Modular Plants
SGS Bateman provides modular processing plants to deliver reliable performance in challenging environments. These modular plants significantly shorten project lead times and reduce risks by arriving on-site ready for rapid installation. Each modular plant is first assembled and pre-commissioned at the factory. It is then marked, disassembled, and carefully containerised for transport.
This process simplifies on-site setup, minimising civil work and allowing for easy relocation.
The modules can function as independent facilities or seamlessly integrate with your existing mineral plant operations. They cover the entire processing flowsheet, from run-of-mine (ROM) reception to crushing, milling, and recovery processes, including gravity concentration, flotation, leaching, and adsorption.
With individual unit capacities ranging from 1 to 200 tonnes per hour (tph), throughput can easily be scaled up by adding more modules in parallel.
The robust design features proven equipment from trusted global suppliers, ensuring high-quality performance and reliable support.
Modular processing plants are used in the beneficiation and recovery of a wide range of commodities, including lithium, diamonds, coal, graphite, copper, magnesite, andalusite, chromite, platinum and gold.
Processing scope
Feed preparation
Primary & secondary crushing (jaw & cone), followed by milling using SAG/AG, ball or rod mills selected for the required duty & mobility.
Gravity concentration
Recovery of free gold in the sub‑2 mm fraction via centrifugal concentrators, with options for jigs on coarser fractions; downstream treatment via shaking tables or intensive leach reactors.
Flotation
Conventional, flash or combined flotation where gold is associated with sulphides; concentrate treatment using intensive leach with regrind, oxidation/roasting, or BIOX as appropriate.
Leaching/adsorption
High‑intensity cyanide leaching to shorten residence times, or conventional CIP/CIL designed for the modular philosophy.
Recovery & refining
Elution, carbon regeneration & gold room packages, where silver ratios dictate, CCD/filtration with Merrill–Crowe is available.
Tailings detoxification
Proven processes to reduce free cyanide to less than 50 ppm.
Modular plant solutions
Our modular plants are purpose-built and factory-assembled for a wide range of applications, from prospecting to full-scale mineral processing design. Delivered as self-contained units, they are pre-assembled, trial-erected, and pre-commissioned at the factory, then containerised for efficient transport and rapid on-site re-assembly. This process significantly reduces on-site work and shortens construction schedules and de-risking commissioning.
We offer standardised designs with configurable options for key commodities, including:
- Copper: Feed preparation, pre-concentration and flotation.
- Gold: Comminution, gravity concentration, flotation, leaching/adsorption (CIP/CIL/RIP), elution and electrowinning.
- Diamonds: Crushing, scrubbing, screening, DMS, and sorting.
- Coal, lithium and other industrial minerals: Crushing, DMS, and fines treatment and water recovery.
These designs are highly scalable, allowing you to start small to generate cash flow and then add modules for capacity or new process steps as your project evolves.
Modular solutions for dense medium separation plants
SGS Bateman supplies modular DMS solutions for pre-concentration and beneficiation across commodities, where mass rejection ahead of downstream processing delivers clear value.
Typical applications include:
- Removal of waste or low-grade material ahead of milling and leaching in gold operations to lift head grade and reduce energy and reagent consumption.
- Pre-concentration of base metals and industrial minerals before flotation.
- Front-end upgrading in remote or infrastructure-constrained projects where water, power and skilled labour are limited.
DMS modules are engineered for accurate cut‑point control, stable magnetite or ferrosilicon media circuits, and simplified media recovery. Skid‑mounted and containerised options enable fast mobilisation, straightforward tie‑ins to existing run-of-mine (ROM) and product handling, and easy duplication for higher throughput. Integration with screening, crushing and product dewatering is provided as part of a coordinated modular package.
Benefits to mining and mineral processing plant operators
- Condensed schedules: factory pre-assembly, trial fit and pre-commissioning remove site re-work and cut construction time; many plants achieve operation approximately within 20 weeks of order.
- Lower installed costs: minimal concrete and structural steel, reduced temporary works, and simplified logistics to remote sites.
- Operating efficiency: ergonomic layouts reduce maintenance; wear and corrosion-resistant materials and proven OEM components reduce downtime and spares holding.
- Process economics: front-end DMS and gravity options lift feed grade and reduce downstream power and reagent consumption; high intensity leaching shortens residence times and tank volumes.
- Risk reduction: standardised, proven modules de risk performance; SGS Bateman’s ISO 9001:2015 aligned quality system and global network underpin delivery and support.
- Containerised modules: each module is designed to provide weather protection and security in remote or challenging environments.
- Reduced skills burden on site: SGS Bateman provides supervision, commissioning and operator training.
- Spares and consumables: dispatched worldwide, supported by process experts for ongoing optimisation.