SOUTH AFRICAN FERROALLOYS HANDBOOK 2017

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HANDBOOK H1/2017

SOUTH AFRICAN

FERROALLOYS HANDBOOK

2017

DIRECTORATE: MINERAL ECONOMICS

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HANDBOOK H1/2017

SOUTH AFRICAN FERROALLOYS HANDBOOK

2017

DIRECTORATE: MINERAL ECONOMICS

Compiled by: Ms RC Ravhugoni

Email: ([email protected])

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

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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.

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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%

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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


Submerged

electric arc

furnace

(SiMn)


Discard Slag

Ladle

Treatment

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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

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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.

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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

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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

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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 [email protected]

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 [email protected]

Witbank Jacques Nell

ii




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 [email protected]

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 [email protected]

S 0,06% max

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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: [email protected] [email protected]

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 [email protected]

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




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 [email protected]

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, preheating, 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: [email protected]

v




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

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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: [email protected]

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 [email protected]

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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: [email protected]

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

[email protected]/[email protected]

North West

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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 [email protected]

TEL: +27 (0) 13 693 8000/8158 E-MAIL LOCAL: [email protected] TEL: +41 41 711 5990 E-MAIL INTERNATIONAL: [email protected]

S 0.015 max [email protected]

High Carbon Ferromanganese (HC FeMn)

Tel: +41 41 711 5990

email international:

[email protected]

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

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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 [email protected]

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% [email protected]

VanChem 274 Witbank tel :013 696 6152

PO 567, Witbank 1035 Fax: 013 656 2558

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Controlling Company 10585 silicon smelters Smelting Silicon Metal-Not mined yet

G Moanakoena

FerroAtlantica RPC 40kt/a Quarts mined [email protected]

Polokwane Silica Metal Tel :015 290 3142

Fax : 015 290 3091

SOUTH AFRICAN FERROALLOYS HANDBOOK 2017

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