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• Manganese Metal Company (MMC) is globally significant as the world’s largest refiner of 99.9 percent pure, selenium-free electrolytic manganese metal (EMM);
• The material is important for industry and energy transition, used in lithium-ion batteries, alloying and welding, and electronics;
• ABB’s controller technology supported overcoming power instability challenges in a facility where continuous supply is essential for operations.
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 refinery1 of 99.9 percent selenium-free EMM. MMC serves over 120 customers across 20 countries, exporting around 95 percent 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 aging 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, 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 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,” said Teheli Morabe, Chief Operating Officer, MMC. “Technical constraints, particularly the use of older rectifier technology, resulted in trips whenever there was adverse weather and during electrical grid fluctuations. The plant’s continuous production demands meant that 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.”
“Our project with MMC is an example of ABB working in an unseen way yet making a significant positive impact to important customer operations,” said Ralph Burgener, Global Business Unit Manager for High-Power Rectifier, ABB’s Process Industries division. “Power supply challenges exist the world over but are particularly well-known in South Africa. To be able to overcome that with automated, power control technologies brings a great deal of satisfaction to our teams as engineers. We are enabling this manganese plant to compete internationally, which aligns with ABB’s mission of engineered to outrun.”
ABB (abb.com) is a global technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. By connecting its engineering and digitalization expertise, ABB helps industries run at high performance, while becoming more efficient, productive and sustainable so they outperform. At ABB, we call this ‘Engineered to Outrun’. The company has over 140 years of history and around 110,000 employees worldwide.
ABB’s Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs from supplying energy, water and materials, to producing goods and transporting them to market. With its ~26,000 employees, leading technology and service expertise, Automation helps process, hybrid and maritime industries outrun leaner and cleaner.
About Manganese Metal Company (Pty) Ltd
MMC’s refinery (mmc.co.za) is situated in Mbombela (Nelspruit), South Africa. In operation since 1974, we are 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.
We supply various quality grades of EMM to a niche market of over 120 established customers in 20 countries, through our unique global marketing network. Our strategically placed warehouse stock in our key markets, is readily available to be delivered to the customer’s door. Our in-house Logistics Team manages our entire supply chain. Exporting around 95% of production, we have excellent relationships with our supply chain partners.
Our systems, equipment, safe operating philosophy and excellent business practices provide our customers with peace of mind, first-class quality and reliable supply.
MMC’s refining plant is aligned with the South African government’s objectives of beneficiation and empowerment.
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