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Mintek
Mintek Pyrometallurgy
Mittal Steel Newcastle
Namakwa Sands
Palabora Mining
Pyro 2006
Richards Bay Minerals
SA Calcium Carbide
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Ticor SA
University of Pretoria
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Xstrata Alloys
Zimbabwe Alloys
Zimplats
Zincor
 

Southern Africa

Pyrometallurgy in Southern Africa

by

Rodney Jones


List of Southern African Smelters

Aluminium
Mozal, Maputo, Mozambique, 550 kt/a
Hillside Smelter, Richards Bay, 700 kt/a
Bayside Smelter, Richards Bay, 175 kt/a
(Coega (Alcan), 720 kt/a - construction 2008-2013, cost R20bn, 1350 MW)

Calcium Carbide
SA Calcium Carbide (formerly Karbochem), Newcastle

Cobalt
[Chambishi Metals, Kitwe, Zambia, 3.4 - 4 kt/a Co - Closed]

Copper
Kansanshi (First Quantum), Zambia, 300 kt/a (IsaSmelt)
Konkola Copper Mines Nchanga Smelter, Chingola, Zambia, 300 kt/a (Outokumpu flash smelting furnace and slag cleaning)
Mopani Copper (Glencore), Mufulira, Zambia, 185 kt/a (IsaSmelt)
Palabora Mining, Phalaborwa, 160 kt/a (Reverb)
Chambishi (China Nonferrous Metal Mining Group), Zambia, 250 kt/a (IsaSmelt)
Dundee Precious Metals Tsumeb (previously Namibia Custom Smelters (Weatherly International); formerly Ongopolo Mining and Processing), Tsumeb, Namibia, 40-50 kt/a (Ausmelt)
BCL nickel-copper smelter, Selebi Phikwe, Botswana, 30 kt/a (Outotec flash)
Rubamin, Likasi, DRC, 20 kt/a
Copalcor (secondary smelter), Germiston, 5 kt/a
[Konkola Copper Mines (Sterlite) Nkana Smelter, Kitwe, Zambia, 165 kt/a - Closed in 2009]

Ferrochromium
Glencore-Merafe Lion I and II, Steelpoort, 288 MVA (4 furnaces), 720 kt/a
Ferrometals (SamancorCr), Witbank / eMalahleni, 287 MVA (6 furnaces), 550 kt/a
Glencore Wonderkop, Rustenburg, 6 x 45 MVA (6 furnaces), 545 kt/a
Glencore Rustenburg, Rustenburg, 210 MVA (6 furnaces), 430 kt/a
Hernic Ferrochrome, Brits / Madibeng, 54 + 78 + 37 + 37 MVA (4 furnaces), 420 kt/a
ASA Metals (SamancorCr / was Sinosteel), Dilokong, 33 + 45 + 2 x 66 MVA (4 furnaces), 410 kt/a
Glencore Lydenburg, Lydenburg / Mashishing, 137 MVA (4 furnaces), 400 kt/a
Tubatse Chrome (SamancorCr / was Sinosteel), Steelpoort, 240 MVA (6 furnaces), 380 kt/a
Assmang Chrome, Machadodorp, 54 + 96 MVA (2 furnaces + 1 remnants), 300 kt/a (Not operating)
Middelburg Ferrochrome (SamancorCr), Middelburg, ~130 MVA (DC) + 96 MVA (AC) (6 furnaces), 285 kt/a
TC Smelter (was IFM) (SamancorCr), Mooinooi, near Brits / Madibeng, 132 MVA (2 furnaces), 240 kt/a
Glencore Boshoek (was SA Chrome), Boshoek, near Rustenburg, 2 x 60 MVA (2 furnaces), 240 kt/a
Traxys (was Tata) Richards Bay Alloys, Richards Bay, 2 x 38 MVA (2 furnaces), 150 kt/a (Not operating)
Mogale Alloys, Krugersdorp / Mogale City, 50 MVA (DC) + 40 MVA (AC) (4 furnaces), 130 kt/a
[Bathlako Ferrochrome (Samancor), 25 kt/a - Closed in 1999]
Zimbabwe Alloys, Gweru, Zimbabwe, 43 kt/a
Zimasco, Kwekwe, Zimbabwe, 220 kt/a
Maranatha Ferrochrome, Eiffel Flats, Kadoma, Zimbabwe

Ferromanganese
Metalloys, Meyerton, 530 kt/a
Cato Ridge Alloys (Assmang), Cato Ridge, 245 kt/a
Advalloys, Meyerton, 75 kt/a
Transalloys, Witbank, 50 kt/a
Okahandja Manganese Smelter, Namibia

Ferrosilicon
Metalloys, Meyerton
Rand Carbide, Witbank, 58 kt/a
Xstrata Silicon Technology, Ballangeich

Ferrovanadium
Vanchem division of Highveld Steel and Vanadium, Witbank, 17 kt/a (vanadium slag)
Rhovan (Xstrata), Brits, 6kt/a FeV .
Vametco Alloys (Stratcor / Evraz), Brits, 5.25kt/a, Nitrovan and FeV
[Vantech (Xstrata), ex Vansa, Kennedys Vale / Steelpoort (converted to FeCr)]

Gold
Rand Refinery, Germiston

Iron and Steel
ArcelorMittal Steel Vanderbijlpark, 3.5 Mt/a
ArcelorMittal Steel Saldanha, 1.4 Mt/a
ArcelorMittal Steel Newcastle, 1.5 Mt/a
ArcelorMittal Steel Vereeniging, 0.4 Mt/a
Zisco Steel, Zimbabwe, 1 Mt/a
Evraz Highveld Steel and Vanadium, Witbank
Scaw Metals, Germiston, 500 kt/a
Dunswart Steel, Benoni
Cape Town Iron and Steel Works (Cisco), Kuilsrivier, Cape Town, 400 kt/a

Lead
Frys Metals (secondary smelter), Germiston, 55 kt/a

Nickel
BCL, Selebi-Phikwe, Botswana, 60 kt/a
Bindura Nickel, Bindura, Zimbabwe (to be completed Q1 2016)
Empress Nickel, Eiffel Flats, Zimbabwe
(also see Platinum Group Metals)

Platinum Group Metals
Anglo Platinum Waterval Smelter, Rustenburg, 2.5 Moz/a Pt
Anglo Platinum Polokwane Smelter, Polokwane
Anglo Platinum Mortimer Smelter, Rustenburg
Impala Platinum, Rustenburg, 2.0 Moz/a Pt
Lonmin Platinum, Mooinooi, 0.9 Moz/a Pt
Northam Platinum, Northam, 0.2 Moz/a Pt
Zimplats (formerly Makwiro Platinum), Zimbabwe, 0.1 Moz/a Pt

Silicon
Xstrata Silicon Technology, Ballangeich, 55 kt/a
Invensil Silicon Smelters, Polokwane, 40 kt/a
Namibia Metals, Omaruru, Namibia, 20 kt/a

Silico-manganese
Metalloys, Meyerton, 200 kt/a
Transalloys, Witbank, 180 kt/a

Stainless steel
Columbus Stainless, Middelburg

Titania Slag
Richards Bay Minerals, Richards Bay, 1000 kt/a
Namakwa Sands, Saldanha Bay, 230 kt/a
Ticor SA, Richards Bay, 250 kt/a
Corridor Sands, Chibuto, Gaza province, Mozambique (feasibility study), 250 kt/a
Highveld Steel and Vanadium, Witbank, 48 kt/a

Zinc
[Zincor, Springs, 120 kt/a - Closed]


Research and Development Companies and Universities
Mintek, Randburg
Anglo Research, Johannesburg
University of the Witwatersrand
University of Pretoria
Stellenbosch University

Furnace builders and supporting companies
Bateman
Hatch
Metix
Pyromet
SMS Demag
G&H Consulting Engineers
ABB
Castall Engineering
Outokumpu
Thermopower
Auburn Furnace Services
Fluor
SNC Lavalin
UCAR
Dickinson Group - Furnace Contractors & Services
Clyde Bergemann Africa, Kya Sands
Ex Mente, Centurion
Thos Begbie
Paul Wurth
Vereeniging Refractories
Vesuvius Refractories
Lafarge
BOC Afrox
Air Liquide
Praxair



Copyright © 2005-2018, Rodney Jones, rtjones@global.co.za, Randburg, South Africa (Last updated on 27 April 2018)