SOUTH AFRICA'S FERRO ALLOYS INDUSTRY - PRESENT STATUS AND FUTURE OUTLOOK

  • Friday, September 21, 2018
  • Source:ferro-alloys.com

  • Keywords:South Africa's Ferro Alloys Industry
[Fellow]The present status of the industry, the factors that are impacting thereon and a view on its future outlook.

ABSTRACT

 

South Africa is a leading player in the international ferro alloys industry. Historical factors that have con- tributed to this dominant position include an abundance of natural resources and relatively low cost electric- ity. A number of relatively recent developments are potentially threatening this position. These include new legislation affecting the mining and minerals industry, a shortage of some types of suitable reductants, deple- tion of surplus electricity generation capacity with resultant threat of real escalation of electricity prices and pressure resulting from the recent strengthening of the South African Rand. The industry is addressing these challenges in a number of ways to ensure long-term viability. Some of these measures include investments in more efficient technologies that have economy of scale benefits and are less dependent on expensive reduct- ants and electricity. Local macro-economic impacts include new legislation regarding ownership of enter- prises, mineral rights and royalties on mineral sales, development plans for port and rail infrastructure, as well as initiatives to expand electricity generation and coke production capacity.

 

The fundamentals for being a successful ferro alloy producer are still largely in place for South African pro- ducers. Therefore the South African ferro alloy industry will remain competitive and is well placed for con- tinued growth in line with the international growth in ferro alloy demand. The industry should emerge leaner, more efficient and ready to respond to any future demands of the industry. This paper will cover the present status of the industry, the factors that are impacting thereon and a view on its future outlook.

 

1.    HISTORICAL PERSPECTIVE

 

The ferro alloy industry in South Africa can i.a. be attributed to the foresight of the late Dr. H. J. van der Bijl who was a pioneer in the exploitation of the mineral wealth of the country by the formation of African Metals Corporation (Amcor) Limited. The company was incorporated on 23 July 1937 and started production of pig iron and high carbon ferromanganese (HCFeMn) in a 10 ft hearth blast furnace in Newcastle, Natal. In 1939 a decision was taken to construct two electric furnaces for the production of ferro alloys in Vereeniging, Transvaal. The first 3 MVA rectangular furnace was commissioned on 15 February 1942 for the production of HCFeMn, followed by a second furnace on 23 April 1942 for ferrosilicon (FeSi) production. Shortly there- after, two 1,2 MVA tilting refining furnaces for the production of medium and low carbon alloys were com- missioned. The plant finally closed down on 29 March 1953. At that time it had produced not only HCFeMn, high  carbon  ferrochromium  (HCFeCr)  and  FeSi,  but  also  medium  and  low  carbon  ferromanganese  (M/ LCFeMn), medium and low carbon ferrochromium (M/LCFeCr), ferrotungsten (FeW), ferrotitanium (FeTi), lead (Pb), martensitic 13% Cr stainless steel, low carbon 18/8 austenitic stainless steel and mild steel. The plant was relocated to a site near Meyerton, Transvaal where production commenced on 11 April 1951. This plant is still in operation today and is known as Samancor Manganese’s Metalloys plant.

 

Highlights in the history of ferro alloy production in South Africa are summarised below.

•In  1918  Rand  Carbide  Limited  was  founded  in  Germiston,  Transvaal  for  the  production  of  calcium carbide and FeSi. The plant was relocated to Witbank in 1926 and in 1978 Highveld Steel & Vanadium Corporation Limited acquired the total issued share capital.
•In 1957 Assmang established the Cato Ridge Works (formerly Feralloys Limited) for ferromanganese production.
•Vanadium production started in 1957 in South Africa when Minerals Engineering of Colorado started producing vanadium pentoxide near Witbank, Transvaal. Anglo American acquired a majority share in 1959.
•Ferrometals became part of Amcor Ltd on 1 December 1959 when it purchased the entire share capital of Ferrometals Ltd from Wire Industries Steel Products and Engineering Company Ltd. At the time, Ferro- metals had two 7 500 kVA furnaces for FeSi production on a 950-acre site near Witbank.
•Transalloys was started in 1960 in Witbank as an integrated HCFeCr/LCFeCr plant, based on the Perrin process. During 1967, the plant was converted from ferrochromium to ferromanganese production. At the time Airco Alloys had a 40% share in the plant, the balance belonging to Anglo American. In 1976, Highveld Steel acquired the 65% stake in Transalloys, previously held by Anglo American.
•The origins of Middelburg Ferrochrome (now part of Samancor Chrome) can be traced back to the RMB Alloys Ferrochrome Pilot Project in 1963.
•Palmiet Chrome Corporation came about through the endeavours of John Hahn. The first furnace for the production of charge chrome (ChCr) was started up on 22 February 1963 at the plant near Krugersdorp. On 28 December 1983 the first DC plasma arc furnace for ferrochromium production was commissioned at Palmiet.
•In 1971 Feralloys Limited erected a ferrochromium smelter at Machadodorp for the production of ChCr and LCFeCr.
•Amcor and S.A. Manganese merged in 1975 to become Samancor Limited.
•The CMI plant of JCI at Lydenburg (now part of Xstrata) came into being during 1975 for the production of ChCr, based on the Showa Denko SRC process.
•Tubatse Ferrochrome was initially built as a three-furnace operation in 1975 as a joint venture between Gencor Ltd and Union Carbide Inc (USA). In the same year, the Union Carbide Inc. shareholding was taken over by Samancor, and in 1989 Samancor acquired the Gencor Ltd shareholding. During the years 1989-1990 the plant was expanded to five furnaces with the sixth furnace being built in 1996. The plant is situated in Steelpoort, Mpumalanga.
•Chromecorp Technology (Pty) Ltd was registered in October 1987and erected a furnace at Batlhako and later  two  furnaces  for  ChCr  production  in  Rustenburg.  In  April  1995  the  name  was  changed  to Chromecorp Holdings Ltd and the company was listed on the Johannesburg Stock Exchange on 23 May 1995. The company was delisted on 2 April 1998 and the full share capital was acquired by Sudelectra South African Holdings (Pty) Ltd. The name Sudelectra SA was changed to Xstrata South Africa (Pty) Ltd on 9 April 1999. Xstrata has become the largest producer of ChCr in the world with plants at Rusten- burg, Wonderkop, Boshoek, Lydenburg and the new plant near Steelpoort, Lion Ferrochrome.
•Hernic Ferrochrome was founded in 1995 for the production of ChCr, as a venture amongst Hernic (Pty) Ltd, ELG Haniel, Nippon Steel Trading and management. In 1996 the company commenced production on two 37MVA furnaces. Presently Mitsubishi Corporation holds the majority share of 53,2%.
•Purity Ferrochrome was started in Rustenburg in 1991 with two furnaces for ChCr production. It was taken over by CMI in 1993 and CMI in turn was taken over by Xstrata in 1998.
•ASA Metals (Pty) Ltd was established in February 1997 near Polokwane and is a 60/40 joint venture between EAMI (Eastern Asia Metals Investment Co. Ltd) and LEE (Limpopo Economic Enterprise). ASA Metals produces ChCr.
•South African Chrome & Alloys Limited ("SA Chrome") was incorporated in South Africa on 24 July 1987 as Southern Witwatersrand Exploration Company Limited and changed its name to SA Chrome in December  1999.  The  main  focus  of  the  business  is  the  ChCr  smelter  constructed  at  Boshoek. Subsequently, SA Chrome entered into a Pooling and Sharing venture with Xstrata in 2004.
 

South Africa’s Ferro Alloys Industry - Present Status and Future Outlook   5

 

Thus, from very humble beginnings in 1918, the South African ferro alloy industry has prospered and grown to become a leading producer of bulk ferro alloys on a global scale. Details of the present ferro alloy industry in South Africa are found in the next section.

 

2.  THE CURRENT STATUS OF THE INDUSTRY

 

The summarised capacity of South African ferro alloy plants is shown in Table 1.

Table 1: Installed Capacities of SA Ferro Alloy Plants

 

Operating Company

Production Units

Capacity (tpa) (excludes feed to refined products)

Samancor Cr Ferrometals

2x25MVA semi-open AC 1x48MVA semi-open AC 1x63MVA semi-open AC 2x63MVA closed AC

Primary ChCr 400 000

Recovery ChCr 20 000

 

 

 

 

1x30t CLU converter

MCFeCr 70 000

Samancor Cr Middelburg Ferro- chrome

2x48MVA semi-open AC

 

1x63MVA closed DC

Primary ChCr 220 000

 

Recovery ChCr 10 000

 

 

1x18MVA open arc AC 2x18MVA semi-open AC

LCFeCr 40 000

 

Samancor Cr Tubatse Ferro- chrome

3x30MVA semi-open AC

 

3x37MVA semi-open AC

Primary ChCr 340 000

 

Recovery ChCr 20 000

 

Mogale Alloys

1x40MVA closed DC 2x20MVA semi-open AC

Alt: 2x20MVA semi-open AC

Primary ChCr 120 000

Recovery ChCr 5 000

SiMn 40 000

 

 

Samancor Mn Metalloys

2x18MVA semi-open AC 1x21MVA semi-open AC 2x25MVA semi-open AC 2x75MVA closed AC 1x81MVA closed AC

Primary SiMn 120 000

Recovery SiMn 5 000

 

Primary HCFeMn 300 000

Recovery HCFeMn 10 000

 

 

 

 

 

1x30t converter

MCFeMn 60 000

Siyanda Inkwali Resources DMS Powders

1x12MVA open AC

14/16% FeSi 36 000

Xstrata Alloys Lydenburg

3x33MVA closed AC 1x38MVA semi-open AC

Primary ChCr 380 000

Recovery ChCr 20 000

 

Xstrata Alloys Lion

2x60MVA closed AC

Primary ChCr 340 000

Recovery ChCr 20 000

 

Xstrata Alloys Rustenburg

5x33MVAsemi-open AC 1x45MVA semi-open AC

Primary ChCr 410 000

Recovery ChCr 20 000

 

Xstrata Alloys Wonderkop

6x45MVA semi-open AC

Primary ChCr 440 000

Recovery 20 000

 

Merafe Boshoek

2x60MVA closed AC

Primary ChCr 230 000

 

 

Recovery ChCr 10 000

Glencore Siltech

1x51MVA semi-open AC 1x40MVA semi-open AC

75% FeSi 40 000

 

Assmang Chrome Machadodorp

1x54MVA closed AC 2x33MVA semi-open AC 1x30MVA semi-open AC

Primary ChCr 285 000

Recovery ChCr 15 000

 

 

Assmang Manganese Cato Ridge

1x24MVA semi-open AC

 

1x24MVA closed AC 2x22MVA semi-open AC 2x12MVA closed AC

Primary HCFeMn 180 000

 

Recovered HCFeMn 15 000

 

 

 

 

1x30t converter

MCFeMn 50 000

Hernic Ferrochrome

2x37MVA semi-open AC 1x54MVA closed AC 1x78MVA closed AC

Primary ChCr 410 000

Recovery ChCr 20 000

 

 

ASA Metals

1x33MVA semi-open AC 1x45MVA semi-open AC

Primary ChCr 115 000

Recovery ChCr 10 000

 

International Ferro Metals

2x66MVA closed AC

Primary ChCr 250 000

Recovery ChCr 10 000

 

Highveld Steel Transalloys

2x21MVA open AC 1x23MVA semi-open AC 2x48MVA semi-open AC

Primary SiMn 150 000

Recovered SiMn 10 000

 

 

 

2x7MVA open arc AC

MCFeMn 50 000

Highveld Steel Rand Carbide

1x20MVA semi-open AC 1x46MVA semi-open AC 1x16MVA semi-open AC

75% FeSi 60 000

 

 

Invensil Silicon Smelters

3x30MVA semi-open AC

Si metal 40 000

Xstrata Alloys Rhovan

1x3,5MVA DC

FeV 5 500

Highveld Steel Vanchem

2x3MVA AC

FeV 7 000 (theoretical)

Stratcor Vametco

Not defined

FeV 2 000 - 6 000 (potential)

 

The  South  African  ferro  alloy  industry  is  experiencing  interesting  changes  in  terms  of  ownership  and restructuring. This reflects an increasing interest from non-South African organisations in the investment and strategic potential of the business. This is a far cry from 20 years ago when the ferro alloy industry was basically dominated by Samancor, MS&A and Highveld Steel.

 

•In 2006 Russian group Evraz acquired the majority share in Highveld Steel and Vanadium Corporation, which includes alloy businesses Transalloys and Rand Carbide, as well as their vanadium business.
•In 2006 final approval was given for the erection of a HCFeCr plant by the Indian steel giant Tata Steel in Richards Bay, South Africa.
•In  2005  Samancor  Chrome  was  acquired  by  the  UK  group  Kermas,  a  company  with  considerable experience in the chrome ore and alloy industry
•In 2002 Japanese group Mitsubishi Corporation became the majority shareholder in Hernic Ferrochrome.
•JISCO, the Chinese steel producer, became a 24% shareholder in International Ferro Metals (IFM), a new ferrochromium producer. IFM is an Australian owned company, listed on London AIM.
 
 

South Africa’s Ferro Alloys Industry - Present Status and Future Outlook   7

 

•In 1997 ASA Metals, a ChCr producer, was established with Eastern Asia Metals Investment Company as the major joint venture partner.
•A number of organisations have acquired new order mineral rights for manganese ore reserves. Most of these  organisations  have  international  shareholding  and  are  presently  in  various  phases  of  feasibility studies to assess the viability of investing in manganese ore mining and manganese alloy production.

The major growth and activity has recently been in the ferrochromium industry. The manganese initiatives may lead to significant investments in the near future, which would change the South African manganese landscape significantly. Expansion plans for Xstrata’s Rhovan vanadium operation have recently been an- nounced[1].

Primarily as a result of the abundance of good quality raw materials (ores, reductants and fluxes), cheap electricity, a well-developed infrastructure and relatively cheap capital, South Africa’s ferro alloys industry has burgeoned over the last five decades to become the world leader in ferrochromium production, a major exporter  of  manganese  ore  and  alloys  and  a  significant  producer  of  vanadium  products.  In  addition, ferrosilicon of different grades as well as silicon metal are produced. South Africa is also a producer and exporter of Söderberg electrode paste.

At the moment, there are seven ferrochromium producers viz. Samancor Chrome, Mogale Alloys (produc- ing ChCr and SiMn in campaigns), Xstrata Alloys/Merafe, Assmang Chrome, Hernic Ferrochrome, ASA Metals and International Ferro Metals. The major producers have plants in more than one location.

 

•Samancor Chrome has three plants: Ferrometals in Witbank, Middelburg Ferrochrome in Middelburg and Tubatse Ferrochrome in Steelpoort.
•Xstrata Alloys/Merafe has five plants: Boshoek (formerly SA Chrome), Rustenburg (formerly Chrome Corp Technology and Purity Metals), Wonderkop, Lydenburg (formerly CMI) and Lion Ferrochrome.

By  early  2007  the  gross  installed  annual  ChCr  capacity  (including  feedstock  to  refined  products  and reclaimed alloy from slag dumps) would be in the order of 4,2 million tonnes.

Major ferrochromium expansion projects in South Africa are in the pipeline. Xstrata Alloys/Merafe is well advanced with the construction of a major green field ferrochromium plant, Lion Ferrochrome, at the site of the Vantech plant near Steelpoort, which incorporates two submerged arc electric furnaces, based on the patented Premus technology. Provision has been made to treble this first phase capacity to 1 million tonnes of ferrochromium by 2015[2]. In addition, International Ferro Metals will commission their green field, two- furnace smelter near Brits in the North West Province early in 2007. This plant has a reported capacity of 267 000tpa[3]. Samancor Chrome has announced a planned investment of US$1,46 billion to double its charge chrome capacity by early in the next decade. Construction of the first phase of 500 000 tpa green field plant is planned to commence in 2007, in addition to 260 000tpa brown field expansions presently underway[4]. Tata Steel’s project for a 135 000tpa HCFeCr plant in Richards Bay should be completed towards the end of 2007[5]. They already plan to double this plant’s capacity as the next stage[6]. ASA Metals plans to triple its charge chrome output by 2008[7].

In  contrast  to  ferrochromium  production,  South  Africa  is  a  relatively  small  player  in  manganese  alloy production with only three producers and one swing producer. Of the three, Samancor Manganese is the largest  (Metalloys,  Meyerton),  followed  by  Assmang  Manganese  (Cato  Ridge)  and  Highveld  Steel (Transalloys, Witbank) with Mogale Alloys (formerly Palmiet Ferrochrome) as the swing producer. As most plants  have  the  possibility  to  switch  between  HCFeMn  and  SiMn,  production  capacities  are  flexible. However, the nominal annual capacities, excluding Mogale, are as follows (including feedstock to refined products):

 

•HCFeMn 635 000 t

•   SiMn 300 000 t

•M/LCFeMn 160 000 t
 

8  INFACON XI

 

In terms of manganese alloy capacity the most significant development was the announcement by Kumba Resources and Samancor Manganese of their joint feasibility study for a 200 000tpa HCFeMn project based on a new process, developed by Kumba Resources’s AlloyStream technology. Furthermore, after the recent allocation of manganese ore mineral rights, a number of potential new entrants have embarked on feasibility studies for investment into new manganese ore mining and alloy production facilities.

Ferrosilicon production is small with production mostly for the local market. Rand Carbide (division of Highveld Steel) and Siltech are the only producers of 75% FeSi with a combined estimated annual production capacity of 100 000 tonnes. DMS Powders produces 14/16% FeSi for dense media separation. The only silicon metal producer is Silicon Smelters in Polokwane, part of the Ivensil Group, with an estimated annual capacity of 40 000 tonnes. Apart from low electricity cost, South Africa’s competitive benefits to produce silicon alloys are limited.

There are three producers of vanadium based products in South Africa viz. Xstrata Alloys (Rhovan) in Brits, Vanchem (division of Highveld Steel) in Witbank and Vametco, a division of Stratcor, also in Brits. Vametco has the capacity to produce 4 500 t/a Nitrovan®[8], which can be switched to FeV, while the other producers have the capacity and flexibility to produce a range of vanadium products and can vary production between V2O5, V2O3  and FeV. It is thus difficult to estimate the capacity of FeV. The market was in a state of flux at the time of writing, as it had just been announced that the Russian producer, Evraz would effectively purchase the majority stake in Highveld Steel and Vanadium from Anglo American, having also recently acquired Stratcor, which owns Vametco.

 

3.RAW MATERIALS

South Africa has vast reserves of chromite, manganese ores and vanadiferous ores. This position makes South Africa unique in the world.

 

1.Chromium

The latest USGS (United States Geological Survey)[9] cites the world resources of chromite as being greater than 12 billion tonnes of shipping-grade chromite, sufficient to meet conceivable demand for centuries. About 95% of the world’s chromium resources are geographically concentrated in Kazakhstan and southern Africa. Shipping-grade chromite ore is defined by the USGS as the deposit quantity and grade normalized to 45% Cr2O3. The total global chromite reserves (shipping-grade) are estimated by the USGS at ~474 million tonnes.

According to Cramer et al[10] South Africa’s chromite reserves probably exceed 75% of the world’s eco- nomic resources. All the chromite in South Africa is located in the BIC (Bushveld Igneous Complex). The economically viable seams are the LG6 (lower group 6) with a Cr/Fe ratio of 1,5-2, the MG1/2 (middle group 1 & 2) with a Cr/Fe ratio of 1,5-1,8 and the UG2 seam (upper group 2). The UG2 with a Cr/Fe ratio of 1,3- 1,4 is primarily a source of platinum group metals (PGMs). However, with technological innovations (DC plasma arc smelting, improved chromium yields) UG2 is gaining acceptance as source of chromium for ChCr production. Thus, South Africa’s chromite reserves can meet increased demands to meet the rapid escalation of ferrochromium production for an almost indefinite period[11].

It should be noted that the South African in situ chromites are generally low grade (<45% Cr2 O3) and low ratio (Cr/Fe<1,6) and are generally friable.  The resultant alloys produced from these ores are ChCr, with Cr- content of typically <55%. There is also  a general requirement for agglomeration of the  ore  to render it suitable for efficient charge chrome production. The production of ChCr with lower Cr content also impacts adversely on transport costs per Cr unit.

 

2.Manganese

As with chromite, South Africa has extensive deposits of manganese ore, mostly concentrated in the Kalahari Manganese Fields in the northwestern region of the country. Again, quoting the USGS[9], South Africa has about 80% of the world’s identified resources. 

 

 

  • [Editor:张德众]

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