New Proudly South African smelting technology, which uses 70% less electricity, cuts costs, slashes carbon emissions and can process low-grade material, has all the attributes needed to win back the top ferroalloy production renown that South Africa enjoyed in the not too distant past.
The inventive new green, clean, economically competitive, locally patented smelting technology, which is tried, tested and proven, needs only 1.2 MW of power is to produce a ton of ferrochrome compared with the conventional 4 MW of power needed to do so.
It not only has all the attributes to reverse South Africa's downward ferrochrome and ferromanganese slide but could even boost back the likes of Highveld Steel and Vanadium as well open the way for a return of the local production of high-manganese rail.
Slogging away at developing SmeltDirect since 2012 has been Johannesburg Stock Exchange-listed African Rainbow Minerals (ARM), headed by executive chairperson Dr Patrice Motsepe.
Crucial for South Africa is that ARM has manged to come up with a trailblazer that is not only 300% more efficient but also provides bottom-of-the-cost-curve benefit.
Very advantageous as well is that it enables existing mothballed furnaces to produce three times more efficiently.
In addition, biocarbon can be used to oust fossil fuel reductants, carbon dioxide emission is decimated, and manganese and iron ores that are currently unsaleable can be processed.
A detailed bankable feasibility study has been completed, engagement with ferroalloy peers on joint venture partnerships has taken place, and funding and co-financing arrangements for what will be major generator of direct and indirect jobs are showing early promise. Some 700 jobs are created for every 200 000 t of alloy production a year and South Africa was once a producer of about four or five million tons a year, which points to the potential of creating tens of thousands of new jobs.
Moreover, the use of renewable energy with biocarbon can slash Scope 1 and 2 carbon emissions by up to 80% and Scope 3 emissions are halved, resulting in good carbon credits being on the cards when Europe's carbon border adjustment mechanism (CBAM) comes into effect from January 2026.
Visiting experts from around the world have given the fully operational demonstration plant at ARM's Machadodorp Works a firm thumbs up.
"If we work together, we can, in a pretty short timeframe, get South Africa back to being a leader in ferroalloy production," ARM Ferrous Division CE Andre Joubert, in the company of ARM executive technology development Henk Bouwer, predicted in a Zoom interview with Mining Weekly. (Also watch attached Creamer Media video.)
"I'm looking at this from a South African perspective, where we can partner with existing producers in South Africa and then start with the process to convert one furnace at a time, confirm the technology, see that it can produce at a commercial level, and from there on roll it out through all our mothballed furnaces and the current low or marginally profitable smelters in South Africa.
"It's very, very important that we, as a country, unite. We have big alloy producers in South Africa, people with a lot of experience, a lot of know-how, that we expose this technology in that context, to partner with these entities where there are already existing plants and infrastructure. You just need to retrofit this technology on to that.
"Secondly, I think we need to have a bilateral with government…If we work together, and we're very smart, we can revive this whole beneficiation process, which we can put back into our own hands and create the necessary employment," Joubert enthused.
Mining Weekly: In what manner should this new technology be deployed to ensure that it adds maximum value in our country?
Joubert: I want to raise three key elements of this technology. The first one, which I want to emphasise, is that this technology isn't just a nice or cute technology. It is a process that will bring us t...