Post on 04-May-2023
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HANDBOOK H1/2017
SOUTH AFRICAN FERROALLOYS HANDBOOK
2017
DIRECTORATE: MINERAL ECONOMICS
Compiled by: Ms RC Ravhugoni
Email: (rudzani.ravhugoni@dmr.gov.za)
Picture on front cover
Source: The Arcelomittal SA’s Vanderbijl Park Plant, Gauteng Province
www.bdlive.co.za(Finacial Mail)
Issued by and obtainable from
The Director: Mineral Economics, Trevenna Campus,
70 Meintjies Street, Arcadia, Pretoria 0001, Private Bag X59, Arcadia 0001
Telephone (012) 444 3851 Telefax (012) 444 3134
Website: http://www.dmr.gov.za
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DEPARTMENT OF MINERAL RESOURCES
Director-General Adv. T Mokoena
MINERAL POLICY AND PROMOTION BRANCH
Acting Deputy Director-General Mr. A. Moatshe
MINERAL PROMOTION CHIEF DIRECTORATE
Chief Director Ms. S Mohale
DIRECTORATE MINERAL ECONOMICS
Director: Mineral Economics Mr. TR Masetlana
Deputy Director: Precious Metals and Minerals Ms. L Malebo
and Ferrous Minerals
THIS IS THE FIRST EDITION, PUBLISHED IN 2017
ISBN: 978-0-621-46000-1 COPYRIGHT RESERVED
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DISCLAIMER
Whereas the greatest care has been taken in the compilation of the contents of this publication,
the Department of Mineral Resources does not hold itself responsible for any errors or omissions.
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TABLE OF CONTENTS
1. INTRODUCTION ................................................................................................................ vi
2. SOUTH AFRICA’S FERRALLOY’S OVERVIEW ................................................................. vi
2.1 South Africa’s ferroalloy’s production ................................................................................ vi
3. CHROMIUM ALLOYS ....................................................................................................... viii
3.1 Ferrochrome production ................................................................................................. viii
3.2 Ferrochrome End-use Markets ......................................................................................... ix
3.3 Ferrochrome production process .................................................................................. x
4 MANGANESE ALLOYS ..................................................................................................... xii
4.1 Manganese alloys production .......................................................................................... xii
4.2 Manganese alloy production process .............................................................................. xiii
4.3 Manganese End-use Market ...................................................................................... xiv
5. FERROSILICON ................................................................................................................ xv
5.1 Ferrosilicon production .................................................................................................... xv
5.2 Ferrosilicon End – use Market .................................................................................... xv
6. FERROVANADIUM ......................................................................................................... xvii
6.1 Ferrovanadium production ............................................................................................. xvii
6.2 Ferrovanadium production process ........................................................................... xviii
6.3 Ferrovanadium Production End-use Market .................................................................... xix
7. CONCLUSION .................................................................................................................. xix
8. REFERENCES .................................................................................................................. xx
ANNEXURE A: FERRO ALLOYS OPERATIONS IN SOUTH AFRICA ......................................... i
vi
1. INTRODUCTION
South Africa is amongst the largest producers and exporters of chrome ore, manganese ore and
vanadium ores as well as leading suppliers of their alloys. It is also a significant producer of iron
ore, and a minor producer of ferrosilicon and silicon metal. With more than 85 percent of global
consumption of ferrous minerals, steel manufacturing is by far the leading demand driver of
ferrous minerals and their alloys. South Africa’s ferrous mineral production increased on average
by 8.84 percent over the last decade (2006-2016), with a proportion of these ores being processed
to value-added alloys. Ferroalloy’s production also increased by 3 percent, over the same period.
In 2016, ferrous minerals were produced from 64 mines and 27 ferroalloys smelters. The objective
of this document is to report on the ferrous alloys, production, specifications and their effect on
steel products.
2. SOUTH AFRICA’S FERRALLOY’S OVERVIEW
2.1 South Africa’s ferroalloy’s production
South Africa’s total ferroalloys production grew at an average rate of 3 percent annually, from
3 831 kilotons in 2006 to 4 417 kt in 2016 (Fig. 1), driven by the global steel demand. The global
economic crisis had the worst effect on the industry, which saw South Africa’s total ferroalloys
production declining by 11.7 percent and 31.3 percent in 2008 and 2009, respectively. However,
the recovery in the global steel market during 2010 drove the recovery of South Africa’s ferroalloys
market, increasing by 58 percent in that year. Year on year, ferroalloys production for the period
2015 to 2016 declined by 4 percent, from 4 586 kt in 2015 to 4 417 kt in 2016. The decline was
contributed by an oversupplied market, together with low demand and low prices of most ferrous
commodities, in that period.
vii
FIGURE 1: SOUTH AFRICA’S PRODUCTION OF FERROALLOYS, 2006 – 2016
Source: DMR, Directorate Mineral Economics: 2016
Ferrochrome production at 3 524 kt contributed about 88 percent to total ferroalloys production,
followed by ferromanganese and ferro silicon at 23 percent and 4 percent respectively, while ferro
vanadium contributed only 0.1 percent (Fig. 2).
FIGURE 2: PERCENTAGE CONTRIBUTION TO TOTAL FERROALLOYS PRODUCTION, 2016
Source: DMR, Directorate Mineral Economics 2016
0
1000
2000
3000
4000
5000
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Pro
du
cti
on
(kt)
FeCr72%
FeMn23%
FeSi4%
FeVn1%
viii
3. CHROMIUM ALLOYS
3.1 Ferrochrome production
Ferrochrome (FeCr) is an alloy of chromium and iron containing 50 percent to 70 percent
chromium by weight, and is produced by electric arc carbothermic reduction of chrome ore. Most
of the world's ferrochrome is produced in China, South Africa, Kazakhstan and India, all of which
have large domestic chromite resources, with China being the exception. Ferro chrome is
classified by the ratio of chrome to carbon (Cr: C) it contains (Table 2). South Africa’s FeCr
production constitutes mainly of HCFeCr or charge chrome at 99 percent of total FeCr production,
with medium and low carbon FeCr being insignificant contributors.
TABLE 1: CHEMICAL COMPOSITION OF FERROCHROME
Grade Chrome Carbon Phosphorus Sulphur Silicon
HC FeCr 60% Min 8% Max 0.05 % Max 3 % Max 1.5 % max
MC FeCr 65% min 0.5-2 Max 0.03 Max 0.03 Max 1.5 % max
LC FeCr 60% min 0.25 0.03 0.03 1.5 % max Source: www.balaorealloys.com/products
The majority of ferrochrome produced is charge chrome, with a lower Cr: C ratio and is most
commonly produced in South Africa for use in stainless steel production. Charge chrome is
produced from metallurgical chrome grade ore of 44 percent, and has chrome content of 48 - 55
percent and carbon contents ranging from 6 - 8 percent. High Carbon Ferro Chrome (HCFeCr) is
the second largest segment of the market with a higher chrome content produced from higher
grade chrome ore with an average chrome content of 67 percent.
Medium carbon ferrochrome (MCFeCr) is produced by further refining of charge chrome. The
silicon in the product is reduced to below 0.3 percent, and carbon is reduced to less than 1.5
percent for the lowest intermediate grade. The process takes place in a convertor where the liquid
charge chrome is bottom blown by oxygen and steam to a specific carbon content. The final
product, an intermediate carbon ferrochrome, is produced in granulated form.
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Low Carbon Ferrochrome (LCFeCr) is produced by combining charge chrome, quartzite and
reductants in a submerged arc furnace to produce ferro-silicon-chromium (FeSiCr) in a ‘dry’ or
slag-free process. The ferro-silicon-chrome has a low carbon content.
3.2 Ferrochrome End-use Markets
The stainless-steel industry consumes over 90 percent of ferrochrome produced. Approximately
2 - 2.5 tons of chrome ore is consumed in order to produce 1 ton of ferrochrome, while 0.2755
tons of ferrochrome is needed to produce 1 ton of stainless steel (stated differently, approximately
27.5 tons of ferrochrome are required per 100 tons of stainless steel) (Fig. 3). Stainless steel is in
principle low carbon steel which contains a minimum of 10.5 - 11 percent of chromium. This
unique steel does not corrode, rust or stain like ordinary steel due to the addition of chromium.
Addition of chromium in steel thus improves strength, hardenability, toughness/Impact resistance,
wear resistance and bright attractive finish.
The chromium forms a passive layer of chromium (III) oxide (Cr2O3) when exposed to oxygen,
which is too thin to be visible, and the metal remains lustrous. The layer is impervious to water
and air, protecting the metal beneath and reforms when the surface is scratched. There are over
150 grades of stainless steel, of which 15 are most commonly used. The alloy is milled into coils,
sheets, plates, bars, wire, and tubing to be used in cookware, cutlery, hardware, surgical
instruments, major appliances, industrial equipment and as an automotive and aerospace
structural alloy as well as construction material in large buildings.
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FIGURE 3: CHROME VALUE CHAIN
Source: Almaty, Kazakhstan, June 9-13, 2013
3.3 Ferrochrome production process
A generalized process flow diagram, which indicates the most common process steps utilized by
the South Africa’s FeCr producers, is shown in Figure 6. The country utilizes four process
combinations to produce FeCr, namely:
• Conventional semi-closed furnace operation with bag filter off-gas treatment. This is the
oldest technology applied in the country, but still accounts for a substantial fraction of
overall production. In this type of operation, coarse (lumpy and chips/pebble ores) and fine
ores can be smelted without an agglomeration process undertaken to increase the size of
fine ores.
• Closed furnace operation usually utilizes oxidative sintered pelletized feed. This has been
the technology most commonly employed, with the majority of green and brown field
expansions during the last decade utilizing it.
• Closed furnace operation with pre-reduced pelletized feed. The pelletized feed differs
substantially from the oxidative sintered type since the pellets are pre-reduced and mostly
fed hot, directly after pre-reduction, into the furnaces.
• Direct Current (DC) arc furnace operation is a type of operation where the feed can consist
exclusively of fine material.
Chrome ore
2-2.5 tons
Ferrochrome
1 ton
Ferrochrome
0.2755 tons
Stainless Steel
1 ton
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FIGURE 4: FERROCHROME PRODUCTION PROCESS FLOW DIAGRAM
Source: Almaty, Kazakhstan, June 9-13, 2013
Ore (Lumpy,
Chips/Pebbles, Fines,
Recycle etc)
1. Grinding/Milling
(Wet or Dry)
2. Pelletizing
(Drum or disk)
3. Curing
(Sintering or Pre-
reduction)
4. Pellet Storage
5. Batching
6. Preheating
(or drying)
7. Submerged arc furnace
(Semi-closed, closed) or
DC (open bath, closed
environment)
8. Slag cool-
down
9. Product handling
(Casting,
Granulations or hot
metal to Stainless
steel plant
11.Wet scrubbing
10.Bag house
Metallurgical grades
and other fine ores
Reductants (Char,
Coke, Anthracite and
Coal)
Fluxes (Quartz,
Limestone,
Magnesite and
Dolomite
Slag FeCr
Landfill Market
Closed
Semi-closed
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4 MANGANESE ALLOYS
4.1 Manganese alloys production
Manganese alloys are produced by carbo-thermic reduction of either high, medium or low-grade
manganese ores in a blast furnace or a submerged electric arc furnace (SEAF). The burning of
coke is the primary source of energy in the blast furnace, where the coke serves as a reducing
agent as well as the energy source. In the submerged arc furnace, the heat requirement is
supplied by the electrical energy and the coke is both the reducing agent and electrical resistant
element. According to the International Manganese Institute, 2010, countries producing
manganese alloys are amongst others, Egypt, South Africa, Zambia, Bahrain, Iran, Saudi Arabia,
China, India, Japan, South Korea, and Australia. Metallurgical ore is converted into manganese
alloys namely: high carbon ferromanganese (HC FeMn), silicon-manganese (SiMn) and refined
grades with medium carbon (MCFeMn) and low carbon (LCFeMn). These alloys vary in
manganese, carbon, silicon, phosphorus and sulphur contents (Table 3).
TABLE 3: CHEMICAL COMPOSITION OF MANGANESE ALLOYS
Grade Manganese Carbon Silicon Phosphorus Sulphur
HCFeMn 65-79% 8% max 2% max 0.5% max 0.03% max
SiMn 57-77% 0.1-3.5% min 10-35% 0.05-0.35% max 0.03% max
Refined FeMn 80-81% 0.1-2% max 2% max 0.15-0.35% max 0.03% max Source: www.apratiminternational.com/ferro-alloys.
High carbon ferromanganese is an alloy with high content of manganese and requires high grade
ore for production in a blast furnace or SEAF. The raw material components are weighted out
based on the chemical analysis of the ores, fluxes (limestone and dolomite) and carbonaceous
agents and the required composition of alloy and slag. The interior of the operating furnace is
divided into pre-reduction zone and a coke bed zone. The higher oxides of manganese are pre-
reduced in solid state to manganese (II, III) oxide (Mn3O4) in the pre-reduction zone and preferably
further to manganese (II) oxide (MnO) by carbon monoxide (CO) gas. The melting together of the
ores and the fluxes takes place in the coke bed zone. The metal will collect at the bottom of the
furnace from where it is tapped together with the slag.
Silico-manganese has high contents of manganese and silicon and is produced using low grade
ore in a SEAF. The SiMn production is often integrated with the production of HC FeMn so that
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the resulting slag can also be reprocessed to produce SiMn. Standard SiMn is typically produced
from the blend of MnO-rich slag from the HC FeMn process, manganese ores, quartzite and coke.
The high manganese content in refined ferromanganese is achieved by using high grade ore.
Refined ferromanganese is either produced from HC FeMn through the oxygen blown converter
(OBC) or SiMn through electro-thermic route.
4.2 Manganese alloy production process
A commonly used production process for manganese alloys is summarized in Figure 5.
FIGURE 5: MANGANESE ALLOYS PRODUCTION PROCESS
Source: www.apratiminternational.com/ferro-alloys.
Molten
Metal
LC SiMn
SiMn
Ref FeMn
HC FeMn
Alloy
Molten Metal
Metal Fines
Metal Fines
Alloy
Alloy
Metal Fines
Slag Slag
Electric Energy Electrode paste Ores Quartzite Coke
Electric Energy Electrode paste Ores Coke
Blast Furnace/
Submerged
electric arc
furnace
(HC FeMn)
Refining
Process
Crushing Screening
Crushing Screening Packing
Crushing Screening Packing
Submerged
electric arc
furnace
(SiMn)
Crushing Screening Packing
Discard Slag
Ladle
Treatment
xiv
South Africa has a smelting capacity of approximately 1.3 Mt for manganese alloys production
with 4 metallurgical works. In 2016, 415 kt of manganese alloys was produced from four
Metallurgical works.
4.3 Manganese End-use Market
The steelmaking process consumes about 90 percent of manganese alloys produced.
Approximately 2 -2.5 tons of manganese ore is consumed in order to produce 1 ton of manganese
alloys, while 1 ton of manganese alloys is required to produce 100 tons of crude steel (Fig. 6).
The apparent consumption of manganese is estimated at 10 kg per ton of steel produced. The
amount varies significantly from region to region with the differences related to the steel
production process, the quality of raw materials used, such as iron ore grades, and types of steel
products produced.
FIGURE 6: MANGANESE VALUE CHAIN
Source: www.manganese.org
Steel is an alloy of iron and carbon with high content of oxygen and sulphur. Insufficient
manganese in steel results in the sulphur combining with iron to form a sulphide with low melting
point, causing surface cracking. Out of the total manganese alloy that is added in steel making,
30 percent is used as a de-sulphurizing and de-oxidising agent while 70 percent is used as an
alloying element. Manganese intensive steel can be classified into two groups i.e. the first group
containing low amounts of manganese as an alloying agent between 0.8 - 2 percent and the
second group containing high amounts of manganese as an alloying agent between 11 - 16
percent and is known as austenitic steels. Addition of manganese in steel improves the following
properties: strength, elasticity, forging, welding and grain refining and wear resistance.
Mn ore
2 – 2.5 tons
Mn Alloys
1 ton
Steel
100 tons
xv
5. FERROSILICON
5.1 Ferrosilicon production
Ferrosilicon is an alloy of iron and silicon with an average silicon content between 15 and 90
weight percent and contains high proportion of iron silicides. Ferrosilicon is produced by reduction
of silica or sand with coke in presence of iron. Ferrosilicons with silicon content up to about 15
percent are made in blast furnaces lined with acid fire bricks. Ferrosilicons with higher silicon
content are made in electric arc furnaces. The usual formulations on the market are ferrosilicons
with 15 percent, 45 percent , 75 percent , and 90 percent silicon.
Ferrosilicon, which accounts for 80 percent of the world’s silicon produced, vary in silicon content.
The most commonly produced grades contain 15, 45, 75 and 90 percent silicon, with the
remainder being iron and about 2 percent consisting of other elements (Table 4).
TABLE 4: FERROSILICON GRADE SPECIFICATIONS
Source: Westbrook Resources Ltd
5.2 Ferrosilicon End – use Market
Ferrosilicon is mainly used as a source of silicon in the production process of carbon steels,
stainless steels and other ferrous alloys. Ferrosilicon is also used for manufacture of silicon,
corrosion-resistant and high-temperature resistant ferrous silicon alloys, and silicon steel for
electro-motors and transformer cores. In the manufacture of cast iron, ferrosilicon is used for
inoculation of the iron to accelerate graphitization. In arc welding, ferrosilicon can be found in
some electrode coatings. Approximately 1.8 - 2 tons of quartz is consumed in order to produce 1
ton of ferrosilicon, while 1 ton of FeSi is required to produce 200 - 400 tons of steel (Fig. 8).
Grade Silicon Carbon Sulphur Phosphorus Aluminium
Stabilised/Unstabilized 43-47 0.10 0.03 0.03 1.5
Atomised 43-47 0.10 0.05 0.05 2.0
Steel >72 0.15 0.05 0.05 1.5
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FIGURE 8: SILICON VALUE CHAIN
Source: Westbrook Resources Ltd
South Africa has a smelting capacity of approximately 7 95kt for ferrosilicon production with 3
metallurgical works and silica is produced from 23 operations. In 2016, 44 kt of ferrosilicon was
produced from seven Metallurgical works.
FIGURE 7: FERROSILICON PRODUCTION PROCESS
Source: www.pyrometallurgy.co.za
Quartz
1.8 - 2 tons
FeSi
1 ton
Steel
200-400 tons
SiO2
Purification
Mixing
Purificatio
Mg/Mg(liq
Condensat
ion
Mg(gas)
Mg
Reaction 4SNSi+Mg
Electrostatics
MgO Pigeon Process
Ferrosilicon FeSiO2
4-5NSi
Purification
5N + SOg-
Si
xvii
6. FERROVANADIUM
6.1 Ferrovanadium production
FerroVanadium (FeV) is produced by reduction of vanadium oxides using carbon, silicon or
aluminium as reductants. The oxides can be in a form of vanadium(IV) oxide (V2O4), vanadium(III)
trioxide (V2O3), vanadium(V) pentoxide (V2O5) or a mixture of these oxides. Depending on the
production process and the raw materials used, the vanadium content in the alloy ranges from
40-85 percent and it is classified into grades accordingly (Table 5).
TABLE 5: FERROVANADIUM GRADES SPECIFICATIONS
Vanadium Carbon Aluminium Silicon Phosphorus Sulphur
50-60% 0.2% max 2% max 1% max 0.05% max 0.05% max
70-80% - 1% max 2.5% max 0.05% max 0.1% max
77-83% 0.5% max 0.5% max 1.25% max 0.05% max 0.05% max Source: www.arthmetallurgicals.com/ferro-vanadium
The production of FeV by the aluminothermic reduction process requires the addition of
aluminium, lime and iron scrap to V2O5. The mixture is placed in a refractory lined ladle, which is
ignited with the reaction being fully autogenous. On completion of the reaction, the FeV collects
at the bottom of the ladle and a high aluminum oxide (Al2O3) slag forms above the FeV. After
cooling, the slag and metal are separated. The FeV is crushed, sized and packed to customer
requirements.
The DC arc furnace is used to produce FeV which contains 80 percent vanadium. The furnace
requires the addition of V2O3, aluminium, lime and scrap iron to produce the ferrovanadium
product. Although the reaction between V2O3and aluminium is exothermic, the reaction still
requires additional electrical energy which is supplied by the DC furnace. After completion of the
furnace melt, the metal and slag are tapped out of the furnace into a tap pot. The pot is emptied
after a cooling and solidification period, then the metal and slag are separated.
xviii
6.2 Ferrovanadium production process
The vanadium processing starts by concentrating the magnetite ore through crushing, grinding
and magnetic separation to produce a magnetic concentrate (Fig. 9), which is then blended with
sodium salt and roasted in a kiln to produce a water-soluble sodium vanadate. The sodium
vanadate solution is then leached with water to produce a solution containing sodium vanadate
with high silica content. This is followed by the de-silication process to remove and the solution is
treated with ammonia sulphate to precipitate insoluble ammonium vanadate. The precipitation is
either directed towards the drier or the de-ammoniator, where moisture is driven off and then
transferred to V2O5reactors.
FIGURE 9 : VANADIUM PRODUCTION PROCESS
Aluminium Sulphate
Ore Crushing
Kiln
Milling Magnetic Separation
De-silicate
Magnetic
Concentration
Leaching
Precipitation De-ammoniation Filtration
Solubilization Purification
Fuse
Precipitation Filtration
De-ammoniation
Screen
Vanadium
Chemical
Fuse &
Flake
V2O5
FeV
Reaction
vessel
FeV Crushing
Fluxes
Ammonium Sulphate
xix
6.3 Ferrovanadium Production End-use Market
Ferro Vanadium is a universal hardener, strengthener and anti-corrosive additive for steels like
high-strength low-alloy (HSLA) steel, tool steels, as well as other ferrous-based products. Most of
the ferrovanadium manufactured is utilized in the alloying process used to manufacture hardened
and heat-resistant steel. Hardened steel further finds application in the manufacturing of axles,
bicycles frames, crankshafts and other highly critical steel components. It is also used in
manufacturing high carbon steel alloy which is widely used in the manufacturing of medical tools
as well as in the manufacturing of jet engines and highspeed airframes, when used in titanium
alloys. Ferro vanadium reduces the overall weight of the steel and hence, is widely used in the
light weight automobiles.
7. CONCLUSION
Power price rises enacted by Eskom in recent years have seriously impacted the economics of
ferroalloys production in South Africa and closures at some of the ferroalloys production plants,
are, in a large part, caused by high power costs. The depreciation of the Rand, which has been
far greater than for other currencies, has somewhat cushioned the pain of higher electricity prices
in very recent quarters and is expected to continue to do so in 2017. According to CRU forecasts,
power rates will increase by 12 percent per annum in local currency terms and that the Rand will
appreciate, modestly over the next few years. As a result, the contribution of electricity to
ferroalloys production costs, in US Dollar-terms, will rise from 23 percent in 2015 to 30 percent in
2020, resulting into most South African ferroalloy industries struggling to be competitive.
Engineering news states that, global steel production decreased in all regions except Oceania,
which registered a 4.6 percent gain. South African steel production fell by 7.6 percent year on
year basis, in the first half 2015 to 3.2-million tonnes as the industry battled with electricity supply
disruptions and subdued domestic demand. The poor demand was in part due to the
government’s multibillion rand infrastructure investment plans failing to gain traction, as
investment in steel-intensive railway corridors such as links to Swaziland and the Waterberg
coalfields, remain plans, not projects. Global steel demand contract by 0.8 percent to 1.48-billion
tonnes in 2016, following a 3 percent contraction in 2015, with global steel demand expected to
return to growth of 0.4 percent to 1.49-billion tonnes in 2017. The future of alloy production in
xx
South Africa is more uncertain, since most if not all manganese ferroalloy plants are integrated
with domestic manganese ore supply. Over the medium-term, producers are expected to change
mix of ore and ferroalloy production, in an attempt to maximise profit. The South African ferrous
ore sector is expected to be most competitive than ferroalloy production.
8. REFERENCES
1. South Africa’s Ferroalloys Production Trends, 2005-2015, Directorate Mineral Economics
2. The Mineral Resources of South Africa, 6th Edition, Handbook 16
3. Personal communication with Sean du Toit, Columbus Stainless, 21 November 2016
4. Wikipedia, http://en.wikipedia.org
5. World Steel Association, www.worldsteel.org
6. Xstrata, www.xstrataalloys.com
7. www.intermetmin.co.za
8. www.mintek.co.za
9. www.sigmamixer.in_chrome
10. www.engineeringnews.co.za
11. www.roskill.com
12. www.futuremarketingsights.com
i
ANNEXURE A: FERRO ALLOYS OPERATIONS IN SOUTH AFRICA
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
FERROATLANTICA GROUP
1296 Rand Carbide Smelting Ferrosilicon % Silicon Smelters
SILICON SMELTERS PO Box 214, Emalahleni, 1035 RPC 40kt/a Si 75-78 max P. O. Box 657
P. O. BOX 657 Tel: +27 (0) 13 690 8236 Al 1 max Polokwane, 0700
POLOKWANE, 0700 Fax:+27 (0) 86 758 2775 C 0.12 max
TEL: +27 (0) 15 290 3100 Ca 0.50 max Tel: +27 (0) 15 290 3100
FAX: +27 (0) 15 290 3091 Fax: +27 (0) 15 290 3091
Mpumalanga thandekile.mashiane@siliconsmelters.co.za
VANCHEM VANADIUM PRODUCTS (PTY) LTD
1270 Vanchem Ferrovanadium Roast/Leach Vanadium pentoxide Vanchem Vanadium Products
PO BOX 567, WITBANK, 1035
PO Box 567, Witbank, 1035 RPC 10,8kt/a 99,0% typical (fused flake and powder)
Tel: +27 (0) 13 656 1921
TEL: +27 (0) 13 656 1921 Tel: +27 (0) 13 696 6062 RPC 12,5kt/a Ferrovanadium Fax:+27 (0) 13 656 2558
FAX:+27 (0) 13 656 2558 Fax:086 212 8926 80% typical jacquesn@vanchem.co.za
Witbank Jacques Nell
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Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
AFRICAN RAINBOW MINERALS &
1201 Cato Ridge Works / Assmang Manganese
Smelting HC Ferromanganese %
Ore & Metal Company Ltd
ASSORE LIMITED PO Box 21, Cato Ridge, 3680 RPC 240 kt/a Mn 76 Private Bag X03
(gross) C 6.7-7.2 Northlands, 2116
PO BOX 7, SANDTON, 2146
Tel: +27 (0) 31 782 5136 Converter Si 1.00 max
TEL: +27 (0) 11 779 1000
Fax:+27 (0) 31 782 5096 P 0,1 max Tel: +27 (0) 11 770 6800
FAX:+27 (0) 11 779 1029 Including: S 0,03 max Fax:+27 (0) 11 268 6440
Cato Ridge Alloys (JV) email:
Kwazulu- Natal
Refined alloysales@assore.com
Ferromanganese % Raj Narain
Mn 80,0
C 1,5 max
AFRICAN RAINBOW MINERALS &
1290 Machadodorp Works Smelting Charge Chrome Ore & Metal Company Ltd
ASSORE LIMITED PO Box 152, Machadodorp, 1170
RPC 285 kt/a Cr 51.5-52.5 Private Bag X03
PO BOX 7, SANDTON, 2146
(gross) C 6.3-8% Northlands, 2116
TEL: +27 (0) 11 779 1000
Tel:+27 (0) 13 256 5000/4 Fax:+27 (0) 13 256 5026
Metal Recovery Plant
Si 3-6% Tel: +27 (0) 11 770 6800
FAX:+27 (0) 11 779 1029 Mpumalanga RPC 15 kt/a P 0,03% max chromesales@assore.com
S 0,06% max
iii
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
SAMANCOR Ltd Lydenburg, Steelpoort
1176
4.3 Tubatse Ferrochrome (Pty) Ltd PO Box 46 Steelpoort, 1133 Tel: +27 (0) 13 230 8200/8401 Fax: +27 (0) 13 230 8370 Mpumalanga
Smelting Primary 340 kt/a (gross) Recovery 20 kt/a
HC Ferrochrome % Cr 50-54 Si 6-9 C 1,5-6 max P 0,03 max S 0,05 max
Samancor Limited Chrome Division email: Sales@SamancorCr.com mabotsha.mankge@samancor.com
SAMANCOR CHROME ltd 1307 Ferrochrome Smelting HC Ferrochrome % Samancor Limited
Private Bag X 251846 Slag Recovery 10 kt/a
Cr 50-54 Chrome Division
Middelburg, 1050 Primary 220 kt/a
Si 6-9 anita.steyn@samancorcr.com
LC Ferrochrome %
Tel: +27 (0) 13 249 4421 Cr 60-65
Fax:+27 (0) 13 249 4678 C 0,1 max
N 0,4 max
Mpumalanga Si 1,0 max
P 0,03 max
S 0,05 max
Silicochrome %
Cr 27-31
C 0,1 max
Si 45-50 typical
Fe 18-22
iv
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
BHP BILLITON/ South 32 Controlling Company SAMANCOR MANGANESE (PTY) LTD P. O. BOX 8186 JOHANNESBURG, 2000 TEL: +27 (0) 11 376 9111
2510
Samancor Manganese (Pty) Ltd PO Box 66 Meyerton, 1960 Tel: +27 (0) 13 360 2511 Fax: +27 (0) 13 362 3391 Gauteng
Smelting Slag Recovery RPC 510kt/a (gross) Converter and Refining plant
HC Ferromanganese %HC Ferromanganese oxide Mn 76 C 7,5 Si 0,5 max P 0,1 max S 0,02 max
Samancor Manganese Tel: +27 (0) 11 376 9111/02302 Admore Mwanyangadza admore.mwanyangadza@south32.net
HERNIC FERROCHROME PTY LTD Controlling Company HERNIC FERROCHROME PTY LTD PO BOX 4534 BRITS, 0250 TEL: +27 (0) 12 381 1100 FAX: +27 (0) 12 381 1111
3055
Hernic Ferrochrome PO Box 4534, Brits, 0250 Tel: +27 (0) 12 381 1100 Fax: +27 (0) 12 381 1111 North West
RPC 220kt/a (gross) Pelletising, pre- heating, smelting
Charge Chrome Cr 49% min C 6-8% min Si 3-7% P 0,025 max
Hernic Ferrochrome PO Box 4534 Brits, 0250 Tel: +27 (0) 12 381 1100 Fax: +27 (0) 12 381 1111 email: marketing@hernic.co.za
v
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
Glencore Merafe Venture 1316 7.3 Xstrata SA Chrome Pelletising and HC Ferrochrome % Xstrata SA Chrome
Division Smelting Cr 50-53 Division
LTD Smelters Primary 380 kt/a C 8,0 min Private Bag 82288
PO Box 195 (gross) Si 1,5-6,0 Rustenburg, 0300
Lydenberg, 1120 P 0,025 max
S 0,035 max Tel: +27 (0) 14 590 2430
Tel : +27 (0) 13 230 6000 Fax: +27 (0) 14 590 6002
Fax: +27 (0) 13 230 6002
luella clifton
Mpumalanga
Glencore Operations SA (pty) ltd
2169 7.4 Lion Smelters Pelletising and HC Ferrochrome % Xstrata SA Chrome
Division Smelting Cr 50-53 Division
Lion works Primary 340 kt/a C 8,0 min Private Bag 82288
PO Box 218 (gross) Si 1,5-6,0 Rustenburg, 0300
Steelpoort, 1133 Recovery 20 kt/a
P 0,025 max
S 0,035 max Tel: +27 (0) 14 590 2430
Tel :+27 (0)13 230 5271 Fax: +27 (0) 14 590 6002
Fax: +27 (0) 13 230 3108
Mpumalanga
Glencore International Ag 2667 7.5 Xstrata Alloys Pelletising and Ferrovanadium Xstrata SA Chrome
Rhovan works Smelting also PO Box 3620
PO Box 3620, Brits, 0250 FeV 5.5 kt/a Vanadium pentoxide(V2O5)
Brits, 0250
Tel: +27 (0) 12 318 0750 Fax: +27 (0)86 532 1760
Tel: +27 (0) 12 318 0700
North West Fax: +27 (0) 12 318 0702
vi
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
GLENCORE XSTRATA PLC
2927 8.1 Silicon Technology Smelting Ferrosilicon % Silicon Technology
Controlling Company PO Box 1 RPC 55kt/a Si 75-80 PO Box 1 SILICON TECHNOLOGY (PTY) LTD
Ballengeich, 2942 (gross) C 0,2 max Ballengeich, 2942
P. O. BOX 1 Al 2,0 max
BALLENGEICH, 2942 Tel: +27 (0) 34 377 7210 P 0,05 max Tel: +27 (0) 34 377 7210
Fax: +27 (0) 34 377 7012 S 0,02 mx Fax: +27 (0) 34 377 7012
TEL: +27 (0) 34 377 7210 Kwa Zulu-Natal
FAX: +27 (0) 34 377 7012
Glencore Merafe venture 3559
Merafe Ferrochrome &Mining (Pty) Ltd
Smelting Ferrochrome % Merafe Resources
P. O. BOX 652157 Private Bag X4011 Primary 230 kt/a Cr 50-51 PO Box 652157
BENMORE, 2010 Boshoek, 0301 (gross) C 0,2 max Benmore, 2010
Recovery 10 kt/a
Al 2,0 max Frits Bouwer
TEL: +27 (0) 11 783 4780 Tel: +27 (0) 14 573 1214 P 0,05 max Tel: +27 (0) 11 783 4780
FAX: +27 (0) 11 783 4789 Fax: +27 (0) 14 573 1239 S 0,02 mx Fax: +27 (0) 11 783 4789
North West emai: frits.bouwer@glencore.co.za
STRATEGIC MINERALS CORPORATION
650 Vametco Alloys Smelting Ferrovanadium and Vametco Minerals Corp.
DANBURY, CONNECTUIT, USA
PO Box 595, Brits, 0250 2-6 kt/a (potential)
Nitrovan PO Box 595
Controlling Company
Tel: +27 (0) 12 318 3295 also mixed oxides 0250 Brits
EVRAS VAMETCO ALLOYS (PTY) LTD
Fax: +27 (0) 12 318 3201 Tel: +27 (0) 12 318 3295
P. O. BOX 595 North West Fax: +27 (0) 12 318 3201
BRITS, 0250 tania.mostert@evraz.com
vii
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
ASA METALS (PTY) LTD 3332 Dilokong Ferrochrome Smelting Charge chrome ASA Metals (Pty) Ltd
POSTNET SUITE 782
PO Box 169, Burgersfort, 1150
RPC 125 kt/a Postnet Suite 782
PRIVATE BAG X9
RPC 400kt/a (gross)
Private Bag X9
BENMORE, 2010 Benmore, 2010
Tel: +27 (0) 13 230 7674 email: tnonyane@asametals.co.za
TEL: +27 (0) 11 666 6000 Fax: +27 (0) 13 230 7754 T Nonyane
FAX: +27 (0) 11 666 6194 Mpumalanga Tel: +27 (0) 11 666 6000 Fax: +27 (0) 11 666 6194
Inter
IMF SOUTH AFRICA (PTY) LTD
4419 International Ferro Metals (Pty) Ltd
Smelting Ferrochrome IFMSA Pty Limited
P. O. BOX 2223 Buffelsfontein JQ465 RPC 267 kt/a PO BOX 2223
MOOINOOI, 0325 Mooinooi (gross) Mooinooi, 0325
TEL: +27 (0) 14 574 6300
FAX: +27 (0) 14 574 6401 Tel: +27 (0) 14 574 6300 Tel: +27 (0) 14 574 6300
Fax: +27 (0) 14 574 6401 Fax: +27 (0) 14 574 6401
aronm@ifmsa.co.za/info@ifmsa.co.za
North West
viii
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
13. RENOVA MANGANESE INVESTMENTS
2466 13.1 Transalloys Smelting Silicomanganese % Transalloys (Pty) Ltd
Controlling Company Clewer Road RPC 170kt/a Mn 65- 68 Tel: +27 (0) 13 693 8000/013 693 8056
TRANSALLOYS (PTY) LTD
Emalahleni, 1035 Tel: +27 (0) 13 693 8000/8158
(gross) Si 16-18 email local:
P. O. BOX 856 Fax:+27 (0) 13 690 7411 C 2.0 max Tebogo Mokone
EMALAHLENI, 1035 Mpumalanga P 0.15 max tebogom@transalloys.co.za
TEL: +27 (0) 13 693 8000/8158 E-MAIL LOCAL: Sandram@Transalloys.co.za TEL: +41 41 711 5990 E-MAIL INTERNATIONAL: roland_suter@afrominerals.ch
S 0.015 max keving@transalloys.co.za
High Carbon Ferromanganese (HC FeMn)
Tel: +41 41 711 5990
email international:
roland_suter@afrominerals.ch
TATA GROUP 4838 Tata Steel (KZN) Smelting HC FeCr Tata Steel (KZN) (Pty) Ltd
Controlling Company Alton North, Richards Bay, 3900
RPC 150kt/a P. O. Box 9690
TATA STEEL (KZN) (PTY) LTD
(gross) Richards Bay, 3900
P. O. BOX 9690
RICHARDS BAY , 3900 Tel: +27 (0) 35 788 0710/1
Tel: +27 (0) 35 751 1861 Fax: +27 (0) 35 788 0779 TEL: +27 (0) 35 788 0710/1
Fax:+27 (0) 35 751 1895
FAX: +27 (0) 35 788 0779 Kwa-Zulu Natal
ix
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
SIYANDA INKWALI RESOURCES
1281 DMS Powders Smelting FeSi DMS Powders
Controlling Company P. O. Box 945, Meyerton, 1960 RPC 42 kt/a Atomised and milled P. O. Box 945 DMS POWDERS (PTY) LTD
(gross) Meyerton, 1960
P. O. BOX 945
MEYERTON, 1960 Tel: +27 (0) 16 360 5200
Fax: +27 (0) 16 360 5314
TEL: +27 (0) 16 360 5200 Tel: +27 (0) 16 360 5200 Distribution@dmspowders.com
FAX: +27 (0) 16 360 5314 Fax: +27 (0) 16 360 5314
Gauteng
Controlling Company 275 Evraz Highveld Steel and vanadium Ltd
Smelting vanadium A Wesstrate and MC Phahlane
P. O. Box 111 RPC 42 kt/a V205-28% P. O. Box 111 UNDER BUSINESS RESCUE
Witbank, 1035 (gross) 38.70% Witbank, 1035
Vanadium slag
Tel: +27 (0) 13 690 9094
Fax: +27 (0) 13 690 9192
Tel: +27 (0) 13 690 9094
Fax: +27 (0) 13 690 9192
Mpumalanga-Emalahleni
Controlling Company VanChem Smelting Fused V2O5 and V2O5
Corlia Pretorious
Vanchem Vanadium Products
PO 567 4 500 t/a 99.40% corliap@vanchem.co.za
VanChem 274 Witbank tel :013 696 6152
PO 567, Witbank 1035 Fax: 013 656 2558
x
Group Company Mine Code
Ferroalloys operations Capacity Products and Specification
Marketing: Local & Export
Controlling Company 10585 silicon smelters Smelting Silicon Metal-Not mined yet
G Moanakoena
FerroAtlantica RPC 40kt/a Quarts mined gift.moanakoena@siliconsmelters.co.za
Polokwane Silica Metal Tel :015 290 3142
Fax : 015 290 3091