1. AC Submerged Arc Furnace (SAF)

AC Submerged Arc Furnace (SAF)

Tenova specialises in Submerged Arc Furnace design and technology for furnace projects that ensures continuous operation and technical feedback.

This increases Tenova 's leading edge technology and depth of experience by fulfilling our passion for continuous improvement and providing the best available practice to customers.

The raw materials, operating philosophy and smelter layout of these projects are unique for each customer. Therefore, each project provides the opportunity for the Tenova design, project and process engineers to interact with the customer to design a smelter which combines the best available practice with the customer's particular raw materials, operating philosophy and site layout.

Furnace Technology

Tenova' specialisation in Furnace design and technology and a comprehensive list of current and past furnace projects ensure continuous operation and technical feedback.

This further increases Tenova' leading edge technology and depth of experience in fulfilling our passion for continuous improvement and providing the best available practices to customers.

The raw materials, operating philosophy and smelter layout of these projects are unique for each customer, providing the opportunity for Tenova design, project and process engineers to interact with the customer to design a smelter which combines the best available practice, with the customer's particular unique needs around raw materials, operating philosophy and site layout.

The most important aspects of designing a furnace are understanding the effect of the client's specific raw material on the furnace design and determining the correct furnace critical dimensions, such as diameter and depth of the furnace crucible, electrode diameter, electrode spacing, length, width, feed chute arrangement, alternating or direct current, transformer characteristics and bustube arrangement. Tenova has mastered these fundamental design aspects, which are custom designed for each project. This cutting-edge knowledge is clearly demonstrated in the way all our furnace designs regularly exceed contracted performance guarantees.

Control of the furnace process, safety and equipment protection is achieved using advanced automation, as developed by Tenova with input and collaboration from the customer. The combination of Tenova' innovative culture and an in-depth understanding of the smelting business has ensured many innovations, ranging from detailed design improvements that improve efficiency and reliability, through to ground-breaking changes that effect the direction of the industry.

Tenova Pyromet offers a comprehensive list of services to its clients, including:

  • Full LSTK execution
  • Design, supply and supervision package
  • Site supervision services, including commissioning assistance and operator training
  • Plant productivity analysis
  • Studies
  • Engineering Modelling and Investigations, including FEA and CFD Modelling
  • Efficiency

    Efficiency

    • Utilization of pre-heated, pre-reduced charge materials
    • Gas-tight, high efficiency furnaces with complete recovery of CO-rich gasses
    • Minimum reactance, minimum unbalance solutions for the secondary circuit
    • Dependable electrode slipping system
    • Power input up to 100 MVA
  • Technical Excellence

    Technical Excellence

    • Furnaces have been installed for various types of ferroalloys (ferrochrome, ferromanganese, silicomanganese, ferrosilicon, ferronickel) as well as for silicon metal, pig iron, calcium carbide, phosphorous and non-ferrous metals such as copper, nickel, silver, platinum group metals, etc.
  • Environment

    Environment

    • Special smelting furnaces perform slag cleaning or dust recycling processes can be devoted to the production of materials as diverse as Rockwool, abrasives, refractories, etc
  • Reference

    Reference

    • Tenova Pyromet has built >70% of the SAF for ferroalloys in South Africa and +30% world SAF market outside China

Downloads

References

  • Customer
    Project name
    ASA Metals Expansion Project
    ASA Metals (Pty) Ltd
    South Africa
    2000, 2002, 2009

    Turnkey design, supply, erection, commissioning and equipment and process guarantee of furnaces, furnace building, off-gas scrubbing, slurry handling, raw material storage and batching systems, electrical HV, MV, LV, control and instrumentation.

    In 2007 ASA Metals awarded a Lump Sum Turn Key contract to Tenova Pyromet for the ASA Metals expansion project. The project scope included the design, supply, installation and commissioning of 2 x 66 MVA closed submerged arc furnaces, complete with single shaft pre-heating systems. Tenova Pyromet had supplied and installed ASA Metals No1 furnace in 1999 and No2 furnace in 2005.

    The expansion project scope of work included the upgrade of No1 & 2 furnace material feed system, which resulted in a fully automated raw material system feeding all of the ASA Metals furnaces. One of the major challenges to be overcome was the physical site layout for the expansion project, with the ASA Metals site located on the slope of the Lebalelo mountain.

    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. 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.

    Of major interest is the evolution of the design from what was agreed to in the contract to what was commissioned on site. During the design review the client appointed a mechanical manager; upon his request, the roof design, water cooled off-gas duct, position of gas cleaning plant and water cooling header and tundishes were changed.

    Project Figures

    66 MVA
    45 MVA
    30 MVA
  • Lonmin

    Customer
    Project name
    Lonmin
    South Africa
    2012

    Design and supply of the furnace equipment.

    As a brownfields project, space and operational constraints were significant challenges to overcome. The circular furnace had to be successfully integrated into a building designed for a rectangular furnace, while there were to be no interruptions to production on existing furnaces or converters during construction or commissioning. To achieve this, the removal of old transformers and installation of the new transformers and shell into the building were accomplished using a 500 ton crane to lift them over existing equipment. Integration of the raw material, slag and matte and exhaust gas handling facilities into the existing plant was an important design consideration.

    Project Figures

    12 MVA
  • International Ferro Metals

    Customer
    Project name
    International Ferro Metals
    South Africa
    2007

    Turnkey design, supply, erection, commissioning and equipment and process guarantee of furnaces, furnace building, off-gas scrubbing, slurry handling, raw material storage and batching systems, electrical HV, MV, LV, control and instrumentation.

    The first of the two furnaces were started-up three weeks ahead of schedule and the second furnace four weeks ahead of schedule. The project duration from the date that Tenova Pyromet received the green light to proceed was 15 months for the first furnace and 16 months for the second furnace. This project duration is an exceptional feat by Tenova Pyromet bearing in mind that this was a greenfield project. The scope of work was implemented to a high standard of quality, technology and attention to detail. The early start-up is a testament to Tenova Pyromet's extensive experience in large greenfield Turnkey projects and the good working relationship between Tenova Pyromet and its clients.

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  • ContactContact PersonPositionLegal EntityDepartmentPhoneFaxE-mailAddress
    Tenova South Africa (PTY) Ltd.
    General
    +27 11480 2000
    +27 8674 30389
    pyromet@tenova.com

    Midrand Business Park, Building no 4, 563 Old Pretoria, Main Road Halfway House, Midrand, Johannesburg

    1685 Johannesburg

    South Africa

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