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MEI Online: Plant Operation News: Africa: November 24th 2005


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:: Metal-recovery Plant Upgraded for MultiServ

Bateman has completed a lump-sum turnkey project for MultiServ South Africa to upgrade a plant recovering traces of stainless-steel from furnace slag at the Columbus Stainless Steel plant in Middelburg, RSA. MultiServ is a division of the worldwide Harsco group.

The upgrade has increased the plant throughput substantially. The project involved installing a new primary crusher and screen, a manual picking station, new conveyor belts throughout the plant, a new steel-separating screen and a new primary screw classifier. A complete module for the dewatering plant, which matched the existing dewatering plant, was relocated from another MultiServ plant and a new hydraulic system was provided for the grizzly's tilt mechanism. Civil construction and structural work for the new plant included the foundation for a large rod mill which was relocated from Scandinavia.

Bateman was awarded the contract because it proposed using a superior process based on MultiServ's basic concept. The process involves screening the slag delivered to the plant at a rate of 75 t/h through a static grizzly stockpiling the lumps smaller than 50 mm. The larger lumps are recycled by cleaning in the manual-picking station to remove tramp iron and timber and then crushed to break the lumps.

Stockpiled material at a rate of 52 t/h is then rod-milled wet and screened and steel particles larger than 6 mm are returned to the Columbus steel plant. The smaller particles are passed on to a screw classifier to separate the more dense particles which are ball milled. The steel in the ball milled product is further liberated by passage through two screw classifiers in series and also returned to the steel plant. The less dense slag particles are dewatered using hydrocyclones, thickeners and filter presses and the water pumped back to the wet-milling plant.

This brownfields project in a fully operational facility involved the challenges associated with relocating and refurbishing second-hand equipment. It was, however, completed on schedule and the ramp-up was achieved within an exceptionally short period of time, the plant reaching nameplate capacity during the first run of the performance test.




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