Outokumpu Technology Ferrochrome projects in South Africa
Outokumpu Technology Ferrochrome projects in South Africa Jorma Daavittila Vice President, Ferroalloys sales More out of ore!
Content Ferrochrome pr...
Outokumpu Technology Ferrochrome projects in South Africa Jorma Daavittila Vice President, Ferroalloys sales More out of ore!
Content Ferrochrome projects in South Africa
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Base Metals division Introduction Technology transfer sales Typical scope in company’s projects Project implementation Summary of projects Success factors References
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Base Metals division • Base Metals offers industry-leading technologies for the processing of non-ferrous metals and ferroalloys Copper technologies
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Nickel technologies
Zinc technologies
Precious metals technologies
Ferroalloy technologies
Introduction 1.
Chrome reserves
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2.
Ore production
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3.
South Africa - 5,000 million tonnes (MT), 76% world’s reserves Zimbabwe - 930 MT Others - 800 MT
World total - 19 MTPA South Africa - 7,5 MTPA, 40% of world’s total production Kazahkstan - 3 MTPA
South African ferrochrome plants
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FeCr production 3,2 MTPA (e2006) 49% world’s FeCr production
Main source: MB-ferroalloys conference 2006
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Introduction (cont) 4. Outokumpu Technology’s activities in South Africa
I.
Before sanctions
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II.
During sanctions (1985 – 1993)
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III.
Contacts maintained, no sales New Outokumpu process developed
New South Africa
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Close cooperation and some deliveries
Marketing restarted immediately after the removal of the sanctions 9 Ferrochrome projects in South Africa in last 10 years More under development
South Africa Bushwelt complex
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Outokumpu Technology’s Technology Transfer sales
1.
Outokumpu Technology’s technology used in almost half of the South African FeCr production in 2006
2.
The technology has set new standards for environmental requirements
3.
Only one major producer is not using Outokumpu Technology’s technology yet (negotiations ongoing)
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Preheating - energysaving 500 kWh/t
Grinding
Filtering Sintering – smelting capacity increased by 15% Pelletizing
Gas cleaning Smelting – high metal recovery
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Typical scope of supply
1.
Technology transfer package • Basic engineering of the plant • Supply of the key equipment • Training of customer’s personnel • Installation and start-op supervision • License
2.
South African contractor • Supply of the remaining equipment • General managing of the project • Construction and actual installation of the plant
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South Africa ferrochrome plants Hernic Ferrochrome,
Basic engineering, 5 months Equipment manufacturing and supply, 7-11 months • Manufacturing in Europe (FOB-delivery) • Manufacturing in South Africa (DDU-supply) Installation and start-up • Outokumpu Technology’s supervision • Mechanical completion -> Start-up • Performance demonstration Acceptance • Overall schedule, 18 months Customer support service • New deals
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Success factors
Own technology, (Tornio plant) • Good references • Operating and maintenance experience • Proven competitive technology ¾ Environmentally friendly ¾ Energy efficient (figures in flow sheet) ¾ Very high operational availability, 95 – 99%
Pori Research Center • Technology development incl. pilot tests • Testing of customer’s materials to define design and operating parameters • Process support in marketing and sales as well as in project implementation and start-up
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Success factors (cont)
Good, reliable products based on own development • Steel belt sintering • Smelting with preheating and effective gas cleaning and gas utilization
Cooperation with local partners
Good personal relations/mutual trust
Well operating plants in South Africa • Active service after start-up • Process support • Life cycle commitment
