Manganese Metal Company Partners with ABB for Enhanced Power Stability
Manganese Metal Company (MMC) stands out as the world’s leading refiner of 99.9% pure, selenium-free electrolytic manganese metal (EMM). This crucial material plays a significant role in various industries, particularly in the energy transition, where it is essential for lithium-ion batteries, alloying, welding, and electronics. ABB’s advanced controller technology has been pivotal in mitigating power instability issues in facilities where a consistent power supply is vital to operations.
Advanced Technology Implementation at MMC’s South African Refinery
ABB recently introduced high-performance controller technology designed for high-power rectifier applications at the MMC refinery located in Mbombela, South Africa. Situated in Mpumalanga, this plant is notable not only for being the only high-grade EMM producer outside of China but also for ranking among the largest 99.9% selenium-free EMM refineries globally. MMC caters to over 120 clients across 20 countries, exporting approximately 95% of its annual production to sectors focused on industrial and energy transition applications.
Importance of Operational Stability in a Competitive Global Market
Operational stability is crucial for success in today’s competitive market, and ABB technology was deployed to tackle power fluctuations stemming from unstable sources that had been straining older transformers. The AC 800PEC high-performance controller, combined with six MCR1000 units of ABB’s high-power rectifier technology, is engineered to swiftly and accurately respond to these fluctuations, enhancing availability and productivity. This controller operates high-performance applications leveraging fast control algorithms, with cycle times as rapid as 100 microseconds for essential control loops.
Successful Installation and Operational Improvements
Feedback from customers indicates that the newly implemented advanced control system has significantly curtailed unplanned outages, thereby bolstering operational stability. With enhanced system robustness, MMC’s production processes have become more predictable and reliable.
Addressing Technical Constraints and Ensuring Continuous Production
Tehri Molave, the Chief Operating Officer at MMC, highlighted that technical limitations, particularly tied to outdated rectifier technology, had been causing production interruptions during adverse weather or fluctuations in the power grid. Given the factory’s continuous production demands, downtime was simply not an option. “We needed to resolve these issues without causing disruptions,” he stated. The solutions provided by ABB not only addressed immediate operational challenges but also laid the groundwork for long-term stability and competitiveness.
ABB’s Commitment to Innovative Engineering Solutions
Ralph Bergener, ABB’s Global Business Unit Manager for High Power Rectifiers, expressed that the project with MMC exemplifies ABB’s mission to contribute positively to the operations of its vital customers in subtle yet impactful ways. He noted that power supply challenges are pervasive globally but are particularly pronounced in South Africa. By deploying automated power control technology, ABB aims to ensure that the manganese plant remains competitive on an international scale, aligning with its overarching mission of technological advancement.
ABB: A Leader in Electrification and Automation
ABB is recognized as a global technology leader in electrification and automation, driving a more sustainable and resource-efficient future. By integrating engineering and digital expertise, ABB empowers industries to operate with high efficiency while enhancing productivity and sustainability. With a heritage spanning over 140 years, ABB employs approximately 110,000 professionals worldwide. Its shares are publicly traded on the Swiss SIX Exchange (ABBN) and Nasdaq Stockholm (ABB).
Through its Automation division, ABB automates, electrifies, and digitizes essential industrial operations, catering to a diverse array of needs—from supplying energy, water, and materials to manufacturing goods and facilitating transport to market. With around 26,000 employees and state-of-the-art technology, ABB Automation aids process, hybrid, and maritime industries in achieving greater efficiency and sustainability.
