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f e r r o - a l l o y s

Tenova Pyromet's picture book

CHINA

A project for Henan Sunshine Silicon Metal in China includes the design, fabrication and supply of equipment for two 39 MVA silicon metal furnaces for a 25 MW plant in the city of Luoyang, Henan Province, China. The furnace shell is fitted with a mechanism that can rotate the furnace in either direction at specific speeds to produce silicon metal. The electrodes were designed around a prebaked carbon electrode, but there is the option to change it to a composite one.

FRANCE

French firm Bus Valera commissioned a rebuild of its number one furnace two years ago. The revamped plant was switched on in August last year and used Bus Valera's existing transformer, but the furnace power was increased by 10%. The furnace shell is fitted with copper coolers to provide a freeze lining: they cool the slag, which then freezes onto the inside of the furnace, thereby creating protection for the refractory lining.

Based in South Africa, Tenova Pyromet provides complete smelting plants for ferro-alloy production, as well as for base metal reduction, slag cleaning and alloy refining. The company has built many of the ferro-alloy furnaces operating in its home country ­ and notably 70% of the ferro-chrome furnaces built there in the last 20 years. Snapshots of the firm's now international supply of equipment demonstrates the variety of plant now used by alloy producers around the world.

INDIA

Balasore Alloys, part of the Ispat group of companies, is building a 16.5 MVA ferro-chrome furnace in the state of Orissa, on the east coast of India in the Bay of Bengal. Tenova Pyromet will be supplying lower electrode equipment, comprising the contact shoe, pressure bellow and pressure ring. The equipment is wholly South African in design and manufacture and will be exported to India on completion.

Tenova Pyromet

ASA Metals' existing ferro-chrome furnace plant

wall copper cooling system is employed together with an oil-based cooling fluid, instead of cooling water.

RUSSIA

Norilsk Nickel will upgrade its two nickel slag cleaning furnaces in Siberia. Tenova Pyromet will supply the furnace, including the hearth cooling system, the steel shell and refractory lining, its Maxicool® sidewall copper cooling system, the furnace refractory roof with support structure and its patented Söderberg electrode column. The company will also supply the gas cleaning plant, the secondary electrical supply system, the furnace control system, the lining management system and PLC, as well as key components of the furnace feed system. Supervision during installation and commissioning is included in the contract.

PERU

A 15 metre slag launder, comprising water-cooled copper launder sections, which will convey matte and slag from an IsasmeltTM furnace to a settling furnace, was ordered by a client in Peru in May. Developed and manufactured in South Africa, Tenova Pyromet's slag launders are used on Anglo Platinum's Waterval Smelter in South Africa; the BCL nickel smelter in Botswana; STL's cobalt smelter in the Democratic Republic of Congo; and BHP Billiton's Olympic Dam works in Australia.

NORWAY

Norway-based Elkem Solar awarded a contract to design and supply a slag furnace for its patented metallurgical process for the production of solar grade silicon in March last year. It will be the first production plant of its kind. Tenova Pyromet's high-intensity MaxicoolTM side-

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2010, and the second during the third quarter of 2011.

SOUTH AFRICA

In its biggest project yet in South Africa, Tenova Pyromet is designing, installing and commissioning two 66 MVA ferrochrome furnaces with pre-heaters at the Dilokong chrome mine in the Polokwane, for China-based Asa Metals' project. Raw material handling, civil, structural, mechanical, electrical and automation work is included. Completion of the project is scheduled for October 2009. Tenova Pyromet completed two other turnkey projects for ASA Metals in 1998 and 2003. A complete furnace package has been supplied for Tata Steel's ferro-chrome plant in Richards Bay, South Africa. The project covered the design, construction and commissioning of two 38 MW submerged arc furnaces, and the scope included the plant control system, with electrical and mechanical equipment. This comprised the entire gas-cleaning scrubber system for the furnace off-gas, as well as the tap hole off-gas extraction bag filter systems. The first furnace was commissioned in April this year, and the second in May. International Ferro Metals listed on the London Stock Exchange in October 2005 and its ferro-chrome project started immediately. Pyromet designed, constructed, commissioned and guaranteed the smelter on a turnkey fixed price basis. The scope included the ore beneficiation plant and the smelter. The former processes run-of-mine ore, received direct from the mining operations, into metallurgical concentrate, foundry grade concentrate and lumpy ore. The latter includes the submerged arc closed furnaces, raw material handling, screening, dust extraction, storage and batching, furnace off-gas scrubbing, electrical, automation and tapping equipment. Both furnaces started up in January last year. Project duration from the date that Pyromet received confirmation to proceed was 15 months for the first furnace and 16 months for the second. Last year the company supplied Mogale Alloys with a scrubber plant and it has recently signed a contract with Anglo American for the design and supply of a slag cleaning furnace.

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Tenova Pyromet

Tenova Pyromet

Two furnaces for Tata Steel's ferro-chrome plant in Richards Bay were commissioned in April and May this year, respectively. The top picture shows a furnace roof.

Tenova Pyromet

International Ferro Metals' smelter. From the foreground: stores, raw material batching and furnace building.

The diameter and power input of the furnaces will be increased to allow processing of approximately 2,400 tonnes of flash furnace and converter slag for each furnace. The furnace power rating will be

increased to 30 MVA, with a maximum power input of 25 MW achievable, depending on process requirements and conditions. The first furnace is expected to come on line during the last quarter of

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