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2009
– Comprehensive services for
nickel & cobalt producers
N ickel O re P rocessing & C obalt R ecovery
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Pyrometallurgy Hydrometallurgy
Project services
Ore conveying– Belt– Overland– Curved– Trucking– In-plant
Ore preparation– Materials handling– Crushing– Milling & fine grinding– Pre-concentration– Dewatering
– Heap– Tank– Autoclave
– New technologies– Liquid/ solidseparation
– Flash– Conventional– Tank cells– Column cells
Stacking
RAWMATERIALSSTOCKPILE
FEEDPREPARATION
FLOTATION
LEACH
ACIDPLANTS
Blending
Reclaiming
ENVIRONMENTALMANAGEMENT
Dust- & air-pollution control
Toxic emission control Closed-circuit processing Solid waste handling
Nickel ore processing
ROMORE
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– Re-pulping– Thickening &
density control– Pumping– Cycloning
– Au, Ag– PGMs
– Bag-houses– Scrubbers
– Electrostaticprecipitators
– Pulsedcolumns
– Reverse flowmixer-settlers
Alternatively:H2 Reduction
Alternatively:
Cobalt Salt Production
Cellhouses
– Small, manual– Semi-automated– Anode / cathode bags
– Peirce-Smith– TBRC– Top submerged
lance (Ausmelt)– Granulation
– Iron removal– Precipitation– Cementation
– Undivided cells– Divided cells (anode bags)
– Vacuum de-gassing
– AC arc– DC arc– Flash– Top submerged lance
furnace (Ausmelt)
CONVERTING
SMELTING
IMPURITYREMOVAL
PURIFICATIONSX & IX
COBALTELECTROWINNING
NICKELELECTROWINNING
BY-PRODUCTSRECOVERY
COBALTCATHODEDISPATCH
GAS
CLEANING
NICKELCATHODEDISPATCH
TAILINGSDISPOSAL
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Ore handling and preparation Materials handling
Bateman Engineering has the capability to design and supply materials handling systems to transport nickel-
bearing ores and tailings. All types of conveyor systems to move ore and tailings to, from
and within the processing plant.
Stockpile systems for the efficient, effective and economic
stacking, blending and reclaiming of ore and the safe disposal
of tailings.
Plants to process tailings and extract coarse material for use as
backfill.
Comminution
We design comminution systems that take into account the
specific requirements of downstream metallurgical processes.
Crushing Bateman Engineering has designed and constructed allforms of crushing circuits including in-pit, primary, secondary,
tertiary and quaternary crushing systems.
Grinding Circuits Our experience includes the design andconstruction of large autogenous grinding (AG) and semi-
autogenous grinding (SAG) circuits. We also have many rod
and ball milling references.
Fine Grinding We have utilised tower mills, stirred mills and
ISA mills for flotation concentrate re-grinding and are experiencedin the operational and maintenance requirements of equipment
essential for the development of efficient plant designs. The
technology has applications in sulphiding of laterite-generated
solutions and nickel sulphide leaching.
Pre-concentration
Physical separation processes can often be used prior to flotation to upgrade the flotation feed by making use of differences in the physical properties of ore and gangue minerals.
Dense-Media Separation (DMS) DMS is applicable to nickel
sulphide plants where Platinum Group Metals (PGMs) or chromiteare present or where the nickel sulphide ore has significant silicate
nickel unrecoverable by flotation. Bateman Engineering’s track
record includes DMS plants for many different applications.
Gravity Separation Bateman Engineering’s experience includesthe use of spirals to recover chromite concentrate from PGM
flotation feed and the application of jigs to recover metal from slag.
Magnetic Separation Bateman Engineering has been involvedin studies and projects incorporating the use of magnetic
separation to recover nickel from slag, as well as to concentrate
PGM from slow-cooled converter matte into a magnetic fraction.
Screening of Laterites In some cases screening can be used inbeneficiation of laterite Ni ores.
A pilot scale
jig in
operation.
DMS chromite processing plant, UAR.
Milling circuit at Hartley Platinum Mine, Zimbabwe.
50 t/h
modular
process
plant.
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Flotation and dewatering Flotation
During flotation, surface chemistry is applied to selectively recover valuable minerals or to reject gangue materials.
Flash Flotation In circuits employing multiple stages of milling,flash flotation cells are used to recover liberated mineral species
after each stage, in order to prevent overgrinding.
Conventional Flotation Bateman Engineering has manyreferences of plants using banks of conventional flotation cells and
supplies proprietary cells in addition to providing design and
installation services.
Tank Cells Large tank cells have become very popular andBateman Engineering has completed several such installations in
recent years.
Column Cells Our experience in flotation circuits includescolumn and Jameson cells. This experience includes the pumping
of high air content froths associated with fine grinding of
concentrates.
Reagent Plants Bateman Engineering has designed and installednumerous packaged reagent plants, e.g. Impala UG2 plant,
Lonmin, Anglo Platinum and Aquarius, either as stand-alone or as
part of concentrator plants.
Dewatering
Bateman Engineering designs and supplies the unit processes to dewater the flotation concentrate and tailings streams, before being transferred to the next process.
Thickeners Bateman Engineering has wide experience of the useof conventional, high-rate, ultra-high rate and paste thickeners to
dewater both concentrate and tailings streams.
Vacuum Filters Our experience extends to drum, disc and beltfilters on a wide range of projects.
Filter Presses Recessed chamber and membrane presses havebeen used successfully to generate concentrate cake for sale and
occasionally even dry tailings for dumping in arid locations. Theyare also widely used in base and precious metal refineries.
Continuous Pressure Filters Bateman Engineering has installedseveral horizontal-plate pressure filters at a number of different
metallurgical plants, including both concentrators and refineries.
The Hartley flotation circuit, Zimbabwe.
Bafokeng Rasimone Platinum’s Ultrasep thickeners, RSA.
The vacuum separators of the belt filter, Chambishi Cobalt,
Zambia.
A filter press in the Zn-SX plant at Chambishi Cobalt, Zambia.
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Nickel extraction – Pyrometallurgy
Bateman Engineering has wide experience of both pyrometallurgical and hydrometallurgical processes for nickel extraction.
Pyrometallurgical plants still process a high percentage of non-ferrous metal flotation concentrates, despite the advent of new hydrometallurgical treatment routes.Bateman Engineering has a number of references in pyrometallurgical plants for PGM operations where nickel is often a by-product and this process could potentially apply to a primary nickel process route.
SmeltingBateman Engineering has many electric-arc furnace plant
references. We have also been exposed to other technologies
such as flash smelting, Noranda and Teniente processes, andtop submerged lance furnaces. Bateman Engineering’s DC
furnace technology is also being increasingly applied in the
ferronickel industry.
ConvertingAs well as conventional Peirce-Smith converters, Bateman
Engineering has worked on top-blown rotary converter
installations and has been involved in several Ausmelt furnace
studies.
Peripherals
Bateman Engineering offers proprietary engineered systemsaround:
belt, chain and pneumatic conveyors
metal, matte and slag tapping and granulation
off-gas scrubbing
bag-houses and
electrostatic precipitators
We also build acid plants and have an exclusive licence
agreement for Sub-Saharan Africa with Noram Engineering
and Constructors, Canada.
The COSAC 40 MW DC-arc furnace, Zambia.
Converter aisle
at the Hartley
smelter,
Zimbabwe.
The largest-to-date Bateman-Elex electrostatic precipitator installed at
Impala Platinum’s Phokeng site, Rustenburg, RSA.
Rendering of sulphuric acid production plant for Ambatovy Nickel,
Madagascar.
Smelting tests
on Shevchenko
nickel ore in
Mintek’s
DC-arc furnace.
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Hydrometallurgical processes are gradually becoming more favoured than smelting for the treatment of ore,concentrate and mattes.
LeachingBateman Engineering has wide experience of base metal leaching
processes and designs to process ore, concentrate and smelter
mattes.
Heap Leach This experience covers varying environments fromlow to high elevation and arid to tropical climates. Projects aretaken from interpretation and management of column testworkprogrammes through to scale-up and construction.
Tank Leach Bateman Engineering has experience of many acid-
leach processes carried out in trains of agitated tanks. In thistype of plant, selection of materials is critical.
Pressure Leach Our strong process group experienced in
autoclave design has been used to develop high-grade sulphide
ore, concentrate and converter matte process routes. We have
designed circuits utilising brick- and titanium-clad autoclaves
operating at up to 240 °C and 47 bar.
Emerging Technologies Bateman Engineering has worked on
projects including bacterial heap leach and several bacterial
tank leach plants have been designed and constructed. We
have also investigated sulphide oxidation using microwaves.
We have experience of project investigations using various
novel, proprietary, leach processes and experience in applying
pressure leach to nickel flotation concentrates and other metals.
Residue and Impurity RemovalThe removal of leach residues and dissolved impurities withminimum loss of nickel is a critical step in most hydrometallurgicalprocesses.
Neutralisation and Iron Removal Between leaching and
downstream purification, it is often necessary to neutralise the
slurry or solution. This process is often coupled with ironremoval and we have extensive experience of such processes.
Residue Separation and Washing Our experience includescounter-current decantation (CCD), counter-current vacuumfiltration and filter presses.
Solution Clarifying It is important to clarify leach solutionsbefore downstream nickel recovery. Bateman Engineering canoffer their patented Pinned-bed Clarifiers or conventionalthickener-clarifiers for this duty.
Precipitation & Cementation Efficient dissolved impurity
removal is essential in most hydrometallurgical processes,especially nickel. We apply our experience in the industry todevelop precipitation processes that minimise operating cost
and maximise metal recovery.
7
Kasese Cobalt’s bio-leach tanks, Uganda.
Bulong Nickel’s autoclave, Australia.
Nickel extraction – Hydrometallurgy
CCD circuit at Bulong Nickel, Australia.
By-Product Recovery An important component inmany nickel projects, which Bateman Engineering can
offer, is the design of processes and plants to recovervaluable by-product metals including:
gold and silver
PGMs (platinum, palladium, rhodium, etc)
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Solvent Extraction and Ion ExchangeBateman Engineering has wide experience of solvent
extraction (SX) and ion exchange (IX) to remove various
impurities from solution streams.
IX Through an exclusive agreement with Mintek, Bateman
Engineering can offer traditional fixed-bed or fluidised bed
technology, as well as the novel resin-in-pulp (RIP)
technology. The Mintek application base combined with a
testwork capability enhances the delivery of effective
process solutions. Typical applications are:
removal of various impurities from base metal and zinc
refinery solution streams.
removal of copper, zinc and nickel from cobalt
electrowinning solutions.
trace nickel collection and / or cobalt, copper and zinc
removal from slurries using RIP. RIP can be successfully used to replace expensive solid-
liquid separations prior to metal recovery steps.
For environmental clean-up, RIP systems can:
clean effluent streams and recover trace elements
without the need for costly ultrafine filtration.
extract acid and recover metal from mine leach
solutions.
SX Bateman Engineering has wide experience of SX
processes and has a specialist Solution Purification Group
(SPG) offering SX / EW technology for several metals,including nickel and cobalt.
Bateman Pulsed Columns: a high-efficiency, cost-effective,
continuous contactor for extraction, stripping and scrub
applications in metal recovery systems. Benefits include no
degradation or loss of organic solvent, low operational and
maintenance costs, minimal crud formation, a small
footprint and reduced fire risk.
Bateman Reverse-Flow Mixer-Settler®: provides substantial
operational and performance benefits over the traditional
mixer-settler design and enables side-by-side orientation of
the pump mixers which reduces capital costs and providesimproved access for operators and maintenance. The
coalescence enhancement channel and other design
aspects provide higher process efficiencies and reduced
organic loss.
Electrowinning (EW)Bateman Engineering designs cellhouses of all sizes, from
small heap-leach operations to large-scale, automated systems
for nickel EW and purpose-designed cobalt EW circuits.
Electrolytic Cells Bateman Engineering’s redesigned cells
provide an improved catholyte distribution flow patternaround each cathode resulting in improved cathode quality.
The design can also accommodate anode bags and/ or a
close-capture aerosol / gas emission system, providing a safe
The solvent extraction circuit at Kasese Cobalt, Uganda.
Nickel extraction and purification
working environment, particularly important in the design
of nickel and cobalt EW circuits.
Cellhouse Layout Our designs provide low-cost operating
facilities for both manual- and automated-strip plants.
Attention to detail in materials handling allows operators to
focus on good operational practices that lead to efficient
metal production.
Alternative Metal Production Processes As an
alternative to EW, Bateman Engineering can design and
install nickel / cobalt hydrogen reduction circuits which
include all peripheral unit steps, such as nickel
briquetting and sintering.
EW cellhouse at Empress Nickel, Zimbabwe.
Construction of 10 Bateman Pulsed Columns for uranium extraction at
WMC Olympic Dam, Australia.
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The recovery of valuable cobalt metal is often a key requirement of copper and nickel processing flowsheets, greatly enhancing project viability.
We have considerable experience in this very specialised field.
Leach Cobalt is often recovered into solution together with
copper and / or nickel in the primary leach stage. Bateman
Engineering has also built a bio-leach plant for treatment
for cobaltiferrous pyrites concentrate.
Purification by Precipitation Cobalt solution streams are
often purified by precipitation, with various reagents,
before proceeding to metal production.
Solvent Extraction SX, employing several different organicreagents, is used to remove selected impurities and cobalt
itself from solution streams.
Cobalt recovery
Bateman Engineering utilises various simulation programs to perform front-end modelling of chemical and physical processes.
Steady-State SimulationWe have developed Limn, Metsim®, Aspen and Pyrosim modelsfor a range of unit operations commonly used in base metal
comminution, flotation, hydrometallurgy and pyrometallurgy
operations. We also use the JK-SimMet modelling package for
examination of comminution circuits.
Dynamic SimulationThe Windows-based package used for the dynamic simulation of
processes, SysCAD, models transient operating conditions, providing
upset analysis, surge verification and downstream de-bottlenecking.
When interfaced with actual control hardware, it becomes a time-
saving control system for debugging and an excellent training tool.
Finite Element Analysis (FEA) and Computational FluidDynamics (CFD)FEA and CFD are applied in the design of furnace components and
for the design of a wide range of other process and mechanical
equipment. We can determine the response of structures to loads
and the flow characteristics of fluids and gases without the need to
build and test costly prototypes and conduct lengthy field trials.
Engineering Design & DraftingWe use an extensive array of proprietary and in-house software to
develop cost effective designs. We use 2D and 3D drafting to gain abalance of cost effectiveness across the design office, fabrication
shops, construction site and operator training requirements and
apply several 3D-modelling packages.
Process modelling
CFD modelling of
particle tracking in a
slag-granulation sump.
CFD analysis of
temperature distribution
of DC-arc plasma jet.
Predicted temperature profiles in a CFM
element from a multi-
physics CFD analysis.
Cobalt EW at Kasese Cobalt, Uganda.
Ion Exchange IX is used to remove critical impurities
especially copper, zinc and nickel from cobalt EW circuits.
Electrowinning Cobalt EW is a difficult and specialised
technology, since cobalt does not electro-plate easily as
do copper, nickel and zinc.
The Bateman Solution Purification Group can offer uniqueprocess expertise in the important fields of SX, IX and EW
culminating in the production of high-quality cobalt metal.
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Nickel & Cobalt ProjectsProject Client Comp. DescriptionEl Boleo, Mexico Minera y Metalurgica 2010 Design and construction of 2,000 t/yr Co SX/ IX/EW circuit.Tenke Cobalt, DRC Freeport-McMohran 2010 Design and construction of 6,000 t/yr Co SX/ IX/EW circuit.Ambatovy Nickel, Madagascar DMSA 2009 Provision of sulphuric acid facilities producing 5,500 t/day acid.
(Estm)Goro Nickel, New Caledonia Inco Australia On- Supply of 21 pulsed columns for extraction, scrubbing and stripping
Management Pty going of Ni and Co.OMG Kokkola, DRC OMG Kokkola Chemicals, 2005 Basic engineering of EW section, for Cu leach/ EW/Co refining.
FinlandImpala Platinum BMR Expansion, Impala Platinum 2005 First of two phases to expand base-metals refinery.
South AfricaWestern Platinum Base-Metals Lonhro 2005 EPCM contract to extend base metals refinery to increase capacity of
Refinery project, South Africa smelter-matte input from 18 to 60 t/day.Norilsk NNPP, Russia Norilsk Mining Co 2002 Design fully integrated, multi-stage atmospheric and pressure leach,
purification, SX, EW (Ni/Co) sulphur-removal circuit piloting facility.COSAC cobalt project, Zambia Anglovaal Minerals 2001 EPCM contract to establish 40 MW DC-arc smelter for slag reduction plant;
first application of DC-arc technology and alloy atomisation to process cobalt.Chambishi Metals, Zambia Avmin 2000 Expansion of Cu/Co refinery and installation of new Zn-SX plant.Bulong Nickel, Australia Resolute Resources 1999 High-pressure leach, Co/Ni SX and EW.Kasese Cobalt, Uganda Kasese Cobalt Company 1999 Bacterial tank leaching, Fe, Cu, Ni removal with Co SX and EW.Bateman Pulsed Columns Various 1998/9 Provision of pilot pulsed column to various test laboratories
for Ni / Co separation.Hartley Platinum, Zimbabwe BHP Minerals Zimbabwe 1997 EPCM to establish plant to process 2.1 million t/yr of ore consisting of
and Delta Gold of Australia concentrator, smelter, base metal refinery and all surface infrastructure.Empress Nickel Refinery, Zambia Rio Tinto (Zimbabwe) 1996 EPCM contract to expand Ni/ Cu matte leach and EW toll refining plant.Lefkochrysos Platinum Complex, Lefko (Rand Mines) 1991 EPCM contract to establish 160,000 t/month concentrator, smelter,
South Africa base metal refinery and PGM refinery. Ni produced as by-product.
Nickel & Cobalt Studies (Post 1990)Project Client Comp. DescriptionRustenburg Base Metals Refinery, Anglo Platinum 2005 Expansion of refinery.
South AfricaShevchenko Project, Kazakhstan Oriel Resources plc 2005 Prefeasibility and definitive feasibility studies of FeNi process plant
based on DC-arc furnace technology.BSGR/DGI Gecamines GEC (BSGR & DGI) 2005 Refurbishment of Cu/Co concentrator and refinery.
Cu/Co studies, DRCImpala Refineries FEMS study Impala Platinum Limited 2004 Studies of additions to existing refinery to enable treatment of Ni and
– Refineries Co sulphides.Kolwezi Tailings, DRC Anglo Base Metals & AMFI 2002 Pre-feasibility and feasibility study of tailings leach SX and EW plant, to
recover Co and Cu.Goro Nickel, New Caledonia Inco 2002 Pulsed column testwork on site to separate Co and Ni.Norilsk New Nickel Refinery, Norilsk Mining Co. 2001 Feasibility study of 200,000 t/yr brownfield Ni refinery processing matte by
Russia leaching, precipitation, SX and EW.Kasese Optimisation, Uganda Normandy 2001 Optimisation studies to eliminate plant bottlenecks.
Zincor MRT Plant, South Africa Kumba Resources /Zincor 2001 Pilot-plant tests and feasibility study on removal of Co and Ni from Znsulphate solution by MRT.
Chambishi MRT Plant, Zambia Chambishi Metals 2000 Pilot-plant tests to produce and concentrate pure Co sulphate from impureleach solutions.
RBMR Pulsed Column Anglo Platinum 2000 Pulsed column tests on site to separate Co from Ni by SX using Cyanex 27.(BAC) Plant, South Africa
Tati Nickel Metals Plant, Botswana Tati/ Anglo Base Metals 2000 Feasibility study of a concentrate processing plant using pressure leach,Cu removal, Ni and Co SX, precipitation and EW processes.
Kristiansand Pulsed Column Plant, Falconbridge 2000 Pulsed column testwork on site to separate Co from Ni in chloride solutions.Norway
Tenke Fungurume, DRC BHP 2000 Study of oxide leach /SX /EW plant and infrastructure at Tenke to produceCu and Co metal.
Nkomati Metallurgical Plant, Avmin 2000 Feasibility study of flotation concentrator and refinery, plus surfaceSouth Africa infrastructure, to produce Ni, Cu and Co metal and PGM residue from
sulphide-ore feedstock.
Yabulu Nickel Refinery Expansion, QNI 1999 Pulsed column testwork to separate Co from Ni in ammoniacal media.AustraliaKalpini Nickel Laterite Project, Haron Resources 1999 Study of 2 million t/yr plant producing Ni and Co using beneficiation pressure
Australia leach, CCD thickening, hydroxide precipitation, ammonia re-leach, SX and EW.Ravensthorpe, Australia Comet Resources 1999 Review of laterite feasibility study.
Nickel/Cobalt track record Bateman Engineering has base metal plant references in minerals processing, smelting and refining applications dating back more than two decades.
Services have been rendered worldwide, ranging from prefeasibility studies through engineering, procurement
and construction management (EPCM) and lump-sum turnkey (LSTK) services for multi-million dollar facilities.
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COSAC cobalt project , Zambia Anglovaal Minerals 1999 Feasibility study on pyrometallurgical process for slag reduction plant project aswell as refinery including alloy leaching, impurity removal and Co SX / EW.
Abednego, Australia Abednego Nickel 1998 Study of laterite plant using pressure leach, CCD thickening, hydrogen-sulphide precipitation, oxygen re-leach, SX and EW.
Glenbrook nickel plant, Glenbrook Nickel Company 1998 Pre-feasibility study of DC-arc carbothermic reduction of FeNi fines.North America (owned by Cominco)
Marlborough, Australia Lagoon Hill Nickel Resources 1998 Study of laterite plant based on Bulong process.Kakanda, DRC IPRC 1997 Testwork and multiple studies plus commencement of basic engineering for
tailings retreatment project to produce refined Cu and Co.Ruashi Etoile, DRC AMFI 1997 Study of oxide sulphide treatment plant to produce Cu and Co.Palabora Slag Reduction, Rio Tinto 1996 Feasibility study of slag reduction plant using Ausmelt technology to
South Africa produce Fe / Co / Cu alloy for sale.Nkana Cobalt Refinery Expansion, ZCCM 1996 Study of leach and purification plant to process Fe/ Co alloy generated by
Zambia slag reduction.Stillwater Expansion, USA Stillwater Mining Company 1996 Pre-feasibility and feasibility study of tailings leach SX and EW plant, to
recover Co and Cu.
The Crocodile River plant
in 1988. The furnace is
under construction.
At Marlborough a fully
integrated heat and mass
balance was done across all plant areas. This is
believed to be a first for a
new laterite nickel project.
Constructing the Bulong
Nickel plant, Australia.
The pulsed-
colum
demonstration
plant at the
Goro Nickel site,
New Caledonia.
Resin-in-pulp
pilot plant.
The Hartley Platinum
plant consisted of an
integrated minerals
processing, pyro- and
hydrometallurgical
complex in a remote
location. Nickel is
produced as a
by-product.
A 3D model of
the Goro Nickel
primary SX plant,
New Caledonia.
Avebury Nickel,
Australia.
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Bateman Engineering has established a focused niche in developing regions with evolving economies where clients are faced with a daunting web of technical,financial, commercial, political, logistical and cultural difficulties in bringing their ventures to reality.
We offer our clients project management capabilities which can
cope with these difficulties in the exploitation of wealth-creating
products like copper, lead, zinc, cobalt, nickel, aluminium,
platinum-group metals (PGMs), diamonds and gold.
Our track record of more than 3,000 successful projects in many
industries covers nearly 70 countries.
Bateman Engineering has a global infrastructure targeted to serve
its markets in Africa, the Americas, Australia, Asia and Europe.
Bateman Engineering is an ISO 9001-2000 certified company.
Bateman Engineering’s commitment to executing its business in a responsible manner goes beyond mere policy statements and procedures.
We are proud of our safety and environmental record on projects
in harsh locations internationally and make strenuous efforts to
encourage a positive attitude to these issues by all personnel on aproject site.
Safety, Health & the Environment (SHE) is an integral part of the
Bateman Engineering management system and our SHE policy
guides our operations in a way that is safe and without risk to
health and the environment. The responsibility and commitment
expected from our employees, contractors and customers are
clearly defined, not only to accord with the statutory
requirements of the country we are operating in but, more
importantly, to minimise the trauma and the cost caused by
workplace injuries.
We strive for zero injuries with a zero tolerance for unsafepractices.
Global presence
Safety, Health, Environment & Human Resources
The tank farm of the Chambishi belt-filter plant, Zambia.
Tapping slag from the DC furnace at Chambishi Metals, Zambia.
Bulong
Nickel
plant,
Australia.
– process plants that work
Bateman Engineering N.V.Amsteldijk 166, 1079 LH Amsterdam, Netherlands
Offices in Africa, the Americas, Australia, Asia and Europe
Web: www.BatemanEngineering.com
Email:[email protected]
Or consult our website for contact details of your nearest Bateman Engineering office