outotec ausmelt technology

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Outotec Ausmelt Technology

Santiago, Chile

December 1-4, 2013

Outotec Ausmelt Technology for DNMC Design and Commissioning

Mr Wan Jun, Mr Luo Yi and Mr Chen Baizhi (DNMC)Mr Gavin Swayn, Mr Jacob Wood and Ms Stefanie Creedy (OT)


Introduction Thank you to co-authors

Thank you to Daye for allowing this paper to be prepared

2 Copper 2013 Commissioning/Startup DNMC Presentation


Introduction Thank you to co-authors

Outotec colleagues - for the input and efforts to help assess and prepare this paper.



Introduction In 2008, Daye Nonferrous Metals

Company Limited (DNMC) made the decision to expand and improve its operating capacity at its operations in Daye City, Hubei, China.

The expansion aimed to Modernise the operations, Improve process flexibility, Expand capacity in smelting and refinery

operations

The project was cited as Energy Saving Environmentally Efficient Copper Smelter.

Copper 2013 Commissioning/Startup DNMC Presentation


Introduction to DNMC


Daye, Hubei

Ausmelt



6

Daye Non-Ferrous Metals Company Top 500 enterprises in China Founded in 1953




7

Daye Non-Ferrous Metals Company More than 50 years DNMC has grown to be

one of Chinas main copper industries.




8

Main products of DNMC are

Copper cathode

Gold and silver

PGMs Sulphuric acid Other rare

metal products



Outotec Ausmelt Process History

9

1970sDr J. Floyd develops Top Submerged Lance Technology at the CSIRO.

1980s1981 Ausmelt founded. First commercial scale Ausmelt plants installed 4 projects commissioned.

1990-2000Growing acceptance 12 further projects commissioned.

2000AusIron demonstration plant is commissioned for iron production at 2 t/h demonstration scale

2000 - 2010A leading smelting technology 19 further projects commissioned

2010 Ausmelt becomes part of

15 further projects commissioned or commenced design



Outotec Ausmelt Process around the world

10Copper 2013 Commissioning/Startup DNMC Presentation


Outotec Ausmelt Process History

Continually developed - over 30 years experience.

Over 65 commercial AusmeltFurnaces have been installed or in design/construction phase.

Total Solutions available as part of the Outotec smelting team best practices utilized

11

1970sDr J. Floyd develops Top Submerged Lance Technology at the CSIRO.

1980s1981 Ausmelt founded. First commercial scale Ausmelt plants installed 4 projects commissioned.

1990-2000Growing acceptance 12 further projects commissioned.

2000AusIron demonstration plant is commissioned for iron production at 2 t/h demonstration scale

2000 - 2010A leading smelting technology 19 further projects commissioned

2010 Ausmelt becomes part of

14 further projects commissioned or commenced design



Ausmelt TSL Process Overview

3/12/201312

Relative simple furnace constructionTop Submerged Lance (TSL) processInjection of process gases & fuel via lance

High rates of heat and mass transferEnergy efficient process

Good environmental performance Suitable for continuous and batch processes


Outotec Ausmelt Copper Smelting - Daye

Recycled Dusts

Matte

Discard Slag

Matte / Slag

AusmeltSmelter

Settling (ESF)

Copper Concentrates

AirOxygen

Fuel Coal

LimestoneSilica

Cu


Outotec Ausmelt Application Features


Daye ESEE Project

15

Replace Reverbatory and Noranda furnace operations Maintain existing PS Converters and anode furnace in converter aisle Ausmelt furnace and ENFI designed/supplied ESF



Daye ESEE Project Start-up Milestones

2008 Engineering Design for Ausmelt furnace and ESF

Additionally the gas handling system for furnaces

2009 18th July 2009 plant foundations were officially laid

2010 November - following 555 days of plant construction

and cold commissioning, the project moved into the hot commissioning phase

December 31st - copper matte/slag flows from the Ausmelt furnace to the ESF via the weir

3.12.201316 Copper 2013 Commissioning/Startup DNMC Presentation


Daye ESEE Project Technology Transfer Technology Transfer is Integral to All projects Engineering design and Know-how Transfer

Equipment Supply Training

Construction Visits Management/metallurgical/operator training

Cold and Hot Commissioning Support Ausmelt/Outotec provides experienced resources to support site

cold commissioning programs, training etc Ausmelt/Outotec provides experienced resources to support site

hot commissioning leadership/advice and operational training etc

Provide Advisor Tools as art of its control system supply Ongoing Support

Through extensive resources and global company Outotecoffers on going support to all our clients



Equipment Design/Supply Ausmelt Furnace - 2010

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Dimensions Internal diameter 5 m Internal height 16.5 m



Ausmelt Furnace Weir (2010)

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Ausmelt Weir Operation Critical to high throughput Transfers continuously

matte and slag to an ESF

Specifically designed in all Outotec Ausmeltcopper smelter applications

AusmeltFurnace

AusmeltFurnace

WeirMatte + Slag Underflow

Weir overflow spout


Ausmelt Furnace Weir (2010)

3.12.2013 Outotec20


Ausmelt Ancillary Equipment Lances

Coal fired with 60% oxygen enrichment

Air Blower 38,000 Nm3/h at 170 kPa 15,000 Nm3/h at 130 kPa 7,800 Nm3/h at 120 kPa

Oxygen Plant Existing 6,000 Nm3/h at 100 kPa New 28,000 Nm3/h at 100 kPa

(April 2011)



Ausmelt Furnace Feed Preparation

8 New feed bins were installed 4 bins were used for

different concentrates 1 separate bin for

each of silica, lump coal and limestone

Blending of materials is completed in the Ausmelt PCS as set by the operator.



Ausmelt Ancillary Equipment

Waste Heat Boiler 120,000 Nm3/h at inlet

1100 110 t/h steam production

ESP 120,000 Nm3/h at inlet

350



Electric Settling Furnace

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Rectangular 20m x 8m Hearth 1600 m2

Electrical power 2 x 6000kVA 6 x1000mm Electrodes



Converting and Fire-Refining

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PS Converters 1 x 80t capacity (existing) 1 x 120 t capacity (existing)

1 x 120 t capacity installed in 2012

Anode furnaces (existing) 480 t and 240 t



Casting

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Anode Casting 1 x 10 m Twin M16 100t/h Outotec Casting Wheel

(existing) 1 x 10 m Twin M18 110t/h Outotec Casting Wheel

(2012)



Tankhouse (2012 -2013)



The First 12 Months



Process Management

Following completion of the modernisation the Daye Ausmelt Smelter has continued to operate at or above design capacity. Despite some variations in feed grade (%Cu) the

plant has fed up to 230 t/h. Oxygen enrichments of 60 % have not been

detrimental to lance life. Slag/matte temperatures are controlled via pyrometer

measurements from the weir outlet and are typically reported in the range of 118510.

Feed carry over typically less than 0.5%.



Process Management

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ESF Matte and Slag Grade Variation 2011



Process Management - 2013

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0

5

10

15

20

25

30

35

40

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Jan. Feb. Mar. Apr. May June July Aug. Sep.

wt %

Fe

and

SiO

2in

Sla

g

wt %

Cu,

CaO

and

Fe/

SiO

2 in

Sla

gAverage 2013 Ausmelt/ESF Slag

% Cu [Avg 0.827]

Fe/SiO2 [Avg 1.31]

% CaO [Avg 3.93]

% SiO2 [Avg 27.5]

% Fe [Avg 36.1]


Process Management

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Concentrate Grade Variation - 2011



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0

5

10

15

20

25

30Ja

n-13

Feb-

13

Mar

-13

Apr-

13

May

-13

Jun-

13

Jul-1

3

Aug-

13

Sep-

13

wt %

in C

once

ntra

te (

daily

ave

rage

)

DNMC Ausmelt Copper Smelter - Concentrate Grade 2013

Cu

S

Fe

SiO2

CaO



3.12.201334

Jan. Feb. Mar. Apr. May June July Aug. Sep.Oxygen enrichment 59.47 60.54 59.76 58.95 58.65 59.27 59.42 58.23 59.24Matte grade 53.644 56.076 56.625 56.176 57.415 57.366 57.534 57.026 56.954

50

52

54

56

58

60

62

% C

u in

Mat

te a

nd%

O2

in L

ance

Gas

esDNMC Operations 2013

Avg Matte Grade (Cu) and Lance Oxygen Enrichment



Conclusions - Ausmelt TSL Projects - Copper

Client Location Feed Annual Throughput(t/y) Starting YearXinjiang Wuxin Copper Co. Ltd. Urumqui City, China Cu Concentrates 575,000 Oct 2013Yunnan Tin Co. Ltd. Geiju City, China Cu Concentrates 450,000 2012Yunnan Tin Co. Ltd. Geiju City, China Cu Matte 190,000 2012 &Huludao Copper Group Huludao City, China Cu Concentrates 500,000 On HoldDaye Non-Ferrous Metals Co. Huangshi City, China Cu Concentrates 1,500,000 2010Chifeng Jinjian Copper Group Chifeng City, China Cu Concentrates 480,000 2008Russian Copper Company Karabash, Russia Cu Concentrates 550,000 2006Birla Copper Dahej, India Cu Concentrates 350,000 2003 on holdBirla Copper Dahej, India Cu Matte 160,000 2003 on holdAnhui Tongdu Copper Tongling City, China Cu Concentrates 330,000 2003Zhong Tiao Shan Houma City, China Cu Concentrates 200,000 1999Zhong Tiao Shan Houma City, China Cu Matte 60,000 1999 &

Nambia Custom Smelters* Tsumeb, NamibiaCu Concentrates

(from 2008)140,000 1997/2008

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Client Location FeedAnnual Throughput

(t/y) Starting YearGlobal Resources and Materials South Korea Cu Secondaries 110,000 2011Dowa Mining Co. Ltd. Akita, Japan Cu Secondaries 150,000 2007Korea Zinc Onsan, South Korea Cu Residues 70,000 2004

Primary Copper

Secondary Copper


Conclusions - Ausmelt TSL Copper Plant

3/12/2013 Outotec Ausmelt36


Conclusions

Outotec Ausmelt technology has been successfully applied by DNMC as part of the modernisation of their existing operations in China.

The plant is currently operating with concentrate feedrates of greater than 200 t/h and more than 90% availability.

Incorporation of the underflow weir has facilitated not only such high throughput but also improved process control.



Conclusions

The DNMC project demonstrated the advantages of the technology for treatment of variable throughput and low grade concentrates.

The replacement of the Noranda and reverbatory furnace operations has provided superior environmental performance in line with the Chinese National Emission Reduction policies.



Outotec Ausmelt Technology

Sustainable useof Earthsnaturalresources

3.12.201339

THANK YOU!


outotec ausmelt technology

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