Vanchem is a primary vanadium processing facility with a beneficiation plant – located at Ferrobank Industrial Park in Emalahleni Local Municipality, Mpumalanga Province, in South Africa.
The facility is also capable of producing vanadium trioxide.
Vanchem’s ore supply is a blend between the Vametco Upper Seam project and third-party ore, and also utilises the salt-roast beneficiation process.
During the first half of 2023, a new supply agreement for lower-silica ore than the Upper seam ore, was agreed at Vanchem with a third party, and it is anticipated to allow for higher recoveries – resulting in a more stable production rates at no additional costs.
Bushveld Vanadium's Vanchem processing facility employs the standard salt-roast and leach process to produce ferrovanadium.
Crushing, milling and magnetic separation to produce a magnetite concentrate with average grades of 1,65% V2O5 in-magnetite
Sodium salt roasting the concentrate in a kiln at ±1 150°C to form a water-soluble sodium vanadates material
Leaching and purification, with dissolution of roasted vanadium concentrate in water, purification and precipitation of vanadium through the addition of ammonium sulphate, followed by drying and then processing in a reducing environment to produce an Ammonium Metavanadate (AMV) product
De-ammoniating and melting the AMV to produce vanadium pentoxide flakes – a primary product, also used in other processes to produce a spectrum of vanadium chemicals
Reducing vanadium pentoxide by aluminium in the aluminothermic process, in the presence of iron, to produce ferrovanadium – a primary product