Tenova Pyromet, part of Tenova Mining & Minerals, has successfully completed cold commissioning of two 33 MVA ferromanganese/silicomanganese furnaces for SARDA Metals and Alloys (SMAL) in India, entrenching its position as a world class furnace designer, with extensive experience in the Indian ferroalloys market.

Awarded in 2010, the contract from SMAL covered supply of the full electrode columns and automatic furnace controller (AutoFurnTM), as well as the full basic plant design. This greenfield development near Vishakhapatnam includes its own 80MW captive power plant, and the generated capacity will be distributed between the two furnaces and the local power grid. Plans for the world class plant include an extensive greenery project and a rain water harvesting dam, which will reduce the plant’s overall carbon footprint, making it one of the most environmentally friendly plants in India.

In carrying out the project,Tenova Pyromet drew on its operational plant experience as well as on its state-of-the-art software tools, including the latest 3D CAD, FEA and CFD software, to take full account of the characteristics of the client’s raw material in the development of the critical furnace dimensions.

Mass and energy balance models enabled the study of the effects that input changes, such as different raw materials, would have on the process. The process design was complicated by the need to blend the lower manganese-content Indian ores with other higher grade manganese ore from South Africa or Australia, in a “two-step” process route required to produce 78% high carbon ferromanganese and silicomanganese with 65% manganese.

Tenova Pyromet’s unique understanding of the different mineralogies of the South African, Australian and Indian ores, enabled an optimized process to be designed, in conjunction with use of Tenova Pyromet’s submerged arc furnaces and furnace controllers. Optimization included not only the process but, as the mass and energy balance models are directly linked to financial models, also the project NPVs, IRRs, break even and cash flows, in conjunction with changes in input costs, assumptions, input raw materials and process parameters. These models were used ‘live’ to be able to find the best solution for the client’s specific situation.

The Tenova Pyromet electrode columns designed and supplied to SMAL offer exceptional operational availability and power efficiency, with features including a robust lower electrode system with protection for key equipment, and a modular arrangement for easy maintenance. The slipping device, a market leader in

electrode control, has a clamping shoe configuration that is able to exert adequate pressures on the electrode casings, reducing the risk of casing buckling/damage.

Tenova Pyromet’s AutoFurnTM is used to automate the furnace, controlling electrode movement and the transformer. By prioritizing the alarming convention, it is possible to operate these large plants with a lean workforce.

The raw material handling systems to feed the furnaces makes use of a recent Tenova Pyromet development, the rotary conveyor, which feeds the furnace charging feedbins. By being able to rotate both clockwise and anti-clockwise, the rotary conveyor reduces lag time between charging of each bin.

“The advantage of Tenova Pyromet’s extensive capability and wealth of operational plant experience is clearly demonstrated by the fact that all our furnace designs exceed contracted performance guarantees, and comply in all safety and environmental aspects,” says Sachin Arjun, Project Manager, Tenova Pyromet.

Tenova Pyromet has worked with both the private and state sector ferroalloy industry in India since 2004, when it was contracted by Nava Bharat Ferro Alloys Limited to design and supply the electrode column and electrode seals for its 24 MVA silicomanganese furnace. Besides significant repeat work from Nava Bharat, it has also since worked for a number of other leading companies, including Steel Authority of India Ltd (SAIL), Indian Metal & Ferro Alloys Limited,Visa Steel and Visa Bao Limited.

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.

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