TENOVA is a worldwide supplier of advanced technologies, products and engineering services forthe iron & steel and mining industries.

Coal Handling & PreparationTotal technology solutions across the mining value chain

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PROJECT SERVICES

� Plant capacity� Main plants with capacities ranging from 250 to

1200 tph.� Modular and pilot plants ranging from 1 to 250 tph.

� Consulting� Ore-body, production and market evaluation

assesses project viability.� Concept to feasibility, including pilot-plant and test-

rig studies to assist in bankable documents.� In-house laboratory for cost-effective and prompt

scoping work, as a basis for structuring projectdefinitions.

� Project management� All phases of the project, from inception through

design and construction to commissioning,maximising the success and profitability of theventure.

� Comprehensive spares and after-sales back-up� Maintenance and refurbishment ensures peak

productivity.

PROJECT FINANCE

Tenova Mining & Minerals structures, negotiates andsecures optimal and cost-effective financial packages forprojects of all sizes.

FLEXIBLE CONTRACT STRUCTURING

� Turnkey, reimbursable, EPCM, lump-sum, fixed fee orany combination to suit client needs.

� Joint ventures on projects.

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Tenova Mining & Minerals is a total integrated solutions provider to the global mining, bulk materials handling andminerals beneficiation and processing sectors, offering innovative technological solutions and full process andcommodity knowledge across the mining industry value chain.

Tenova Mining & Minerals provides the full range of capabilities to convert run-of-mine (ROM) coal into saleableproducts, to integrate engineering and process know-how in development and optimisation of plant designs, and todeliver processing facilities that meet global environmental standards.

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PROCESS DESIGN

Identification of potential processing routes to optimiseyields of marketable products from the coal resource. The service is supported by� Laboratory facilities and close association with

external R&D organisations and specialist mining andenvironmental consultants.

� Utilisation of in-house coal washing predictioncomputer programs for a quick but comprehensiveanalysis of large sets of borehole or bulk sampledata.The analysis can be used for � Initial mine feasibility studies to predict plant yields,

using the geological database.� Investigation of equipment performance limits and

guarantees during the plant design stage.� Assessing plant acceptance test results.� Simulating unit operations such as screens, dense

media cyclones, larcodems and drums, jigs, gravitycircuits and flotation.

� Optimising total yield when products from differentseams and washing processes are to be combined.

� Technical expertise in� Technical due diligence.� Efficiency auditing.� Sampling process auditing.� Debottlenecking.

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COAL BENEFICIATION

Tenova Mining & Minerals offers a comprehensive rangeof capabilities and technologies to beneficiate coarse,medium and fine coals. This capability is underpinned bykey licence agreements.

Feed PreparationEnergy and cost effective size reduction systems to crushROM coal with minimal production of fines.� Jaw, gyratory and cone crushers.� Bradford breakers.� Rotary breakers.� Roll crushers.

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COAL BENEFICIATION

Separation TechnologiesTenova Mining & Minerals designs efficient comminutionsystems that take into account the requirements ofdownstream metallurgical processes.Separation technologies (specific gravity between 1.35and 2.1) are available for separation of raw coals.� Dense Media Separation (DMS)

� Permanent drum and cyclone plants up to2,000 t/hr capacity and higher.

� Transportable and movable modular systems from1 t/hr to 300 t/hr.

Raw coal, coarser than about 0.5 mm, is beneficiated bydense media.Construction and testing in well-equipped works andtransport and re-erection of modules greatly facilitaterapid commissioning of plants, making them well suitedto remote sites.Units can be used in tandem to increase throughput.

� JiggingApic underbed air-pulsed jigs handle large product-sizeranges and high feed rates for coal cleaning or deshaling.

� Product sizes up to 150 mm.� Unit feed rates of 20 t/hr to 800 t/hr.� Superior jig-scan pulse control system used in

conjunction with unique mechanical air valvedesign.

� Different jig designs and discharge mechanismsfor fine, medium and coarse coals.

� Granulated filtering bed for fine coal.� J-tube batch testwork with Astrad modelling for

feed material characteristics and jig sizing.� SpiralsHigh performance, high efficiency spirals treat coal ofsizes between 2.0 mm and 0.075 mm. Advanced troughprofiles enable the spiral plant to be shortened, with lessturns and space required.� Hindered Bed SeparationThe QVA Teetered Bed Separator either re-treats primaryspiral concentrates or pre-treats spiral feed, efficientlyproducing a low-ash coal and a mid-ash coal as needed.

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COAL BENEFICIATION

FlotationWhen specific mineral removal is required, beneficiationof fine coal is conducted in tanks or columns, using finebubbles to fit the characteristics of the coal.Feed material sizes range from ultrafine upwards.Round tank BQR flotation cells process all floatablevaluables including coal, in roughing, scavenging, cleaningand re-cleaning, unit and pilot cell applications.Unique benefits of the BQR Flotation Cell include� High shear forces due to the rotor / stator assembly

ensure better bubble-particle contact. � Simple process optimisation and start-up under load.� Stable froth – slurry interface and formation of quiescent

zone.� Minimised downtime and easy maintenance due to

“hooded” stator assembly.

� Maximisation of aerated volume to meet residencetime requirements.

� Purpose designed solids suspension.� Flotation cells range in size from 0.5 m3 (BQR5) to

150 m3 (BQR1500).

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MATERIALS HANDLING

Tenova Mining & Minerals designs and supplies materialshandling systems to convey, stack, reclaim, crush, grind,screen ROM coal and handle product and tailings.Materials flow technology controls segregation andoptimises utilisation of surge capacity in coal plants.Unique, in-house laboratory facilities and computersoftware are used to optimise mass flow behaviour andeliminate blockages in silos, chutes and bins.

ConveyingConveyor systems to move coal from the coal face towithin and from the processing plant and also deposittailings.� Curved overland conveyors in excess of 10 km long.� High capacity conveyors move more than 10,000 t/hr.� Pneumatic conveying:

� Medium (up to 80 t/hr) and dense phase (up to400 t/hr) positive pneumatic conveying.

� Dilute / lean phase negative pneumatic conveyingup to 30 t/hr.

� Vacuum systems for plant cleaning and productrecovery.

� Environmentally friendly pipe conveyors preventpollution of the environment.

� Dynamic analysis computer modelling.

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MATERIALS HANDLING

Stacking, Reclaiming and BlendingStockpile systems for efficient and economic stacking,reclaiming, homogenising and blending of coal and safedisposal of tailings.

� Linear and circular coal stockpiles to fit availablespace.

� Stackers with capacities up to 6,000 t/hr, includingfixed and movable yard conveyors and rail-mounted.

� Bridge and portal scrapers rated at up to 4,500 t/hr.� Design of rail foundations, drainage layout,

reticulation of services, control and instrumentation.

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MATERIALS HANDLING

Coal Load-Out StationsTenova Mining & Minerals’s load-out stations enable rapidloading of coal onto moving trains.� Computer controlled, flask loading operation.� Load rates of up to 5,000 t/hr.� Handling of random arrangements of rail wagons of

varying capacity and type.� Loading with accuracies within 0.1 % meeting most

countries’ statutory requirements.� Handling of variations in particle size and bulk density

of coal.

Dewatering SystemsTenova Mining & Minerals supplies efficient systems fordewatering coal processing streams and minimising waterusage.� High capacity vertical shaft centrifuges process up to

55 t/hr of fine coal between 2.0 mm and 0.063 mm.Low product moisture is achieved.

� Horizontal belt vacuum filters, used primarily fordewatering froth flotation concentrates, offersimplicity of operation and low product-cakemoistures.

� Press filters for ultra-low product moistures.

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ENVIRONMENTAL ADVISORY SERVICES

Tenova Mining & Minerals has decades of experience inenvironmental management, and committed to theprinciple of ZERO HARM, ensures that its coalprocessing facilities are environmentally friendly withminimal environmental impact, in compliance with localregulations and guided by ISO 14001.

Dust and Air-Pollution Control Systems installed on conveyor systems, crushers, etc� Scrubbers.� Electrostatic precipitators.� Bag filters / houses.� Cartridge filters.

Emission Monitoring and Control Ensures minimal impact on area surrounding theprocessing plant.

Solid-Waste MaterialRetained in secure tailings-storage areas.

Water TreatmentInnovative but proven plant and technology for treatmentof water encountered in the coal mining industry.� Acid mine drainage water.� Process effluent treatment.� Potable water treatment.

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www.tenovagroup.com

TECHINT GROUP

Tenova Mining & MineralsEmerald Parkway RoadGreenstone Hill, Ext 21 1609PO Box 7737Johannesburg 2000South AfricaPhone +27 11 899 9111Fax +27 11 899 2302enquiries.TMM@za.tenovagroup.com