BATEMAN upgrades ferrochrome
furnace for Crometals
BATEMAN has completed the lump-sum turnkey upgrade of Furnace No. 5
at Samancor’s site in Witbank, RSA, and has increased its ferrochrome
output by 25 % to 125 000 t/yr of metal. Simultaneously, the cost per
ton of ferrochrome produced was reduced by improving the efficiency
of the furnace. Part of the BHP Billiton Group, Samancor is one of the
largest ferrochrome producers in the world.
The client was Crometals,
a joint partnership between Samancor and NSA Metals (Nisshin Steel and
Nissho Iwai of Japan). The contract was secured in January 2002 and
was completed on schedule on 25 November 2002 during a nine-week shutdown
commencing on 23 September.
The enhanced furnace performance was achieved essentially
by providing a new, but proven, design for the furnace and technology
for its roof and lining.
The refractory lining, shell, grillage, roof and feed
chutes of the existing furnace were demolished and a new furnace shell
installed, featuring the BATEMAN/UCAR freeze-type refractory lining.
The shell also features a new cooling system with a furnace-lining monitoring
system. The lining concept is a unique BATEMAN development installed
in furnaces now operating successfully at Hernic Ferrochrome, SA Chrome
and Assmang Chrome in RSA and Temco in Australia.
The furnace preheater at the plant was reinstated
so the raw material could be heated prior to feeding into the furnace.
This feature results in a much more efficient and economical smelting
process.
A new roof was also fitted to the furnace. This is
a BATEMAN design, used successfully at SA Chrome, Assmang Chrome and
Hernic Ferrochrome, and allows efficient smelting because of the appropriate
positioning of the electrodes in the furnace. It also prevents the ingress
of air into the furnace and the release of toxic gases.
The existing raw-materials-handling system was refurbished
to increase the feed to the furnace by 25 % by widening the belts and
structures and changing the drives, pulleys, idlers and feeders.
The carbon-monoxide booster fans were up-rated, as
were the effluent-treatment plant and granulation-cooling system. A
new clay gun and taphole drill was installed.
The power supply to the furnace was increased from
48 to 60 MVA by upgrading the furnace transformers and, simultaneously,
the 33 kV supply in the high-tension yard was modified to suit the new
furnace transformers. New motor-control centres were also installed.
The contract was awarded to BATEMAN following an open-book
negotiation. The successful completion resulted in a follow-up contract
for an identical upgrade of Furnace No. 4 at the site, which will be
done during July and August 2003.
More information may be obtained from:
George Farmer, General Manager, Bateman Ferrous, on
+27-11-899-2531 or Email acfurnaces@batemanengineering.com
Steve Roper, Project Manager, on +27-11-899- 2589 or email Email acfurnaces@batemanengineering.com
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