editor: laura white, laura.whiteoutotec.com 1 … › globalassets › newsletters › output ›...

1

OUTOTEC CUSTOMER eNEWSLETTER 1/2015

Editor: Laura White, [email protected]

SOUTH EAST ASIA PACIFIC

CONTENTS• Case study: Sri Lanka drinking water project, page 1• Conferences and seminars, page 5• Case study: Spotted Quoll tailings paste plant, page 6• FloatForce® - 5 things you may not know , page 9• FloatForce® - Sets new standards, page 10• Business news, page 11• Case study: Tamano Flash Smelting, page 13• Analyser legacy campaign, page 15

2/2015

The NWS&DB is the principal Sri Lankan government authority responsible for providing safe drinking water and sanitation for the population, with a workforce of about 10,000 personnel.

Drinking water situationThe Ampara District is on the east coast of Sri Lanka with a population of about 650,000 in 2015. Most of the population has historically relied on groundwater wells for drinking water supply, but scarcity and poor water quality have become increasingly common.

Phase 1 and Phase 2 supplied water to the previously unserved population in nine towns. Phase 3 was sourced from a separate reservoir at Himidurawa, delivering addi-tional capacity of 6MGD (27,300 m3/day)

TURNKEY PROJECT BRINGS DRINKING WATERTO 450,000 PEOPLE IN SRI LANKA Outotec completes 3rd successive phase in Ampara, Sri Lanka. TEXT IAN DUNN

Sri Lanka’s National Water Supply & Drainage Board (NWS&DB) launched a scheme in 1999 to provide secure, quality piped drinking water to previously unserved communities in the undeveloped and remote Ampara District. This scheme was carried out in two phases by Outotec between 1999 and 2007, supplying drinking water to 300,000 local residents.

Outotec was also awarded the third and final phase in 2010, with completion in 2015. Project scope, as with previous phases, was the turnkey design, construction and commissioning of a water supply scheme - bringing water to 150,000 people in Ampara, totalling 450,000 residents overall.

CHALLENGES• Large, remote project with

complex coordination• Availability of local skilled

workerforce• Unprotected algae-affected

water source• Financing of project

SOLUTION • Turnkey delivery • Robust, appropriate technical

solution• Collaborative approach• Facilitation of finance

packages through ECAs and financial institutions

RESULTS• Quality treated water to

World Health Organisation and Australian guidelines

• Reliable 24-hr supply• Flexible water treatment

process and pumping network

2 Outotec SEAP Customer eNewsletter 2/2015

Project scopeScope was on a design and build turnkey basis, with Outotec working closely with the NWS&DB and Sri Lankan partners. Outotec was involved not only during early feasibility stages but also for testwork and process selection. The project scope comprised engineering, procurement, construction and commissioning, covering raw water intake, water treatment plant, pipelines, storage structures and pump stations. Outotec engineering and project management expertise was integral to tie all the various project elements together.

Financing Outotec is able to facilitate complete project finance packages though strong connections to Export Credit Agencies (ECAs) and international financial institutions. Phase 3 was financed at a total cost of approximately USD 119m by EFIC (Export Finance and Insurance Corporation of Australia), ANZ (Australia New Zealand Banking Group) and HNB (Hatton National Bank).

Seamless project deliveryProject management was key to the project, which faced multiple cultures, language barriers and large geographical distances. The project area covered approximately 500 km2 across as many as 20 sites, and involved up to 780 workers at peak activity. Ampara is remote from the capital Colombo, 350 km by rural roads, with a shortage of skilled labour and an absence of technically equipped workshops.

Mechanical, electrical and process design were carried out in Australia, with civil design and detailing completed in Sri Lanka. Outotec established an office in 1999 in Colombo and Ampara with expat and local personnel, providing project management, drafting and engineering expertise. Outotec introduced an online document management system for the project so that the NSW&DB had instant access to the project’s latest document versions, thereby considerably reducing their internal administration.

Robust solutionIn many locations, particularly remote, a safe, reliable drinking water supply is impossible and unrealistic without truly understanding local conditions and customer requirements. Outotec recognised, and it was also a priority for the NWS&DB, that the remote location and difficulty of maintenance necessitated equipment which was robust and built to last. All equipment for the project was of high quality and sourced from internationally reputable suppliers in Asia, Europe, USA and Australia, as in the previous project phases.

Appropriate technology The project delivered an optimum technology solution in Sri Lanka for managing algae in raw water, considering capital cost, complexity, local capabilities and water quality requirements. Additionally, due to exposure to new technologies during the previous phases, the local work-force was more familiar with new treatment solutions.

Pipe gallery for 4 x 45m2 filters Pressurised system into distribution network

Outotec SEAP Customer eNewsletter 2/2015 3

As a result, phase 3 introduced the use of dual media coal and sand filtration. Widespread elsewhere, but uncommon in Sri Lanka, this filtration method delivers better quality water and is a more robust process than monomedia sand.

Distribution networks - new approachThe NSW&DB requested a pressurised pumping solution for six distribution networks instead of conventional elevated storage water towers, in order to develop their own resources and expertise. Outotec therefore selected banks of vertical multistage pumps. These pumps were automatically controlled (complete with standby equipment and generators) to operate for varying duties.

Raw water intake system - new approachThe common method in Sri Lanka for raw water intake is bridge construction extending into a reservoir. In Phase 3 however, raw water intake was from an earthen irrigation canal downstream of the local Himidurawa reservoir. The canal was lined in sections to mitigate erosion, and new sluice gates installed downstream to control variable seasonal flow and water level. The intake structure and vertical turbine pumps were also sized to accommodate this variability. Construction on the canal and sluice gates took place without disrupting down-stream water flow or quality.

Technological firsts in Sri Lanka In several areas Outotec implemented ‘technological firsts’ for algae management in Sri Lanka. These firsts where introduced in Phases 1 and 2 and also continued in Phase 3. These elements have subsequently been adopted in other installations around the country. One of these ‘firsts’ is DAF (dissolved air flotation) before filtration, used for water pre-treatment and an interna-tionally favoured process for algae affected waters. It replaces conventional sedimentation and Outotec was the first to implement DAF in Sri Lanka in 1999.

PAC (powdered activated carbon) systems is another technology, removing seasonal dissolved algal taste and odour compounds, as well as adsorption of potential dissolved algal toxins.

Another technological first is PACI (polyaluminium chloride) coagulant, which is an alternative coagulant to alum (used across Sri Lanka by the NWS&DB as standard). Outotec pioneered PACl dosing in Phase 2, delivering both improved process performance and also cost reduction. As a result, PACl was also implemented in Phase 3, delivering similar benefits.

Transmission bridge crossing

“Outotec has been our key partner throughout all phases of this project...Outotec was integral to successful project completion and committed to delivering to a very high standard” NWS&DB


Training and operation A well-trained, local workforce is critical to optimal ongoing plant operation. The NWS&DB commissioned Outotec to deliver a detailed training program, covering classroom-based theory as well as hands-on site demon-strations. Outotec also created comprehensive operation and maintenance manuals for all sites. Additionally, a monitoring SCADA system (supervisory control and data acquisition) was installed by Outotec to provide the local workforce with plant operation information. The system shows real time operating data, as well as delivering instant access to digital operation and maintenance manuals, historical data and online remote access. Model treatment plant “Outotec has been our key partner throughout all phases of this project. This project completes the vision we had 15 years ago to supply the people of Ampara with safe water supply,” commented a NWS&DB spokesperson. “Outotec was integral to successful project completion and committed to delivering to a very high standard. We feel that Phase 3 can be a model treatment plant for managing algal issues in Sri Lanka,” the spokesperson concluded.

Project scope• Turnkey - design, supply, construction and

commission

Project details• Source water – reservoir canal• Treatment process – dissolved air flotation and

dual media filtration

Operating systems• Canal lining, new sluice gates and raw water

intake system• A 27,300 m3/day water treatment plant, including

all chemical dosing and residuals handling • Clearwater storage including high lift pump

station• Transmission mains - 98 km of ductile iron

cement lined (DICL) • Intermediate booster pump stations (x6) with

pressurised pumping systems • Distribution network - supply of 698 km of

polyethylene (PE) pipes and fittings

FOR FURTHER INFORMATION PLEASE CONTACT:

[email protected]


CONFERENCES (JUL-SEP) 2015From July to September 2015, Outotec will be at the following industry conferences in South East Asia Pacific. Drop by and meet our technology experts who will be on hand to answer your questions... Iron Ore 13-15 July 2015, Perth Exhibition Centre, Perth WABooth # 29Outotec papers include: • Improvements in service life and cost reduction for gyratory primary crushers through mantle and concaves optimisation• Optimisation process control in iron ore via online analysis of light elements• Iron ore tailings reprocessing to maximise ore production

For more information please visit http://www.ironore2015.ausimm.com.au/

MetPlant7-8 September 2015, Pan Pacific Hotel, Perth WABooth # 15Outotec papers include: • Improvements in flotation cell maintenance, power consumption and operations • Carmen Copper - A sustainable approach to tailings thickener upgrades• Improving cooling tower performance with innovative horizontal outflow design by• Increasing grinding circuit robustness with advanced process control For more information please visit http://www.metplant2015.ausimm.com.au/

TECHNICAL SEMINARS (JUL-SEP) 2015Our series of customer technical seminars continue to prove popular in 2015! These seminars, which are complimentary, often count towards professional development hours.

The seminars provide information on all facets of a technology - from a general overview, to in-depth discussion of operation, control, applications and new technologies. These one and two day seminars are delivered by some of the most knowledgeable and experienced personnel in the industry.

We have two upcoming seminars in the next three months:• Iron Ore Technical Seminar - Thursday 16 July in Perth, WA• Flotation Automation Seminar - Wednesday 9 September in Perth, WA

If you would like to attend or require any more information, please contact [email protected]...

THESE COMPLIMENTARY SEMINARS OFTEN COUNT TOWARDS PROFESSIONAL DEVELOPMENT HOURS.


Screening methodIn order to remove foreign material and break-up consolidated lumps of tailings, the material is screened using a mobile integrated screening unit (MISU) fitted to an excavator. The MISU uses a spinning rotor system to screen the material and will also crush the softer consolidated tailings. This method of screening has proven very successful and cost effective on tailings as it is able to handle very moist material and also the amount of oversize is limited since the lumps of tailings are crushed.

RECLAIMED TAILINGS PASTE PLANT DESIGN FOR SPOTTED QUOLLA traditional paste fill system based on an evolutionary design process.

TEXT MATHEW REVELL

The paste fill system at Spotted Quoll is characterised by the tailings being excavated from a TSF that has been decommissioned for many years. The tailings are relatively dry and friable and in more recent times the tailings have been combined with high quality dune sand.

PLANT FACTS• Organisation:

Western Areas Ltd• Location:

Kondinin, Western Australia • Application:

Nickel

SOLUTION • LSTK paste fill plant based

upon proven technologies and evolutionary design process

BENEFITS• Robust, low cost operation • Highly advanced control

system• Maximised paste quality in

real time via underground data return system


Paste plant designThe plant is designed to produce 130m3/hr of paste and consists of a material feed hopper, belt feeder, inclined conveyor, continuous twin shaft mixer, binder silo and metering system. This plant design is relatively simple, compact, very robust and moderately low cost. It is built on steeply sloping floors and has full access to all compo-nents, maximising ease of maintenance. Regardless of the plant type, producing paste is generally a messy business and good access with the ability to easily clean the plant is critical to ensure the ongoing operability.

CRITICAL DESIGN ASPECTS• The tailings feed hopper is wide and long

and completely lined with ultra high molec-ular weight polyethylene (UHMWPE). This ensures even relatively moist material can be fed into and out of the hopper without hang-ups. The large, wide and long opening requires a relatively high power belt feeder drive. At a number of different sites over the years, second hand plants from the civil industry have been used to produce paste fill. These civil style plants generally have narrow feeders that are suited to free flowing sand and aggregates. The result is that the moist tailings do not discharge evenly from the hopper. If the control sys-tem is not perfect, the general outcome is a slug of very thick/high yield stress paste being produced, often resulting in a blocked underground piping system.

• A variable speed belt feeder and feedback control system using a weightometer on the inclined feed belt. The inclined feed belt is well suited to the moist tailings with little or no spillage and the weight feedback is critical.

• The inclined conveyor is wider than the belt feeder eliminating any material transfer issues between the feeder and conveyor that could occur when treating high moisture material.

• A loss in weight (LIW) binder system. The system at Spotted Quoll consists of a weigh hopper and variable speed auger. The entire system is housed in cladding to minimise disturbance from wind.

• This binder addition system provides moderate accuracy. The disadvantages of the LIW system is that the binder addition is only partially controlled when the bind-er weigh hopper is being refilled and also the screw auger does not provide constant output for a given speed. These downsides are well recognised, however the key ad-vantage of this system is it requires almost no maintenance and takes up limited height resulting in reduced capital expenditure.

• The mixed paste is discharged over a 50mm aperture vibrating screen to capture any foreign material and reduce the risk of an underground pipe system blockage. The paste level is controlled in the paste hopper to ensure the piping system is maintained under vacuum and allows very high solids content paste to be discharged under-ground. The control valve is a high quality pinch valve which has proven hugely suc-cessful on plants in the last few years and can handle full vacuum conditions.

MISU unit fitted to an excavator


Other key aspectsThe other key aspect of the plant is the control system. The plant has a highly advanced control system, with significant levels of in built protection and alarm capabil-ities. Furthermore, underground instrumentation data is returned to the paste plant allowing the operators to optimise management of the underground piping system and maximise paste quality in real time. The plant also has a complete laboratory on the same level as the paste mixer where samples are taken. This allows the opera-tors to complete all quality control activities on the paste which is key to generating a quality paste culture on site.

Design challengesThe only real issue with the paste system in the first three months of operation was a high quantity of rocks that made it into the tailings feed hopper. The rocks tend to block the outlet of the tailings hopper and also can cause significant damage to the paste mixer. The inability to completely ensure rocks do not enter the process is one of the key design challenges in this type of plant.

The twin shaft mixer used in these types of plants is derived from the concrete industry. A number of modi-fications were made by the Outotec backfill team to this mixer, however it is still only able to provide moderate mixing and the maintenance and cleaning required is still moderate. The advantage though is that this type of mixer is extremely robust and can handle foreign material. Other sludge style mixers would provide improved mixing, however they cannot handle any amount of foreign material.

As a result, for future plants more significant design changes are being implemented to produce a true paste mixer. However, the mixer will always be compromised to prevent catastrophic damage when the inevitable rock or foreign material passes through the plant.

Rapid commissioningThe Spotted Quoll paste system was commissioned extremely quickly in mid 2012 and has been very successful.


[email protected]

Spotted Quoll paste feed material stockpiles


GIVE YOUR FLOAT CELLS THE BUBBLES THEY DESERVE! 5 THINGS YOU MAY NOT KNOW ABOUT YOUR FLOAT MECHANISM..

Flotation is a key process in most beneficiation plants. If your cells are not operating at the optimal level due to old or outdated equipment, overall plant performance will eventually suffer. Similarly, changes in ore deposits may require a circuit reconfiguration – so review audit of your float cells can lead to vastly superior new designs, resulting in better bubbles and better performance.

Outotec has a handy online FloatForce calculator to quickly evaluate potential savings from the FloatForce mechanism. Simply input some key data and the calculator will do the rest. More information is available here...

Since 2008, Outotec has supplied an improved flotation mechanism (FloatForce®) to both new and existing operations. Almost 100 concentrators around the globe are now running over 1800 new FloatForce mechanisms. There is often interest regarding this new mechanism, so below are the top five questions asked by sites.

1. I don’t have an Outotec float cell – can I still retrofit with the FloatForce mechanism?YES. FloatForce can be retrofitted to other supplier’s float cells. However, it’s important for us to assess the site conditions to ensure our equipment provides superior performance. In addition, FloatForce is fully interchangeable with our previous design (MultiMix). The FloatForce rotor and stator design matches the previous MultiMix bolt pattern and there is no need for adapter plates or major changes to the tank floor.

2. Can FloatForce increase product recovery?YES. FloatForce has already increased product recovery at various operations. It is however, highly dependent on the site conditions. Outotec can assist with metallurgical testwork and modelling/simulation packages to predict product recovery improvements.

3. Does FloatForce cost more?NO. FloatForce has a lower life of mine (LOM) operating cost when compared to MultiMix. The FloatForce design has components with different wear profiles and the high

wearing components generally cost less than the equiva-lent MultiMix. As a result, most operations experience a reduction in their LOM operating costs.

4. If there is improved pumping performance with

FloatForce, why does it not consume more power?It’s all down to the years of R&D investment which has lead to an optimised design that separates air dispersion and slurry mixing. Thus, Floatforce delivers improved pumping performace, but it is also more energy efficient. FloatForce is installed at lower rotor tip speeds than MultiMix. This results in less drag and most operations observe a 15% to 25% reduction in energy consumption.

5. Does FloatForce require more air?NO. FloatForce operates in the same air flow rate range as MultiMix. Superficial gas velocity rates (Jg) of 1.2 to 1.8m/s are targeted during normal operation and there is no need to upgrade the existing blower or compressor plant.

FOR FURTHER INFORMATION PLEASE CONTACT

[email protected]

http://www.outotec.com/floatforce#tabid-7


FloatForce Around the WorldAlmost one hundred concentrators around the world are already running over 1800 FloatForces across most industrial mineral processing applications. FloatForce references available here...

FloatForce delivered in greenfieldFloatForce upgraded on brownfieldFloatForce upgraded on brownfield

FLOATFORCE® SETS NEW STANDARDSFloatForce is a new-generation mixing mechanism that delivers measureable value in three key areas of flotation:

By improving flotation hydrodynamics and pumping performance at high air dispersion rates, FloatForce technology enhances particle recovery in the flotation cell, while also reducing power consumption, with less risk of sanding.

The FloatForce mechanism comes as standard on all new Outotec flotation solutions, and is also available for existing installations as an upgrade service. More information on how FloatForce technology could add measureable value to your bottom line is available here...




IRON ORE PELLETIZING TECHNOLOGY FOR IRANThe new 5 million tonnes per annum pellet plant is part of B-MISCO’s greenfield investment program. Outotec’s scope covers the technology license, basic engineering of the pelletizing plant, detailed engineering and supply of proprietary and key equipment and automation, as well as advisory site services for installation, commissioning and start-up. The new plant is expected to become operational in 2018. More information is available here....

MODULAR SOLVENT EXTRACTION TECHNOLOGY TO SOUTH AMERICAThe customer is making changes to their heap leaching operation to enhance the copper recovery from secondary sulfide minerals. These changes in the leaching phase require an upgrade in the downstream solvent extraction plant washing capacity. Outotec’s solution comprises the breakthrough VSF®X Modular Solvent Extraction technology, including technology license, engineering, proprietary and auxilliary equipment and advisory services for installation, commissioning and start-up. Deliveries from Outotec will take place in 2015.

More information is available here....

TECHNOLOGY AND SERVICES FOR ZINC PLANT EXPANSION IN MEXICOOutotec’s scope of delivery covers the technology, engineering and license for atmospheric direct leaching of zinc concentrates and down-stream process areas. In addition, Outotec will deliver proprietary and auxilliary equipment for the OKTOP® reactor plant, as well as advisory services for installation, commissioning and ramp-up. The process is flexible, yields high metal recovery with low energy consumption and emissions, and provides operational safety. Deliveries will take place between 2015 and 2017.


WHERE DO ALL THE CARS END UP?There are many types of secondary resources that we have to treat to realise a “circular economy”. Here, Professor Markus Reuter will focus on the car, the complex “minerals on wheels”, as a concrete example to visualise the important ingredients of a circular economy.

Have you heard of the term ASR? It is the Automotive Shredder Residue. It is a rather challenging secondary resource to treat, a secondary resouce after shredding and sepa-rating a car.....

To read the full blog follow this link...

To read all previous blogs follow this link...

Prof. Markus A. Reuter, Director - Technology Management, Outotec Oyj Finland

http://www.outotec.com/en/Media/News/2015/Outotec-to-supply-iron-ore-pelletizing-technology-for-B-MISCO-in-Iran/

http://www.outotec.com/en/Media/News/2015/Outotec-to-deliver-modular-solvent-extraction-technology-to-South-America/

http://www.outotec.com/en/Media/News/2015/Outotec-to-deliver-technology-and-services-for-Met-Mex-Penoles-zinc-plant-expansion-in-Mexico/

http://www.outotec.com/en/About-us/Experts-thinking-ahead/Metal-and-material-recycling/Dates/2015/4/Where-do-all-the-cars-end-up/

http://www.outotec.com/en/About-us/Experts-thinking-ahead/Metal-and-material-recycling/


ZINC CONCENTRATE DIRECT LEACHING TECHNOLOGY TO BOLIDEN IN NORWAYOutotec’s solution comprises the direct leaching technology, basic and detailed engineering and delivery of proprie-tary OKTOP® reactor plant units for leaching and iron precipitation as well as filters and anode handling machines. In addition, Outotec provides extensive services starting from engineering to installation, commissioning and start-up. The deliveries will take place during 2015 and 2016.


OUTOTEC TO DELIVER ANODE RODSHOP TECHNOLOGY TO CHINA XINFA GROUP’S ALUMINUM SMELTER IN CHINAOutotec’s delivery includes process engineering and proprietary process equipment as well as services for the commis-sioning and operational support for a new anode rodding shop, which is part of the new aluminum smelter. The new smelter is expected to produce annually one million tonnes aluminum. The deliveries will take place in 2016 and include both local and offshore equipment supply.


Outotec’s scope of delivery covers the engineering and delivery of the main process equipment for a 12.5 MWe waste-to-energy plant based on fluidized bed technology. The plant will use refuse derived fuel (RDF), mainly consisting of recycled plastics and sorted waste as raw materials. Once fully operational in mid-2017, the plant is designed to export over 75 GWh of electricity and 30 GWh heat per year that is equivalent to the electricity needs of nearly 18,000 homes. The project is also expected to divert over 1.4 million tonnes of waste from landfill.


TECHNOLOGY AND SERVICES FOR A WASTE-TO-ENERGY PLANT IN THE UK

Outotec will provide the technology, engineering, supply and installation of equipment and systems for the expansion of EMAL’s existing green anode plant. After the expansion, scheduled to be commissioned in mid-2016, the plant will be capable of producing considerably larger anodes, which are required for EMAL’s ongoing efforts to increase the amperage and thus the output of the electrolysis.


TECHNOLOGY TO ALUMINUM SMELTER IN THE UNITED ARAB EMIRATES

http://www.outotec.com/en/Media/News/2015/Outotec-to-deliver-anode-rodshop-technology-to-China-Xinfa-Groups-aluminum-smelter-in-China/

http://www.outotec.com/en/Media/News/2015/Outotec-to-deliver-zinc-concentrate-direct-leaching-technology-to-Boliden-in-Norway/

http://www.outotec.com/en/Media/News/2015/Outotec-to-deliver-technology-and-operation--maintenance-services-for-a-waste-to-energy-plant-in-the-UK/

http://www.outotec.com/en/Media/News/2015/Outotec-to-deliver-technology-to-aluminum-smelter-in-the-United-Arab-Emirates/


• Maintaining the proper function of the burner’s eccentricity detector and position adjuster was not easy, and the position adjustment was a time-con-suming task.

We therefore made modifications such as changing the inspection hole layout. The layout was changed to a design that allowed the thorough and quick removal of buildup. In addition, we modified and replaced the supporting structure and also replaced the adjustment system consisting of a jack and a position adjustment device with a system fixed onto a welded plate to maintain the adjusted clearance for an extended period of time.

Performance of the modified concentrate burnerThe modification reduced the inspection frequency from an average of 3.1 times/day to 2.5 times/day, thereby lowering the operating load. The time required on inspec-tions to reduce the rate of the concentrate charge by 15% was shortened by 55 hours/year and the dust generation rate decreased from 8.1% to 5.8%. The modification thus contributed to the stabilization of the reaction in the concentrate burner.

Modification of the Tamano FSF uptake shaftPreviously, the Tamano uptake shaft faced the following problems:• Accretions grew on the uptake shaft’s inner surface

because of the plate cooling element of the off-gas from the FSF, and required removal by scraping into the settler.

• The concentrate feed rate had to be reduced by approximately 30% (for approximately 4 hours at a

TECHNICAL IMPROVEMENTS OF TAMANO FLASH SMELTING FURNACE OPERATIONTEXT MITSUMASA HOSHI, HIROYUKI WAKASA, RYOUHEI KISHIBE

HIBI KYODO SMELTING CO, LTD TAMANO SMELTER & REFINERY

The Tamano Smelter & Refinery was originally designed for copper production of 84,000 mtpy. It now has a capacity of 260,000 mtpy, which was achieved in a stepwise manner through projects carried out over several years. An in-crease in oxygen enrichment, modifications to the furnace and feed system, and various other operational improve-ments have been carried out. The flash smelting furnace feed rate has been increased six times since startup. However, a higher matte grade has resulted in higher copper loss. In this article, we describe the improvements made to the platform of the concentrate burner and the ceiling of the reaction shaft, and also the change made to the structural material of the uptake shaft plate cooling elements, which is now composed of bricks.

Modficication of the Tamano Flash smeltingfurnace (FSF) concentrate burnerPreviously, the Tamano FSF concentrate burner faced the following problems. • The burner inspection hole layout did not allow for

the cleaning and removal of buildup, which made inspections difficult.

• Thorough removal of the buildup was not easy for reason (i) above, and we were forced to continue oper-ation with a poor concentrate reaction.

• The thermal deformation of the platform structure in the concentrate burner area meant that the burner nozzle was prone to misalignment.

• The misalignment explained in (iii) helped the buildup to grow on the concentrate burner jacket and this led to an uneven concentrate reaction.


frequency of once a week) during the abovementioned removal, and this represented a loss of productivity.

• The replacement of the plate cooling element was required at maintenance shutdowns (every 2 years), which meant that the repair cost was considerable.

• The abovementioned factor (iii) did not allow a longer shutdown interval.

To solve the abovementioned problems, we changed the uptake shaft construction from a cylindrical plate cooling element design and a boiler to a refractory construction (Fig. 2). We also added a breeze coke spraying system to the top of the uptake shaft to reduce (deoxidize) the accre-tions that had stuck to and grown on the uptake shaft wall through coke spraying.

Effect of the brick construction of the uptake shaft The previous uptake shaft construction faced problems that were eliminated by rebuilding the uptake shaft with bricks 2 years ago, as described below. • The workload for operators involved in accretion

removal reduced from 4 hours once a week to zero. • The requirement for the abovementioned accretion

removal operation, which lowered the concentrate feed rate for the FSF by approximately 30%, was reduced.

• There was a substantial reduction in the cost of major uptake shaft repair including the replacement of the plate cooling element.

• There was an elimination of long production stop-pages due to water leaks in the plate cooling element.

The concentrate feed rate thereby increased by approx-imately 100 mt/day (the sum of approximately 60 mt/day due to the concentrate burner improvement and approximately 40 mt/day due to the uptake shaft modi-fication). However, the brick construction of the uptake

shaft resulted in an increase in the temperature of the gas flowing through the waste heat boiler by approximately 50 °C, which negatively affected the downstream process.

ConclusionWe changed the inspection hole layout and clearance adjustment method in the concentrate burner.• Dust generation rate improved by 2.3%• Concentrate feed rate increased by 40 tons/day

We changed the FSF uptake shaft design from a plate cooling element type to a brick construction.• A lower workload for the operators was achieved• Concentrate feed rate increased by 60 tons/day


[email protected]

Before Modification After Modification


ANALYSE THIS! A QUICK & EASY HEALTHCHECK ON YOUR ANALYSER

Reliable online monitoring and process control in mineral slurries is no longer a ‘nice to have’ in today’s operations - increasingly, many operations realise this is a necessity to truly optimise recovery and performance.

So, how do you know if your analyser is still performing to its best and delivering fast, accurate analysis at your site? Here is a simple risk assessment formula to help analyse your analyser.


[email protected]

This worksheet will help you prioritize equipment replacement based on a numerical risk assessment. The final risk score and category is determined using the following formula:

Risk Score = FP (AC + PI + RL + SA + SP + LR + NC)

FP = Failure Probability 1 = Very low probability of failure, 10 = Multiple historical failures

AC = Age / Condition 1 = New equipment, 5 = Equipment in service for over 7 years

PI = Process Impact if equipment failure occurs0 = No process impact, 5 = Likely process loss

RL = Revenue Loss if equipment failure occurs0 = No impact on revenue, 5 = Revenue loss due to equipment failure

SA = Service Ability 1 = Equipment easy to service and parts readily available, 5 = Service cannot be serviced internally or externally

SP = Spare Parts1 = Parts easy to find, readily available, 5 = Obsolete parts, hard to find

NC = Network Compatibility 0 = Not applicable, 5 = Obsolete, unable to connect to network

LR = Legal Risk (1-5) 1 = Minimal risk of lawsuit due to equipment failure, 5 = High probability of lawsuit

RISK SCORE RANGE

RECOMMENDED ACTION

RISK CATEGORY

200 - 350 SevereReplace equipment immediatley

75 - 124 ModerateSchedule equipment replacement as budgets permit

125 - 199 HighReplace equipment as soon as possible

35 - 74 LowEquipment replacement not necessary within 5 yrs

<35 Extremely Low

No recommended replacement schedule

editor: laura white, laura.whiteoutotec.com 1 … › globalassets › newsletters › output ›...

Documents