Process Plant Design

Our expertise in minerals and metals processing extends from modular plants to brownfield upgrades and full-scale greenfield developments. With comprehensive EPCM capabilities, we support clients worldwide in unlocking maximum value from their ore bodies.

SGS Bateman specialises in innovative process plant design and engineering, helping clients enhance both the efficiency and financial return of their projects. With expertise in mineral processing plant design and hydrometallurgy, our process design solutions cover a wide range of commodities, including diamonds, industrial minerals, uranium, coal, iron ore, gold, platinum group metals, base metals and rare earths.

We provide expert support across the full project life cycle, from testwork and pilot programmes to feasibility studies and execution under proven management systems.

Our integrated solutions are tailored to client needs, covering process plant design, engineering, procurement, and construction through to commissioning and handover. We also offer flexible contracting models, including EPC, EPCM and LSTK.

We have the solution you need for any commodity

Gold

End-to-end gold processing solutions, from run-of-mine (ROM) feed or reclaimed tailings to finished bullion, covering the complete flowsheet. Our expertise spans both free-milling and refractory processing routes.

We design new gold processing plants and upgrade existing facilities to ensure the efficient production of bullion from run-of-mine ore.

SGS Bateman's capabilities cover the full spectrum of gold processing, including ore handling and preparation, refractory gold ore treatment, gravity concentration, leaching, leach-liquor recovery, CIL/CIP plant design, electrowinning, cyanide recovery or destruction, and bullion refining where required.

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Uranium

SGS Bateman is a leader in delivering engineered systems and uranium recovery process plant designs that incorporate all the unit processes required for the extraction of uranium from ores, including:

  • Feed preparation: comminution, thickening and agglomeration.
  • Pre-concentration: flotation, radiometric sorting and gravity separation.
  • Leaching: acidic and alkaline in tanks, heaps or autoclaves.
  • Solid/liquid separation: high-rate thickening, counter-current decantation, clarifying and filtration.
  • Uranium recovery: ion exchange, solvent extraction and uranium precipitation.
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Lithium

SGS Bateman has a proven track record in delivering lithium gravity plants of various sizes, adding value by helping clients achieve their quality, cost, and schedule objectives.

We provide comprehensive solutions for lithium and other battery minerals covering comminution, dense media separation (DMS), flotation, dewatering and hydrometallurgical processing.

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Rare earths

Rare earths are commonly associated with complex geological settings and often occur within other ore types, making their extraction into intermediates or individual elements both challenging and costly.

SGS Bateman has extensive experience in addressing such complexities, with expertise across ore sorting, pre-concentration, comminution, flotation, sulphation, hydrometallurgical processing, and product handling.

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Copper

SGS Bateman delivers cost-effective facilities for processing base-metal ores, built on strong technological expertise and extensive project experience in minerals processing, smelting, and refining applications.

  • Base-metal concentration: pre-concentration (DMS) and/or flotation.
  • Hydrometallurgical processing: treatment of primary and secondary copper sulphides.
  • Nickel and cobalt processing: refinery design expertise adds significant value in both simple and polymetallic applications.
  • Sustainable solutions: environmentally responsible base-metal processing.
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Zinc

We provide end-to-end solutions for converting zinc ore into saleable products, combining engineering expertise with process knowledge to design, develop, and optimise plants that comply with international environmental standards.

Our extensive experience covers the full zinc processing chain, including pre-concentration, comminution, gravity separation, flotation, leaching, solvent extraction, and electrowinning – delivered as part of a fully integrated mineral separation plant solution.

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PGM

SGS Bateman is the only independent contractor to have successfully installed concentrators, smelters, and base and precious metals refineries, covering the full spectrum of PGM processing from run-of-mine ore to final metal.

  • Comprehensive processing: ore handling and preparation, comminution, classification, pre-concentration, flotation, dewatering, smelting and converting, matte handling, leaching, ion exchange, solvent extraction, electrowinning, precipitation, and refining.
  • PGM and base-metal conversion: transformation of matte into copper and nickel base metals, as well as the six platinum group metals, platinum, palladium, ruthenium, rhodium, iridium, and osmium.
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Diamonds

SGS Bateman is a leader in supplying permanent and modular processing plants for exploring, sampling, recovering, processing and securely handling diamonds.

  • Cost-effective and well-proven technology for feed preparation, old dump re-treatment, dense-media separation (DMS), X-ray and grease-table diamond recovery, sort rooms and the secure handling of diamonds.
  • Comprehensive range of services across the entire diamond pipeline, from prospecting to operational mine support of mines.
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Iron ore

SGS Bateman provides state-of-the-art expertise across the full spectrum of iron ore processes, delivering cost-competitive processing facilities that comply with global environmental standards. Our capabilities include:

  • Feed preparation processes such as crushing, milling, scalping, and screening.
  • Beneficiation methods including jigging, dense media separation (DMS), gravity separation, wet high-intensity magnetic separation (WHIMS), and flotation – all integral to an effective mineral separation plant design.
  • Modular DMS and UHDMS plants.
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Why SGS Bateman

  • Due diligence and audits
  • Testwork programme design, sampling selection advice, mineral processing plant design modelling, and performance improvement on existing plants
  • Feasibility studies and cost estimates
  • Integrated EPCM delivery with process-first process plant design
  • Experienced in remote, logistically challenging locations
  • Modular or conventional plant options to match schedule, capex and operability goals
  • Safety and environmental stewardship embedded from concept to commissioning
Gold

We design, build, commission, upgrade, and detoxify gold plants, including heap leach, CIP/CIL, and refractory BIOX/roast processes.

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Uranium

We design, pilot and deliver uranium plants: heap/pressure leach, CCD/RIP/IX, SX and UO4/U3O8 precipitation.

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Lithium

We engineer hard rock and brine lithium flowsheets: DMS/flotation, roasting/leach, impurity removal, crystallisation.

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Rare earths

We develop REE flowsheets: beneficiation, WHIMS, acid/alkali leach, SX/IX separation, radionuclide control.

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Copper

We design, upgrade and deliver copper concentrators and SX/EW/refinery plants, including. POX and leach circuits.

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Zinc

We design and upgrade zinc plants: leach/purification, CCD/filtration, EW cellhouses, casting, and acid/roaster units.

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PGM

We deliver PGM concentrators, smelters and refineries: MF2 UG2, IX/SX/EW, secure designs and commissioning.

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Diamonds

We design, build and commission DMS and X-ray diamond plants, modular 1–350 tph to mega installations.

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