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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)
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Introduction Thank you to co-authors
Thank you to Daye for allowing this paper to be prepared
2 Copper 2013 Commissioning/Startup DNMC Presentation
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Introduction Thank you to co-authors
Outotec colleagues - for the input and efforts to help assess and prepare this paper.
3 Copper 2013 Commissioning/Startup DNMC Presentation
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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
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Introduction to DNMC
5 Copper 2013 Commissioning/Startup DNMC Presentation
Daye, Hubei
Ausmelt
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Introduction to DNMC
6
Daye Non-Ferrous Metals Company Top 500 enterprises in China Founded in 1953
Copper 2013 Commissioning/Startup DNMC Presentation
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Introduction to DNMC
7
Daye Non-Ferrous Metals Company More than 50 years DNMC has grown to be
one of Chinas main copper industries.
Copper 2013 Commissioning/Startup DNMC Presentation
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Introduction to DNMC
8
Main products of DNMC are
Copper cathode
Gold and silver
PGMs Sulphuric acid Other rare
metal products
Copper 2013 Commissioning/Startup DNMC Presentation
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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
Copper 2013 Commissioning/Startup DNMC Presentation
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Outotec Ausmelt Process around the world
10Copper 2013 Commissioning/Startup DNMC Presentation
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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
Copper 2013 Commissioning/Startup DNMC Presentation
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Ausmelt TSL Process Overview
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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
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Outotec Ausmelt Copper Smelting - Daye
Recycled Dusts
Matte
Discard Slag
Matte / Slag
AusmeltSmelter
Settling (ESF)
Copper Concentrates
AirOxygen
Fuel Coal
LimestoneSilica
Cu
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Outotec Ausmelt Application Features
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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
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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
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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
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Equipment Design/Supply Ausmelt Furnace - 2010
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Dimensions Internal diameter 5 m Internal height 16.5 m
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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
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Ausmelt Furnace Weir (2010)
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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)
3.12.201321 Copper 2013 Commissioning/Startup DNMC Presentation
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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.
3.12.201322 Copper 2013 Commissioning/Startup DNMC Presentation
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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
3.12.201323 Copper 2013 Commissioning/Startup DNMC Presentation
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Electric Settling Furnace
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Rectangular 20m x 8m Hearth 1600 m2
Electrical power 2 x 6000kVA 6 x1000mm Electrodes
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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
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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)
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Tankhouse (2012 -2013)
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The First 12 Months
3.12.201328 Copper 2013 Commissioning/Startup DNMC Presentation
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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%.
3.12.201329 Copper 2013 Commissioning/Startup DNMC Presentation
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Process Management
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ESF Matte and Slag Grade Variation 2011
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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]
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Process Management
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Concentrate Grade Variation - 2011
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Process Management - 2013
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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
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Process Management - 2013
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
Copper 2013 Commissioning/Startup DNMC Presentation
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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
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Conclusions - Ausmelt TSL Copper Plant
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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.
3.12.201337 Copper 2013 Commissioning/Startup DNMC Presentation
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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.
3.12.201338 Copper 2013 Commissioning/Startup DNMC Presentation
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Outotec Ausmelt Technology
Sustainable useof Earthsnaturalresources
3.12.201339
THANK YOU!
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