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

Processing Iron OreTotal technology solutions across the mining value chain

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PROJECT SERVICES

� Consulting: ore-body, production and market evalua-tion to assess project viability.

� Test work supervision: Tenova Mining & Minerals’engineers arrange and oversee laboratory, pilot plantand on-site test work.

� In-house laboratory for cost-effective and promptscoping work, as a basis for structuring projectdefinitions.

� Pre-feasibility and feasibility studies.� Technology supply packages: incorporating basic

engineering design, process guarantees, proprietaryequipment definition and supply, and commissioningsupport.

� Process plant design and project management: allphases of the project, from inception through designand construction to commissioning, maximising thesuccess and profitability of the venture.

� Comprehensive spares and after-sales back-up.� Process audits to Best Practice guidelines.

PROJECT FINANCE

Tenova Mining & Minerals assists clients to structure,negotiate and secure optimal and cost-effective financialpackages for projects of all sizes.

FLEXIBLE CONTRACT STRUCTURING

� Reimbursable, fixed price or any combination to suitclient needs.

� Joint ventures on projects.

PROCESSING TECHNOLOGIES

� For beneficiation of iron ore, Tenova Mining & Mineralsliaises with suppliers and evaluates equipment to makeunbiased selections of the best equipment for the job.

� For stockpiling, materials handling, environmentalprotection and waste disposal, Tenova Mining &Minerals draws upon its comprehensive in-house andlicensed range of engineered technologies and selectsthe most appropriate equipment from all suppliers.

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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) iron ore to saleableproducts, integrating engineering and process know-how in development and optimisation of plant designs for iron ore,that meet global environmental standards. An in-house laboratory is available for scoping work.

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FEED PREPARATION PLANTS

Run-of-Mine (ROM) ore is prepared for processing byremoving unwanted material, eg vegetation, crushed andmilled and classified according to size in circuits compris-ing washing units, trommel screens, cyclones, crushers,mills, etc. Surge bins can be used to control the feed rate.

PRODUCT RECOVERY PLANTS

Valuable components of the ore feed are separated witha range of screening and separating techniques utilisingthe different shape, density, magnetic and surface proper-ties of the constituent minerals.

BULK MATERIALS HANDLING

Conveyor Systems With a thorough understanding of criteria affecting flow,Tenova Mining & Minerals selects systems which will notbe plagued by blockages.� Overland and curved conveyors move up to 10,000 t/h

over many kilometres.� Pipe conveyors protect the product and the

environment from mutual contamination.� Hydraulic conveying systems (dilute, medium, dense

and boosted dense phase).� En-masse (Redler) conveyors and bucket elevators

convey materials gently in dust-tight casings.� Slurry (pipe) conveyor systems.

Stockyard Systems� Stacking, homogenising, blending and reclaiming

systems to handle crushed ROM and final products.� Load-out systems integrated with a QA system and

the rail system.

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COMMINUTION

Tenova Mining & Minerals designs efficient comminutionsystems that take into account the requirements of down-stream metallurgical processes.

CrushingAll forms of crushing systems, including in-pit, primary,secondary, tertiary and quaternary crushing systems.

Grinding CircuitsTenova Mining & Minerals offers the services of a worldauthority in semi-autogenous grinding (SAG) circuits andis experienced in design and construction of largeautogenous grinding (AG) and SAG circuits.Tenova Mining & Minerals also has many rod-milling andball-milling references.

Fine GrindingTower mills, stirred mills and ISA mills for magnetic andflotation feed preparation.

SCALPING AND SCREENING

Tenova Mining & Minerals offers considerable projectexperience on primary, secondary and tertiaryclassification processes, consisting of� Screens, cyclones, spirals and shaking tables.� Wet-gravity circuits and water-handling systems.� Dry-mill circuits with feeders, mills and sand traps.� Feed hoppers, surge bins, conveyors, elevators and

transfer points.

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BENEFICIATION

JiggingApic Jigs offer a cost-effective solution to separatingvaluable products from waste material, processing andupgrading iron ores to effectively produce clean, saleableproducts.

Apic Jigs are available as� Permanent-fixture processing facilities and modular

process plants.� Pilot-scale units for process development testing. � J-tube for laboratory-scale testing.

Apic Jigs incorporate unique features for processinglumpy and fine iron ores� Proprietary JigScan control technology enables a

consistent pulse shape regardless of feed variations,reducing operator attention and improving controlover product quality.

� Specially developed fines gate minimises backmixing of fines before discharge.

� Adjustable weir gap and weir bar at slot gateimproves process performance of gate.

� Product extraction system utilises vibrating screensystem for increased control over product dischargeto increase product recovery.

Dense-Media Separation (DMS)Widely used and also proven in the diamond and coalindustries, Tenova Mining & Minerals’ DMS plants arehighly effective for iron ore processing and can treat ironore at ultra high separation densities.Tenova Mining & Minerals DMS Plants are available as� Permanent-fixture processing facilities and modular

process plants.� Pilot-scale units for process development testing.

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BENEFICIATION

Gravity SeparationGravity separation using a variety of settlers, tables andspiral concentrators.

SpiralsSpiral plants can be utilised on their own or in conjunctionwith TBS Separators for cost-efficient beneficiation offiner fractions.

TBS SeparatorsTeetered Bed Separation (TBS) is used to separate finemineral particles, by size and by specific density.

Magnetic Separation Tenova Mining & Minerals applies magnetic separationtechnologies to minerals with weak and strong magneticproperties, separating those with para-magnetic anddiamagnetic characteristics.The range covers� Wet and dry, low-intensity magnetic separation

(LIMS).� Wet, high-intensity magnetic separation (WHIMS).� Roll magnetic separators to process weakly magnetic

materials.� Induction-roll magnetic separation (IRMS) for

cleaning and concentrating dry materials.

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BENEFICIATION

FlotationTenova Mining & Minerals supplies flotation systemswhich optimise the process through close control of thesolids in suspension, air rates, froth position, etc.� Flash Flotation

In circuits employing multiple stages of milling, flashflotation cells recover liberated mineral species aftereach stage in order to prevent overgrinding.

� Conventional FlotationDesign of banks of conventional flotation cells andsupply of proprietary cells, in addition to design andinstallation services.

� Tank CellsTenova Mining & Minerals has completed severallarge tank celll installations in recent years.

� Column CellsColumn and Jameson cells, including pumping ofhigh air content froths associated with fine grindingof concentrates.

� Reagent PlantsPackaged reagent plants, either as stand-alone or aspart of concentrator plants.

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SCRUBBING AND THICKENING

Tenova Mining & Minerals designs and supplies unitprocesses to dewater flotation concentrate and tailingsstreams, before transfer to the next process.� Thickeners

Conventional, high-rate, ultra-high rate and pastethickeners to dewater both concentrate and tailingsstreams.

� Vacuum FiltersDrum, disc and belt filters.

� Filter PressesRecessed chamber and membrane presses togenerate concentrate cake for sale and dry tailings.

� ScrubbersScrubbers are used to process ores with clay contentsthat pose a problem further in the process flow.

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ENVIRONMENTAL PROTECTION

Tenova Mining & Minerals designs systems to preventpollution of the environment.

Air Cleaning� Reverse pulse bagfilters collect dust at high filter

rates with efficiencies of about 99.99 %.� Wet scrubbers.� Electrostatic precipitators for complex applications to

collect suspended solids.

Waste DisposalTenova Mining & Minerals’ tailings disposal systems cover� Slimes thickening and clarifying systems to remove

particulate solids from effluent streams and to clarifyand chemically treat water for recirculation to theplant. This reduces overall water consumption andminimises environmental pollution.

� Coarse tailings handling systems incorporatingdecades of design experience on environmentally-friendly installations worldwide.

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PRODUCT QUALITY ASSURANCE

Tenova Mining & Minerals designs state-of-the-art qualityassurance systems to ensure optimal utilisation of ore-bodies, which include� Laboratory work.� Sampling systems.� In-line process control systems.

PILOT PLANTS

Design of processes and plants to recover valuable by-product metals.� Cobalt from copper SX / EW circuits.� Uranium from leach circuits.� Gold, silver and PGMs from copper ER circuits.

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

www.tenovagroup.com

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