
South African SmeltDirect Salvation: Ferroalloy Future Found?
African Rainbow Minerals unveiled SmeltDirect, a breakthrough smelting technology reducing electricity consumption by up to 70% and carbon emissions by 60% in ferroalloy production. Conventional smelting requires approximately four megawatts per metric ton of alloy, while SmeltDirect reduces this to roughly 1.2 megawatts. The technology enables utilisation of fine ores, slimes and lower-grade raw materials typically difficult to process. This innovation could revive South Africa's ferroalloy industry, which has struggled due to high electricity prices and unreliable power supply. The country holds some of the world's largest chrome and manganese reserves, but many local smelters have reduced production or shut down. SmeltDirect could enable domestic processing, supporting mineral beneficiation and increasing value generated within South Africa's mining sector. Industry stakeholders believe the technology could help reopen idle smelters, strengthen competitiveness, and support production of lower-carbon raw materials for global steel industry.