Two 33 MVA FeMn/SiMn furnaces, which were switched-in in June 2014 by Sarda Metals & Alloys Ltd. (SMAL), with full support from high capacity furnace and smelting plant specialist, Tenova Pyromet, have consistently met their guaranteed operating parameters since then. Tenova Pyromet is part of the global total technology solutions provider, Tenova Mining & Minerals.
The furnaces are part of a green fields development near Visakhapatnam, India, for which Tenova Pyromet provided the furnace technology package, together with the basic engineering package for the main process plant, following the award of the contract in 2010.
In line with its commitment to supporting its clients during and following the completion of a project, Tenova Pyromet maintained its involvement with and assistance to SMAL throughout the cold and hot commissioning of the furnaces, as well as during the switch-in and ramp-up to full production.
A team of six Tenova Pyromet engineers and process specialists worked in close collaboration with SMAL’s production team throughout the switch-in process. This involved reconfirming the cold commissioning status of the two furnaces by checking the functionality of the equipment and all the alarm and trip set points, followed by the warmup procedure until the switch-in milestone was reached. Once the furnace production was stabilised, the Tenova Pyromet-supplied automatic furnace controller (AutoFurn™) was commissioned and ramp up to full production proceeded.
In carrying out the project and assisting with the cold and hot commissioning, Tenova Pyromet drew on its vast furnace design and operational plant experience. “Switch-in was seamless and the successful first tap on the furnace was achieved within five days“ said Henk van der Bijl, Tenova Pyromet Project Manager. “The support we provided SMAL is typical of our approach to our projects to support our installations throughout their lifecycle, through commissioning, switch-in and ramp up, to comprehensive aftermarket support through our Client Support Services.”
Following cold-commissioning, Manish Sarda, Director – International Business, SMAL, commented: “The flexible and interactive way they execute projects made Tenova Pyromet the ideal technology partner for this strategic venture. Tenova Pyromet has played an integral role in the successful cold commissioning of the plant. During the execution of the project, SMAL and Tenova Pyromet have forged a strong relationship … and all Tenova Pyromet deliverables were honoured within the agreed timeframes.”
The two furnaces, operating on ferromanganese (FeMn) and silicomanganese (SiMn) respectively, are designed based on an optimised two-step process to handle the feed of a blend of lower and higher grade manganese (Mn) ores. The furnaces are equipped with Tenova Pyromet electrode columns, which, considered a benchmark in the industry, offer exceptional operational availability and power efficiency.
Tenova Pyromet’s AutoFurn™ technology keeps the furnace running as optimally and effectively as possible, by maintaining the required furnace power and electrode resistances or currents. Providing an additional level of automation above the SCADA and PLC, AutoFurn™ results in considerably increased plant productivity.
The furnaces’ raw materials feed system utilises the Tenova Pyromet developed rotary conveyor. Rotating both clockwise and anti-clockwise, the rotary conveyor reduces lag time between charging of each feedbin.
Tenova Pyromet is a leading company in design and supply of high capacity AC and DC furnaces and complete smelting plants for production of ferroalloys, base metals, slag cleaning and refining. Tenova Pyromet also designs and supplies equipment for material handling and pre-treatment, alloy conversion and refining, granulation of metal, matte and slag, furnace off-gas fume collection and treatment, and treatment of hazardous dusts and waste. Tenova Pyromet has several technologies to reduce operating costs and increase production power consumption.
Tenova Mining & Minerals is a total integrated solutions provider to the global mining, bulk materials handling and minerals beneficiation and processing sectors, offering innovative technological solutions and full process and commodity knowledge across the mining industry value chain.
Technical Contact: Andre Esterhuizen [email protected] Tel: +27 11 480 2000
Tenova is a worldwide supplier of advanced technologies, products, and engineering services for the metals and mining & minerals industries. More information is available at www.tenova.com.