and Phase 2 (Silos 3, 2 and 1) due for completion in February 2011, with commissioning in February 2013. Medupi power station is South Africas first new coal-fired power station in more than two decades and will have a capacity of 4,800 MW by the time its last unit is commissioned. ateman Engineered Technologies has been responsible for a number of fly ash handling systems since the early 1990s with systems supplied to, amongst others, CLP in Hong Kong and Ash Resources in South Africa, through to the most recent systems for Ulula Ash in 2008 and Sephaku Ash in 2009,
both in South Africa. IBAU, with which Bateman has a long standing
or further information, please contact Warren Hendrikz, (Manager, Cement & Pneumatics) at +27-11-201-2300 or email warren.hendrikz@bateman-bet.com.
Medupi
Johannesburg
SOUTH AFRICA
The Bateman - IBAU ash-classification plant in Hong Kong for CLPs Castle Peak Power Station converts waste fuel ash into valuable, classified, PVA at a rate of 170 t/hr.
INDIA
Hospet
Bangalore
he 2.5 m wide jig, a Bateman-Apic 17 jig, has three compartments and two shaft gates, and is the first jig to have been supplied to the iron ore sector by Bateman Engineering. Before the award of the contract for the design, procurement, fabrication, supply and commissioning of the jig, the suitability of the Bateman-Apic jigging technology for this application was proved in test work. This showed good grade and recovery, well within the expectations of the client. The
jigged material in an economically feasible residence time. The technique applies the ASTRAD (Advanced Stratification Transport Rate And Diffusion) jig-process model, which, amongst other valuable features, has the ability to determine improvements in jig yield as a function of jig size and feed rate. It can also determine the range of yields achievable over an ore body that has a variable but known washability (density distribution), including ore blends.
The BatemanApic jigging plant in India.
the recovery of ferroalloys from slag, coal washing and the washing of wastes. They are supplied as permanent-fixture processing facilities and modular process plants. Pilotscale units are available for processdevelopment testing. Bateman Engineering has, over the past few years, made considerable
CAD rendering of the Bateman-Apic jig with shaft discharge eliminating the need for a bucket elevator.
percentage iron in the product varied between 64.5 % and 65.5 %, with an iron recovery of 80 % and an average mass recovery of 72 %. In addition to this, the jig could recover an additional 16 % by weight as middling product at a grade of 47 %, which would be utilised by the client in future. The test work utilised a unique technique developed by Bateman Engineering for predicting the process performance of industrial-scale jigs by mathematically modelling test results from laboratory-scale air-pulsed jigs. The technique thus permits, with far greater confidence than was previously possible, the selection of industrial systems that will provide an acceptable separation of the components of the
he Bateman-Apic jig is able to handle a wider range of particle sizes than standard jigging equipment, and the density of separation can be much higher than is possible using dense media separation. The JigScan controller, which is supplied as a standard item with the Bateman-Apic jig, enables stable operation with very dense materials and with varying feeds and increases separation efficiency, particularly with difficult materials such as fines and near-density material. Bateman-Apic jigs offer a costeffective solution to the processing and upgrading of iron ores. However, as well as being suitable for the upgrading of both metallic and nonmetallic ores, they are also applied for
enhancements to the jigging processes, systems and design, taking into account feedback from clients and from collaborators, including the South African state-owned minerals research institute, Mintek. For example, the jigs feature a specially developed fines gate to minimise the back mixing of fines before discharge which, together with the JigScan system, has overcome the problem experienced worldwide in the handling of fine ferrous ores.
or further information, please contact Johan Coetzee, General Manager, Gravity Separation, on +27-11-899-8293, or email enquiries@bateman.com. Bateman Globe 79 1st Quarter 2010
Tollie Nel
Managing Director: SubSaharan Africa Business Unit
tolle.nel@bateman.com
well known figure in the South African mining sector, Tollie joined Bateman Engineering in 2001, holding key positions in the Group within its South African and international operations on both the business development and business management sides. As a result, he brings to the position not only his extensive experience in the mining industry in the operational and consultancy sectors, but also an in depth understanding of the company and the engineering contracting business. Tollie commenced his career with 10 years experience on gold and platinum mines with JCI, moving to Gencor Engineering & Technologies as a Consulting Mechanical and Electrical Engineer, and later as a Project Manager for Mineral Processes and Impala Platinum. Following this, he moved to an international consulting firm, ultimately as regional director for project and construction management. Positions he has held within the Bateman Engineering Group include, most recently, Managing Director of the Australia & South-East Asia business unit. Tollie Nel holds a BSc MechEng and is a registered professional engineer.
Thys joined the Bateman Engineering Group in 2005 as General Manager, Project Execution, having had extensive overseas and local engineering, construction and project management experience. He has worked for a number of multinationals including Union Steel Corporation, Sasol, Lurgi and ABB Lummus, in countries as diverse as South Africa, Malaysia, Singapore, Thailand, China, Germany and the USA. Thys holds a BSc Eng (Chem) and is a registered professional engineer.
Tom Fraser
Chief Business Development Officer
tom.fraser@bateman.com
Michael Hughes
Managing Director: India Business Unit
michael.hughes@bateman.com
Thys Greeff
Group Executive: Project Execution
thys.greeff@bateman.com
hys Greeff takes up his new position within the Bateman Engineering
ichael Hughes brings to his new position extensive general and project management experience, having recently successfully project managed a contract to provide sulphuric acid facilities for the mammoth Ambatovy Nickel project in Madagascar. This project marks an
om joins Bateman Engineering from the international, JSE listed engineering and contracting group, Murray & Roberts Limited, where he was Group Brand Executive. He played a major role in the branding process as a critical component of rebuilding Murray & Roberts (including some 30 operating companies internationally) to the high performing company it is today. A well respected figure in the industry, Tom has more than 27 years strategic marketing and brand management experience in the industrial, manufacturing and engineering contracting environments, locally and internationally. Tom is a past lecturer at the Unisa Graduate School of Business Leadership (GSB) and is a Cum Laude graduate of the Unisa (GSB) Advanced Executive Program (AEP). Tom is responsible for leading and co-ordinating the business development initiatives throughout the Bateman Engineering Group.
Bateman Engineering N.V. and THE BEIJING AXIS China Sourcing Unit are pleased to announce the formalisation of Bateman Beijing Axis, a Chinafocused procurement business that will assist industry on a global basis benefit from the optimised cost-effectiveness, delivery times and quality available when sourcing from China for capital projects, equipment and commodities.
ateman Beijing Axis, established as an equity joint venture (JV) between the two parties, provides services in three areas:
I procurement from China for Bateman Engineerings projects across the globe; I procurement for independent external clients across the globe and predominantly in the mining and resources; industrial, manufacturing and engineering; and power and infrastructure sectors; and I bulk commodity procurement, marketing and trading on behalf of both bulk commodity producers and users.
through to procurement that may require intricate project management, complex, technical design and engineering, and product development and testing. At the same time, the company also supports Chinese firms that are looking at global sourcing. Bateman Beijing Axis brings together the complementary skills and knowledge of both entities to create a unique source of expertise available to clients on a global basis, says Chief Executive Kobus van der Wath. Executive Chairman of Bateman Engineering, John Ferreira commented: The combination of Bateman Engineerings project management,
Kobus van der Wath, Chief Executive of Bateman Beijing Axis.
ervices are supplied across the supply chain from procurement needs analysis; to supplier identification, evaluation, prequalification, selection and negotiation; contract management; QA/QC; and expediting and logistics. In addition, services are available for the sourcing of standard off-the-shelf equipment right
leading process engineering and overall technical capability with THE BEIJING AXISs extensive China sourcing experience and knowledge is further enhanced by both entities established networks, supplier databases and execution track record. Bateman Engineering and THE BEIJING AXIS China Sourcing Unit have
both been independently providing China sourcing services for the past eight years, resulting in a comprehensive and tested sourcing capacity. Since its inception in 2009, Bateman Beijing Axis has already developed a significant procurement project track record in its own right in the areas of large complex capital projects, equipment and consumables, strategic raw materials, components, finished goods and services. Bateman Beijing Axis has a multinational management and staff contingent, made up of qualified engineers, senior sourcing consultants and mining specialists all with recognised China knowledge and sourcing experience. The firm works with international clients from its offices worldwide in China, India, Australia, Russia and South Africa. The Executive Chairman of Bateman Engineering, John Ferreira, serves as the Chairman of Bateman Beijing Axis, while the Founder and Group Managing Director of Bateman Globe 79 1st Quarter 2010
HE BEIJING AXIS is a cross-border business bridge to / from China in three principal areas: Strategy, Sourcing and Investment. Since its establishment in 2002, the company has successfully worked with many international and Chinese MNCs across various sectors and industries, with a core focus on the Chinese mining and resources sector and on China's burgeoning industrial and engineering sector. THE BEIJING AXISs work is always cross-border supporting international firms as they act in unfamiliar territory in China, or supporting Chinese firms as they venture out and go global. THE BEIJING AXIS is organised along three synergistic crossborder China businesses: the China Strategy Group, the China Sourcing Unit and China Capital Advisors.
I Haiwei Huang International Marketing Coordinator, Bateman Beijing Axis Tel: +86 10 6440 2106 Mobile: +86 138 1068 0138 haiwei.huang@batemanbeijingaxis.com I Michele (Mitch) Cosani Manager: Johannesburg Office, Bateman Beijing Axis Tel: +27 (0)11 201 2482 Mobile: +27 (0)83 421 6626 michele.cosani@batemanbeijingaxis.com I www.batemanbeijingaxis.com
ateman Engineered Technologies has been contracted to supply a JPC system in a project award from TMSA Bulk Handling Technology (previously known as Tecno Moageira S.A.). The contract covers four JPCs with a total length of approximately 7 km for a new coal power station that is being developed in Brazil by Energia Pecm. This is the second contract for JPCs from TMSA. The JPCs pipe will be 600 mm in diameter, the second largest diameter supplied by Bateman Engineered Technologies. The JPCs are being designed to convey coal, with a maximum lump size of approximately
50 mm, at a rate of 2,400 t/hr. The longest JPC of the four is 2.5 km and the shortest is 1.2 km long. The power station is being developed near the Brazilian harbour of Porto do Pecm and some 60 km north of the city of Fortaleza in Cear State in Northern Brazil. The power station will be fed by imported coal arriving by ship at Porto do Pecm, which will be conveyed to the power station via a series of conveyors. The JPCs will receive the coal from a transfer station some distance from the harbour and convey the coal to the power stations stockyard. One of the major advantages of the
JPC technology to the client is its environmental benefits, as the totally enclosed conveying of the product for the major part of the conveyors travel will minimise any possible environmental pollution in this environmentally-sensitive coastal region. The fast track contract was awarded in October 2009, with the JPCs due for commissioning in November 2010. Bateman Engineered Technologies is responsible for the design of the system and the supply of the belt from Bridgestone, and will also assist with commissioning. TMSA is responsible for manufacturing and installation of the system, as well as developing the conveyor layout together with Bateman Engineered Technologies. In addition, TMSA is carrying out the surveying, civil works, gantries design and structural calculations, etc.
The JPCs will traverse both bush and sandy terrain. Far left shows the starting point for the JPC system, while left shows the location of the destination stockyard.
Belm
Alunorte Project
Energia Pecm
BRAZIL
Bateman Engineered Technologies is well advanced with commissioning expected early in 2010. The 700 mm diameter JPC was ordered by TMSA Bulk Handling Technology for a large alumina-production plant in northern Brazil. The conveyor, with a total length of 776 m and travelling at 2.75 m/sec, will convey 2,500 t/hr of alumina (Al2O3) from the plant to a ship out-loading station, located some distance offshore. The environmentally-friendly concept of the JPC means that the alumina will be carried within a closed pipe that not only protects it, but also prevents the alumina from
contaminating the surrounds. The JPC is being constructed on top and alongside an existing gantry housing several conventional belt conveyors. The client opted for a JPC because of space constraints inside the existing gantry as well as the ability of the JPC to be curved. This meant that the JPC would be able to fit into the existing plant layout without requiring any additional transfer points. In addition, one of the main reasons for using a pipe conveyor in this application is the environmental solution it provides for the transport of alumina, material that has high dust emissions. Bateman Globe 79 1st Quarter 2010
Pipe Conveyors
B
ateman Engineered Technologies was responsible for the supply of all of the engineering-design drawings and proprietary and specialised components, as well as the JPCs Bridgestone belt. TMSA is responsible for manufacture of the structures and some mechanical components of the JPC, as well as the installation and commissioning, under the supervision of engineering personnel from Bateman Engineered Technologies. Bateman Engineered Technologies has been supplying JPCs since 1984 with a track record that features nearly 60 installations.
ore information may be obtained from Peter Cheshire, Manager: Specialised Mechanical Equipment, on +27-11-201-2300 or email sales@bateman-bet.com.
The section of the JPC under construction on top and alongside the existing gantry at the alumina plant.
The section of the JPC that approaches the ship out-loading station, under construction. Tail end of a JPC conveyor where the material is loaded before the pipe shape is formed.
Pipe shape on carry and return sides is maintained by a hexagonal idler layout.
hile the global financial crisis of 2009 forced many businesses to seek ways of reducing operational costs, which in many cases affected the availability of resources for the management of safety, health and environment (SHE) in the work place, Bateman Engineering believes that protecting the safety and health of its employees and minimising the impact
of its activities on the environment cannot be compromised in any way. The evolution of health and safety practices from merely legal compliance to accepting SHE management as an integral part of the overall business management has meant a significant shift in the roles at the company from that the employees are playing to that of upper management in reducing or
he fact that the safety milestones on the projects were achieved despite, in most cases, the majority of the labour force being sourced from the local population, combined with congested work areas, reflects the commitment of all role players in training employees in safe work practices, supported by positive front line leadership on work sites. On the Ambatovy Nickel project, for example, the project management team
Bateman Engineering is pledged to zero lost time incident free projects, while still meeting its commitments to its clients.
Project Moma Mineral Sands United Manganese Kalahari Trekkopje Midi Blue Ridge Platinum Ambatovy Nickel Location Mozambique South Africa Namibia South Africa Madagascar LTI free man hours worked up to end of 2009 8,805,363 408, 039 540,983 491,470 (11 Jan 2010)
500,000
The latest safey milestone to be achieved on a Bateman Engineering project is 250,000 hours worked without a lost time incident on the Foskor Extension 8 De-bottlenecking Project in Phalaborwa, South Africa.
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safety performance
has involved all the Bateman Engineering and contractors employees in the SHE programme and is utilising a comprehensive approach to reducing occupational risk on site. At a recent site based contractors commitment to safety workshop, all site personnel pledged their continued commitment to safety, while an Industrial Theatre on safety was held on site in March 2010. The latter focused on a comprenesive approach to safety from responsibility for safety and creating and maintaining a safety focus mind set, through to the danger of safety complacency, correct use of personal protective equipment, working on a congested site, and prevention of light vehicle accidents, electrical incidents and falling objects. Both the Blue Ridge Project, an EPC contract to design and supply a 1,380,000 t/yr platinum group metals concentrator, and the Moma Minerals Sands Project, to provide an 85,000 t/yr minerals sands processing plant and associated infrastructure, were handed over to the respective clients last year. The 5,500 t/day sulphuric acid facilities for the Ambatovy Nickel Project continued to make good progress with more than 50 % of the construction activities on site complete. The Midi project to build a 3 million ton heap leach facility for AREVA Resources Namibias Trekkopjes uranium project in Namibia is being closed out with construction in the final stages of completion and commissioning about to commence. In addition, the engineering and procurement for the TrekkopjeMaxi project is currently underway for the 36 million t/yr heap leach facility. Phase 1 of the envisaged four phase UMK manganese project to provide crushing and handling facilities has been completed.
or further information, please contact Pieter Oosthuizen, Safety, Health and Environmental Manager on +27-11-899-2587 or e-mail pieter.oosthuizen@bateman.com
The sulphuric acid facilities construction team at Ambatovy Nickel in February 2010, Madagascar. Inset: The Ambatovy Nickel safety pledge.
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ateman Engineering runners Victor Mhlakaza, Sharon Eckhardt, Karen Claassens and Patrick Motaung represented South Africa along with teams from Transet in this years JP Morgan Chase Corporate Challenge Championship, which was held in Johannesburg on March 4, 2010. The four from Bateman Engineering were given the honour of competing in this years Championship, having won the mixed team category in last years JP Morgan Chase Corporate Challenge, run in South Africa. This Challenge is part of an annual series of public races hosted by JP Morgan Chase & Co. across the globe. This was the first JP Morgan Chase Corporate Challenge Championship to be held outside the United States, and featured the worlds 36 fastest corporate teams of last year from the Series 12 cities across five continents and six countries.
Bateman Engineering is the innovative solutions provider to the world of natural resources. With offices in Australia, Europe, Asia, Africa and the Americas, our global network can serve you effectively. Before you make a decision regarding your process facility, or if you wish to take a fresh look at your situation, contact us directly at the above address or at any of our offices around the globe.
Australia Bateman Australia & SE Asia, Brisbane Bateman Engineering, Belmont Delkor, Sydney Canada Bateman Technologies Corporation, Calgary Delkor, Vancouver Chile Delkor, Santiago China Bateman Beijing Axis, Beijing India Bateman India, Bangalore Delkor, Bangalore Netherlands Bateman Engineering, Amsterdam Russia Bateman CIS, Moscow Branch Delkor, CIS +61-7-3320-3333 +61-8-9365-9400 +61-2-9550-5111 +1-403-291-4815 +1-604-451-7767 +56-2-650-4700 +86-10-6440-2106 +91-80-3048-5211 +91-80-2839-2824 +31-20-502-2370 +7-495-787-1770 +7-495-787-1770 South Africa Bateman Africa, Boksburg Bateman Engineered Technologies, Bedfordview Bateman Sub-Saharan Africa, Boksburg Bateman Beijing Axis, Bedfordview Delkor, South Africa United Kingdom Delkor, Bristol +27-11-899-9000 +27-11-201-2300 +27-11-899-9111 +27-11-201-2482 +27-11-201-2300 +44-1761-417-079
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