Abstract Chromite fines (defined as particles smaller than 6 mm) account for a significant fraction of mined South African chromite ore. These fines are pelletized to allow safe furnace smelting conditions. However, pelletization is an energy- and cost-intensive process that requires significant capital investment and has high operational costs as continuous curing temperatures of 1300 – 1500 °C are required. In this study, various cold-bonded pelletization processes were investigated to identify a process to prepare cold-bonded chromite pellets. A feasible process was identified and developed to produce mechanically strong chromite pellets using 3wt% sodium silicate-3 wt% SiO2 as the binder and KOH as an alkaline activator. The binding mechanism is based on the combined effects of sodium silicate and geopolymerization. It was determined that pellets cured at 75 °C had compressive strengths of 2.41 – 3.12 kN. The mechanical strength of these cold-bonded pellets where similar to, or exceed that of pellets currently used in the FeCr industry.

The chromium (Cr) content of stainless steel originates from recycled scrap and/or ferrochrome (FeCr), which is produced mainly by the carbothermic reduction of chromite ore. The oxidative sintered pellet production process is one of the most widely applied FeCr processes. The supplier of this technology specifies that recycling of chromite-containing dust collected from the pellet sintering off-gas and fines screened out from the sintered pellets (collectively referred to as pre-oxidized chromite fines) should be limited to a maximum of 4 wt% of the total pellet composition. However, the results presented in this paper suggest that recycling of such fines up to a limit of 32 wt% of the total pellet composition may improve the compressive and abrasion strengths of the cured pellet. In addition, electron microprobe and quantitative X-ray diffraction (XRD) analyses demonstrate that chromite grains present in the pre-oxidized chromite fines consist, at least partially, of crystalline phases/compounds that will improve the metallurgical efficiency and specific electricity consumption (i.e. MWh/ton FeCr produced) of the smelting process.

Pyrometallurgical smelters consume significant amounts of fossil fuels. Notwithstanding emission abatement technologies, these smelters emit various gaseous pollutants and fine particulate matter, which are important from an air quality perspective. Additionally, carbon dioxide (CO2) and black carbon (BC), the two most important atmospheric climate forcing species, are also emitted. It is important to model the contribution, transport, and impact of pollutants emitted by pyrometallurgical smelters. In order to do this, atmospheric modellers require an accurate emission inventory, which indicates emissions (how much of what species by which processes), emission periods, stack/emission heights, and emission velocities (if emitted through stacks). However, in many countries atmospheric modellers do not have access to a proper emission inventory, or they are legally prohibited from obtaining such information. The current paper demonstrates how fire radiative power (FRP) observations by the Moderate Resolution Imaging Spectro-radiometer (MODIS) instruments on board the Aqua and Terra satellites can be used to estimate the availabilities of pyrometallurgical smelters. Such temporal activity patterns will assist modellers to re-create air quality scenarios for regions more accurately.

The specific energy consumption (SEC) of the pelletized chromite prereduction process is the lowest of all FeCr production processes commercially applied. This process also eliminates the use of chromite ore fines that could result in furnace blow-outs or so-called bed turnovers, yields a high chromium (Cr) recovery, and can produce a low-sulphur (S) and -silicon (Si) FeCr. However, this process requires extensive operational control due to the variation in pre-reduction levels and carbon contents of the pre-reduced, pelletized furnace feed material. The wet chemical analytical method currently applied for the determination of chromite pre-reduction is time-consuming. In this paper, the development of an alternative method consisting of scanning electron microscopy (SEM) micrograph image processing is presented. A strong linear correlation (R² = 0.919) between chromite pre-reduction (%), as determined by wet chemical analysis, and the new method was obtained. Further development could result in the industrial application of the method, which could contribute significantly to the metallurgical stability and enhanced process control of the pelletized chromite pre-reduction process.

Ferrochrome (FeCr) is vital for the production of stainless and high-alloy ferritic steels, since it is the only source of new Cr units. FeCr production is an energy-intensive process. The pelletized chromite prereduction process is most likely the FeCr production process with the lowest specific electricity consumption (SEC), i.e. MWh/t, currently in operation. However, due to increases in costs, efficiency, and environmental pressures, FeCr producers are attempting to lower their overall energy consumption even further. Recently, it was proven that pre-oxidation of chromite ore prior to pelletization and prereduction significantly decreases both the SEC and lumpy carbonaceous reductants required for smelting. This paper presents the first attempt at conceptualizing the techno-economic feasibility of integrating chromite pre-oxidation into the prereduction process. Financial modelling yielded a net present value (NPV) at a 10% discount rate of approximately R900 million and an internal rate of return (IRR) of approximatelyy 30.5% after tax, suggesting that the implementation of pre-oxidation prior to pellet prereduction may be financially viable. Sensitivity analysis indicated that the parameter with the greatest influence on project NPV and IRR is the level of prereduction. This indicates that the relationship between maintaining the optimum pre-oxidation temperature and the degree of prereduction is critical for maximium process efficiency.

The physical properties of oxidative sintered pellets produced from typical South African UG2 ore are compared with the physical properties of pellets produced with conventional South African metallurgical-grade chromite ore (from the Lower Group 6 or the Middle Group 1 and 2 seams). A statistical evaluation of the cured (sintered) compressive strengths proved that pellets prepared from UG2 ore are likely to have the same, or better, compressive strength than pellets prepared from metallurgical-grade chromite ore. The cured abrasion strength of the UG2 pellets was also superior to that of the metallurgical-grade pellets. Scanning electron microscopy (SEM) backscatter, secondary electron, and elemental X-ray mapping were used to determine the reasons for the general superior strength of the UG2 pellets. The case study UG2 ore also required 13 kWh/t less energy for milling to attain the required particle size distribution prior to pelletization, which can lead to substantial cost savings. Results presented in this paper can be utilized by ferrochromium (FeCr) producers to better quantify the advantages and disadvantages associated with the use of UG2 ore for FeCr production.

To braai is part of the South African heritage that transcends ethnic barriers and socio-economic groups. In this paper, a comprehensive analysis of atmospheric gaseous and aerosol species within a plume originating from a typical South African braai is presented. Braai experiments were conducted at Welgegund - a comprehensively equipped regional background atmospheric air quality and climate change monitoring station. Five distinct phases were identified during the braai. Sulphur dioxide (SO2), nitrogen oxides (NOx) and carbon monoxide (CO) increased significantly, while ozone (O3) did not increase notably. Aromatic and alkane volatile organic compounds were determined, with benzene exceeding the 2015 South African one-year ambient air quality limit. A comparison of atmospheric PM10 (particulate matter of an aerodynamic diameter <10μm) concentrations with the 24-hour ambient limit indicated that PM10 is problematic during the meat grilling phase. From a climatic point of view, relatively high single scattering albedo (ωo) indicated a cooling aerosol direct effect, while periods with lower ωocoincided with peak black carbon (BC) emissions. The highest trace metal concentrations were associated with species typically present in ash. The lead (Pb) concentration was higher than the annual ambient air quality limit. Sulphate (SO4(2-)-), calcium (Ca²+) and magnesium (Mg²+) were the dominant water-soluble species present in the aerosols. The largest number of organic aerosol compounds was in the PM25-1 fraction, which also had the highest semi-quantified concentration. The results indicated that a recreational braai does not pose significant health risks. However, the longer exposure periods that are experienced by occupational vendors, will significantly increase health risks.

South Africa holds approximately three-quarters of the world's viable chromite ore resources and dominates the global production of ferrochrome. Albeit completely unintended, small amounts of Cr(VI) are formed during ferrochrome production. Certain Cr(VI) species are regarded as carcinogenic, hence making the treatment of some ferrochrome waste materials necessary. In this paper, the Cr(VI) treatment strategies currently employed by the South African ferrochrome producers are investigated by means of a literature review and a questionnaire survey. From the discussion, it is evident that various treatment strategies are available to deal with Cr(VI)-containing waste in the ferrochrome industry. However, by far the most commonly applied treatment strategy remains the aqueous reduction of Cr(VI) with ferrous iron. The advantages and the correct application of this strategy, together with the disadvantages and pitfalls, are argued. Innovative improvements on historic practices are also discussed

The production of ferrochrome alloy from chromium bearing chromite ores is conducted at high temperature under highly reducing conditions. However, albeit completely unintended, it is impossible to completely exclude oxygen from all high temperature process steps, with the corresponding possibility arising for the generation of small amounts of Cr(VI) species. Certain Cr(VI) species are regarded as a carcinogenic, with specifically airborne exposure to these Cr(VI) species being associated with cancer of the respiratory system. With approximately three-quarters of the world's viable chromite ore reserves located in South Africa, and annual ferrochrome production approaching almost half of total annual global output, aspects of Cr(VI) generation and control are of particular relevance and importance to the local industry, and naturally to the global industry at large. This paper seeks to examine theoretical and practical aspects associated with Cr(VI) generation (based largely on experience within the local South African industry, but considered to be generally encountered in the broader global industry context), together with mitigating measures that can be applied within the context of the production processes. From the discussions it is clear that significant improvements in various Cr(VI)-related aspects have been made by the South African ferrochrome industry. However, it is also evident that several areas of uncertainty still exist, which require further research in order to better quantify risks and enhance the efficacy of mitigating steps.