www.exxaro.com
Exxaro FerroAlloys Ferrosilicon FeSi15
CONTENTS
Exxaro Resources Limited 5
Exxaro FerroAlloys 5
Certification 7
Production process 9
Quality characteristics 10
Benefits of Exxaro FerroAlloys ferrosilicon 11
Location 12
Contact details 13
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Exxaro rEsourcEs LimitEd
Exxaro is one of the largest and foremost black-owned South
Africa-based diversified resources companies, with current
business interests in coal, iron ore and ferroalloys, titanium
dioxide pigments and chemicals in South Africa and Australia.
Exxaro had a market capitalisation of US$1.65bn as at 30 June
2016.
Exxaro is among South Africa’s largest coal producers and is
the largest supplier to Eskom, South Africa’s national electricity
utility, with long-term contracts. Exxaro’s strategy will develop
the company along the electricity value chain within the
African continent. Exxaro is listed on the Johannesburg
Stock Exchange (JSE) and has been included in the FTSE/JSE
Responsible Investment Index since 2015.
Exxaro FErroaLLoys
Exxaro’s FerroAlloys ferrosilicon plant was established in
1996. Two new plants were commissioned in 2014 and 2016
respectively in order to guarantee supply of up to 12 000
tonnes of superior quality gas atomised and milled ferrosilicon
(FeSi) per annum.
Over the last two decades, Exxaro has developed two ground-
breaking processing technologies aimed at improving
beneficiation processes and the recovery of mineral products
from low grade stockpiles, in-situ resources and waste dumps in
order to overcome global mining challenges such as depleting
reserves and resource quality issues.
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cErtiFication
Exxaro FerroAlloys is ISO 9001, ISO 14001 and OHSAS 18001 certified and adheres to
strict control measures to ensure compliance with all quality, environmental and health
and safety standards. In the six years since the original certification, Exxaro FerroAlloys
has successfully met the criteria of surveillance and recertification audits conducted by
an external certification body.
A key component of both the Ultra High Dense Medium Separation (UHDMS)
and Ultra Fine (UF) processing technologies is the high-quality gas atomised
ferrosilicon produced at Exxaro FerroAlloys.
Early commercialisation projects were conducted successfully in the iron
ore industry with the support of Kumba Iron Ore, where Exxaro holds a 20%
shareholding in its subsidiary, the Sishen Iron Ore Company. The UHDMS and
UF processes are currently being commercialised across a number of other
commodities with the intent of growing the market. The production of FeSi is
therefore critical to Exxaro’s long-term growth and investment strategies.
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Production ProcEss
Ferrosilicon powder is made by melting a fixed ratio of high
purity iron and crude ferrosilicon in an induction furnace. The
molten metal is then atomised using a high pressure stream of
inert nitrogen gas to produce a high-grade ferrosilicon powder
with a silicon content varying between 14-16%, known as FeSi
15.
Exxaro FerroAlloys produces gas atomised and milled FeSi of
various particle size distributions and can tailor production to
produce FeSi for most application requirements.
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High particle density range of particle size distributions
spherical shape (Gas atomised Fesi)
• Enables preparation of low viscosity mediums at high density
• Special coarse to fine
• Enables FeSi product selection suited to the density range required
• Results in low medium viscosity even when high separation densities are required
• Leads to lower particle misplacement and higher separation efficiency
superior magnetic properties/susceptibility
High corrosion resistance
High medium stability
• Enables unrivalled recovery of FeSi using LIMS (Low Intensity Magnetic Separator)
• Results in significantly lower medium losses and lower FeSi consumption
• Leads to lower operating costs
• Results in improved medium stability
• Reduces FeSi consumption
• Leads to lower operating costs
• Lower risk of H2 (Hydrogen)
gas evolution
• Exxaro FerroAlloys FeSi is a stable dense medium with correct application
• Results in good separation efficiency
technical support for customers
Packaging transport
• The Exxaro team possesses extensive experience and knowledge in mineral processing
• Technical support is available to all customers
• All packaging used for the FeSi is safe, water resistant, durable, stackable and biodegradable
• Customers can choose between 1 tonne bulk bags or 50 kg bags
• 1 tonne bulk bags have a bottom discharge for ease of handling
• Transportation can be arranged if required
QuaLity cHaractEristics
Exxaro FerroAlloys FeSi has
superior qualities with respect
to physical properties such
as sphericity, homogeneity,
degradation resistance, specific
gravity, corrosion resistance and
magnetism.
The production process guarantees
that each FeSi particle is
consistently small, solid and dense
to ensure superior performance
as a dense medium compared
to conventional atomisation
methods using water/steam. The
superior physical properties of the
Exxaro FerroAlloys FeSi results in
enhanced rheological properties
for beneficiation through dense
medium separation.
BEnEFits oF Exxaro FErroaLLoys FErrosiLicon
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Location
The Exxaro FerroAlloys ferrosilicon plant is situated in the province of Gauteng at
20 Roger Dyason Road, Pretoria West, 0001, South Africa.
GPs coordinates: 25°45’57.8”S 28°08’35.8”E
contact dEtaiLs
Hensa van Wyk
Specialist Marketing
Tel: +27 12 307 3489
Fax: +27 12 307 7157
E-mail: [email protected]
neels Potgieter
Manager, Ferrosilicon Operations
Tel: +27 12 307 8385
Fax: +27 12 307 7157
E-mail: [email protected]
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