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Post Taphole Processes
Handling molten materials safely and effectively
BATEMAN and MINTEK have formed a partnership, called Post Taphole Services, to pool their expertise
and experience in the processing of molten materials from the tapholes of furnaces. The combined
capabilities make this partnership a world leader in liquid-solidification processes, providing complete
process plants with the most up-to-date technology for the safe and effective handling of molten materials.
Solidification processes
The comprehensive range of processes available from Post Taphole Services for solidifying liquid metals
produces particles ranging from the smallest (atomisation) through granulation to larger lumps
(blobulation) to ingots (pig-casting).
Atomisation
Molten masses of metal may be dispersed into small droplets using a variety of means such as spraying
under pressure through a nozzle into different media, by pouring onto a rotating disc and by ultrasound.
The means selected will depend upon the material to be processed and the size (from a mean of about
10 µm to 1 mm) and shape of the solidified particles required.
Post Taphole Services offers pressure, ultrasonic and centrifugal atomisation in water, hydrocarbons,
gas and air, MINTEK Splatterjet and powder metallurgy. It provides a full range of capacities and product
sizes, with its principals having an impressive track record in the supply and installation of a wide range of
flexible technologies.
BATEMAN also represents Atomising Systems Limited (ASL) of Sheffield UK for the ASL-Atomisation
systems in sub-Saharan Africa, maintaining the high standards set by ASL and required by industry. ASL
has successfully completed over 100 atomisation projects in more than 29 countries, often repeat business
from the same clients.
Matte granulation
Systems are supplied which safely granulate molten mattes. They ensure that the mattes are introduced
into the granulation jets in a manner which avoids the sudden generation of energy and maintains the
correct temperatures, pressures and conditions in the granulation bath. The technology was originally
developed by Stillwater Mining Company. The knowledge base is expanded by infusion of the latest
production-plant data to ensure that new plants embody the most up-to-date matte-granulation technology
and can operate safely and free of trouble.
The range of products supplied includes BATEMAN granulators and BATEMAN Stillwater granulators.
The equipment offered primarily uses water as the granulation medium, but where water supplies are
limited units can be supplied using a combination of air and water. The particles produced are generally
in excess of 1 mm in size, but this depends on the process. Mattes which have been granulated include
flash-furnace, electric-arc furnace and converter PGM's such as platinum, platinum / palladium and
copper / nickel mattes.
Slag granulation
All slag-granulation applications are covered in the product range. The equipment offered primarily
uses water as the granulation medium, but, where water supplies are limited, units can be supplied
which use a combination of air and water. Particles in excess of 1 mm in size are generally produced,
but this depends on the process applied.
The range of products supplied includes BATEMAN Launder granulators, BATEMAN Stillwater
granulators and high-tonnage slag granulators.
Metal-lump production
The metal-lump production systems produce solid particles of different sizes with sufficiently high
densities to effectively eliminate the risk of thermal popping when used in melting processes. Large
lumps of metal are generated, with very few fines, to facilitate the bulk handling of the product. This is
achieved by gently uniting a co-current stream of water with a stream of liquid metal / alloy so that the
surface tension of the molten metal / alloy serves to break it into large lumps as it solidifies.
The range of products supplied includes the BATEMAN INCO Lumpenalloy process, the MINTEK
Blobulator and the S-Gran. It has processed pig iron, mild steel, ferronickel and ferrochrome
(high-, medium- and low-carbon), charge chrome, nickel, stainless steel (300 and 400 series),
ferrosilicon (75 % silicon metal), ferromanganese (medium- and low-carbon) and certain high-carbon
grades and silicon manganese. The products are typically 6 to 10 mm thick and 20 to 50 mm across
and suited to bulk handling. They are heavy enough to fall rapidly through a molten-slag layer yet small
enough to dissolve quickly and reproducibly.
Pig and ingot casting
The BATEMAN pig- and ingot-casting machines produce products of a reliable shape, weight and quality
to suit individual customer requirements. The single strand pig-casting machines have been used to
successfully produce ingots of aluminium, copper, bronze, zinc, lead, ferro-aluminium, cobalt, iron, mild
and alloyed steels. The ingot-casting machine was specifically designed to produce ferromanganese
ingots of the appropriate size and is well suited for all slow cooling processes.
Particulate metal and slag dewatering
A full range of technologies is available for the effective dewatering of atomised, granulated and lump
metals, mattes and slags to enable them to be stored or handled and moved to further processing and
in the case of certain slags to be safely disposed of without contaminating the environment. The
product range includes BATEMAN static-dewatering systems, BATEMAN Spiro shaftless spiral
de-watering systems, BATEMAN dewatering-bin and -pond systems and bunkers, rake classifiers,
magnetic separators and vacuum filters.
Ladle tilters
Bateman ladle tilting devices are purpose designed for each application and ensure a controlled
discharge of molten metal and slag and a safe working environment.
In Bateman systems, computer simulation programmes generate pouring curves which are used to
derive tilting curves for the PLC to control the flow of molten metal or slag during pouring.
A comprehensive range of Bateman ladle tilting devices are available with hydraulic tilting or vertical
up and tilting movements.
Taphole equipment
The range of taphole systems available include those which have been developed in-house as well as
other specialised systems for all types of smelting furnaces in the ferrous, non-ferrous and ferroalloy
industries. The equipment meets all functional needs and tapping platform designs and handles
process-related demands such as long tapping times and regular metal, matte or slag flows. It is
simple, rigid, functional, reliable and maintenance free. Repeatable positioning on the taphole is
assured because of its high power.
The systems include hydraulic-taphole guns and drills and the Bateman Titaco taphole gun and drill.
Ladle metallurgy
A range of ancillary equipment and systems is available for the mechanisation of ladle metallurgy and
includes spreading and stirring apparatus, re-heating equipment including water-cooled and composite
lances as well as temperature monitoring and sampling. This equipment has been designed for ease
of operation and is a cost-effective alternative to static downstream practices.
Molten metal handling systems
A range of equipment and technologies for the pre-heating and de-skulling of launders, ladles and
tundishes is available for the optimisation of post tap hole practises. The available technology includes
plasma lances and Oxy-fuel burners thus providing a cost-effective means of reducing losses and
avoiding unnecessary manual cleaning and maintenance of post tap hole equipment.
Post Taphole Services maintains the high standards required by industry and has successfully
completed twenty five turnkey projects and twenty one service contracts both in Southern Africa and
abroad, often repeat business from the same clients.
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