Smelter engineering firm Metix, a subsidiary of the German privately owned SMS Group, has commissioned the second set of furnace electrodes at the Lion ferrochrome complex Phase 2 (Lion II) expansion project, in Steelpoort, Limpopo, which is owned by the diversified mining major Glencore and ferrochrome producer Merafe Resources chrome joint venture (JV).

Metix MD Andrew van Niekerk tells Engineering News that this follows the company’s successful commissioning of the first set of furnace electrodes earlier this year, including 1 600 mm electrodes with forged copper pressure rings and heat shields, which provide high-current supply to the electrodes and ancillary equipment.

He highlights that the Lion II plant uses the energy efficient Premus technology, “which reduces electrical consumption, as the technology uses a prereduced feed to the furnace”.

Additionally, he says Metix is refurbishing a furnace for Glencore at its chrome smelter plant in Lydenburg, Mpumalanga.

“We are replacing the plant’s C furnace roof and feed chute tips with our forged copper solutions. We will soon have five plants using our copper solution on their furnace systems, including the plants at ferrochrome producers International Ferro Metals and Hernic Ferrochrome, which are located in the Bushveld Complex, in the North West,” Van Niekerk states.

Expanding Offering

Meanwhile, he says that Metix intends to add the SMS Siemag direct current (dc) furnace to its local product offering once the company concludes its bankable feasibility study on the technology later this year.

“SMS Siemag recently started the commissioning of the first of four 72 MW dc furnaces for diversified natural resources company Eurasian Natural Resources Corporation’s Kazchrome ferro- chrome plant in Aktobe, Kazakhstan.”

Van Niekerk states that the SMS Siemag dc furnace will provide local ferrochrome processing companies with several advantages, including improved thermal efficiency, air-cooled refractory roofs, arc deflection control, high-speed thyristor ignition control and on-power electrode slipping and nippling.

“Local technology sourcing of the SMS Siemag dc furnace will
provide solutions to effectively process fines from mines and, thereby, also ensure the availability of lower-grade reductants that can be offered at competitive prices,” he asserts.

African Projects

Meanwhile, Van Niekerk notes that Metix completed the engineering, procurement and supply (EPS) work for the first six-in-line 24 MVA copper matte settling (MS) furnace for Toronto-listed company First Quantum Minerals’ Kansanshi mine, in Zambia, in September 2013.

The scope of the EPS work included the charging system, the complete MS furnace with refractories, tapping equipment, electrodes, the high-current system and transformers.

The furnace treats the liquid slag directly using Glencore’s Isasmelt energy-efficient smelting process through minor reduction and settling of the copper matte to improve process efficiencies. 

“Once commissioned, this will be the third furnace used for this application based on SMS Siemag technology,” he states, adding that the commissioning of the furnace will start later this year.

Van Niekerk, further, says that, given the challenging nature of undertaking construction work in Africa, FQM has a unique advantage, as it has the in-house capabilities and equipment to carry out the installation themselves with Metix providing supervision services. 

Malaysia

Van Niekerk says that Metix has secured a complete engineering, procurement and construction (EPC) contract for Sakura Ferroalloys in eastern Malaysia.

The furnaces are scheduled to begin operating in the second half of 2015.

Sakura Ferroalloys is a tripartite JV of Assmang (a JV between South African JSE-listed mining companies African Rainbow Minerals and Assore), Japanese global miner Sumitomo and Taiwan’s integrated steel manufacturer China Steel Corporation. 

The project will include the construction two 81 MVA ferromanganese and silico-manganese closed submerged arc furnaces, gas cleaning, raw material handling, product handling, infrastructure and associated services.

“The plant is based on field proven SMS Group technologies and important input from the client’s technical design team to improve operability and decrease maintenance,” Van Niekerk emphasises.

He adds that the hot duty-standby gas cleaning plants will improve availability and provide high-quality clean gas. 

Van Niekerk adds that, by early July, about 30% of the project was completed.

He says that some of the milestones achieved on the project to date include completion of all terraces, all weather bridge and site access, F1 concrete foundation construction and first structural steel construction in June, while the site was established in late 2013. 

Moreover, Van Niekerk believes that the Sakura project is a “major opportunity” for Metix to learn more about doing business in Malaysia and to create relationships with its clients’ shareholders, the local authorities, local engineering partners as well as local fabrication and construction contractors. 

“We established Metix Malaysia to manage all Metix’s local resources and construction.  We have already gained significant experience in setting up this company, particularly about exchange rules, local taxes, import duties, certification of equipment, construction permits and compliance, which has improved our competitive international offering and capability,” he states.

Flying SA’s Product Flag

Van Niekerk highlights that the company has sourced a large portion of the material and equipment for the Sakura project – such as fabricated electrode columns, clarifiers, belt filters and vibrating feeders – from South Africa.

“We are confident in the quality of the imported products and Metix aims to continue promoting the use of locally produced products in all our future projects locally and abroad,” he concludes.