Nova Analytical Systems: #111 - TENOVA Projects

Project Description

In October 2007 ASA Metals awarded a lump sum turn key contract to Tenova Pyromet for the ASA Metals expansion project. The project was for the design, supply, installation and commissioning of 2x66MVA closed submerged arc furnaces, complete with Outotec single shaft pre-heating systems.

The Pyromet scope included the submerged arc closed furnaces complete with pre-heaters, raw material handling, screening, dust extraction, storage and batching, furnace off-gas scrubbing, electrical, automation and tapping equipment.

Scope

The Tenova Pyromet scope of work included civil works, structural steelwork, raw materials handling, storage and blending, HV, MV and LV electrical reticulation, plant automation, furnace off-gas cleaning and the furnace and auxiliary equipment and technology.

The complete plant was designed by Tenova Pyromet, and the majority of the technological equipment fabricated at Tenova's Timec facility located in

China

Tenova Pyromet provided guarantees for completion, furnace power, production capacity and product grade, all which was met shortly after the plant was commissioned.

One of the major challenges that had to be overcome was the physical site layout for the expansion project. The ASA Metals site is located on the slope of the Lebalelo Mountain near Burgersfort, South Africa. The Tenova Pyromet engineers delivered an innovative site layout which not only managed to fit the complete plant in a small foot print, but also provide unrestricted maintenance access.

Google Image of ASA Metals Plant

The new plant had to be constructed next to the existing operating plant, which meant that the construction philosophy had to be flexible and not interfere with the existing operation.

A further challenge was to manage the extensive logistics involved in supplying a substantial amount of equipment from Tenova's Timec workshop in China. All equipment fabricated met with Tenova Pyromet's world class quality requirements and was delivered to the ASA Metal site well within schedule.

The smelter incorporates the following technology:

Pyromet submerged arc closed furnace technology
Outotec single shaft pre-heating system
Pyromet patented electrode columns, which are installed on all six of the ferrochrome furnaces constructed in South Africa during the last two years
Complete plant automation system designed by Pyromet
Pyromet designed furnace off-gas scrubbers, two per furnace with each scrubber rated at 130% of furnace capacity
Fully integrated and automated raw material handling system from the mine through to the Pyromet ore beneficiation plant

Project Information

Project name: ASA Metals Expansion Project

Client: ASA Metals (Pty) Ltd

Site: Burgersfort, Limpopo province, South Africa

Project description: Brownfield turnkey design, supply, erection, commissioning and equipment and process guarantees of furnaces, furnace building, off-gas scrubbing, slurry handling, raw material storage and batching systems, electrical HVA,MV, LV, control and instrumentation.

Disciplines included: Process Technology, civil, structural, mechanical, electrical, instrumentation and automation

Produces: Charge chrome (ferrochrome)

Furnace capacity: 2 x 66 MVA (54 MW)

Production capacity: 254,000 tpa charge chrome

Project duration: 20 months

Commissioned: July 2009

Plant startup: August 2009

Project Statistics

Concrete: 20 000 m3

Steel structures: 7 000 tons

Construction Man hours: >1 million

Project team: 70 persons