ABB has deployed its high-performance controller technology for high-power rectifier applications to ensure stable power supplies at the Manganese Metal Company (MMC) refinery in Mbombela, South Africa.
The plant in the northeastern Mpumalanga province is nationally and internationally significant as the world’s only non-China based producer of high-grade electrolytic manganese metal (EMM), and the world’s largest refinery of 99.9% selenium-free EMM.
MMC serves more than 120 customers across 20 countries, exporting around 95% of its annual production for industry and energy transition applications including lithium-ion battery manufacturing, alloying and welding, and electronics.
With operational stability critical to its success in a competitive global environment, ABB technology was deployed to mitigate power fluctuations from unstable power supply that was putting a strain on ageing transformers.
ABB’s AC 800PEC high-performance controller, which is designed for rapid and precise responses to power fluctuations, was coupled with ABB high-power rectifier technology, six MCR1000 units (pictured), to provide maximum availability and highest productivity. The controller can run high-performance applications with fast control algorithms – cycle times that can run at 100 microseconds for fast control loops.
The customer has reported that the advanced control system has significantly reduced unplanned outages and enhanced operational stability. With improved system robustness, MMC has achieved greater predictability and reliability in its production processes.
“We were faced with several critical challenges that affected our operations and potentially our market position,” says Teheli Morabe, chief operating officer at MMC. “Technical constraints, particularly the use of older rectifier technology, resulted in trips whenever there we adverse weather and during electrical grid fluctuations. The plant’s continuous production demands meant downtime was not an option, and so we had to resolve these issues without disrupting operations. ABB’s innovations not only addressed our immediate operational challenges but also established a foundation for long-term stability and competitiveness.”
Comments Corné Jordaan, Local Business line manager for ABB’s Process Industries division: “The project’s success was a testament to the collaborative partnership between ABB and MMC. Throughout the project, we worked closely with our customer to ensure the solution met the plant’s specific needs and operational goals. ABB’s engineers tailored the system design, aligning every element with MMC’s stringent key performance indicators.
“The partnership also required adaptability and ingenuity, as installation and commissioning were carried out without halting production – an achievement made possible through meticulous joint planning and the engineering teams’ technical expertise.”