Concept and preliminary engineering of a gas treatment system in a copper smelter (GA14)

ISSUE

A smelter operates a continuous melting, casting, and rolling line to produce copper cables. Copper is melted in a vertical furnace equipped with three rows of gas burners at the bottom, with a direct flame on the copper material to be melted. Combustion is adjusted within a reducing range (excess CO). The furnace has a molten copper discharge point at the bottom and a stack at the top, as well as three nearby roof vents. During operation, the plant generates emissions (mainly copper and silica) at these points in the form of fine powder and coarse particles. Following sampling measurements, the client sought treatment solutions to reduce emissions from the vertical furnace stack and the two hoods of the refractory trough. In addition, as part of an energy-saving initiative, the possibility of recovering heat from the exhaust gases was also examined. STS Canada completed the concept and preliminary engineering phases of this project.

TECHNOLOGICAL CHALLENGE

The objective of the project was to identify treatment solutions to reduce emissions from the vertical furnace stack and the two hoods of the refractory trough. Additionally, with energy savings in mind, the potential for heat recovery from the gases was studied.

RECOMMENDED SOLUTION

This project was completed in two stages, beginning with concept engineering, which involved evaluating families of technological options for gas treatment. This study enabled the selection and recommendation of the option best suited to the client’s needs. A cost estimate based on supplier pricing was included among the project deliverables.

The second phase of the project was preliminary engineering. Calculations and design criteria were used to determine the capture parameters required to size the system equipment. Once the equipment sizing was completed, a technical specification was issued to various suppliers to obtain a budgetary price (±30%) for the system’s main component.

RESULTS

The concept engineering phase enabled the evaluation of technology families, leading to the selection and recommendation of the solution best suited to the client’s needs.

The next phase of the project included calculations to support equipment sizing. This project made it possible to develop a robust solution from both an economic and technical standpoint. By optimizing the use of existing equipment, the final cost was kept under control. In addition, it will improve the particle dispersion model and reduce particle concentrations at various locations while enabling heat recovery. STS’ expertise also made it possible to select a filtration technology offering a capital investment (CAPEX) three times lower, along with simplified maintenance (OPEX).

This large-scale project illustrates how our expertise and innovative solutions earned the client’s confidence to proceed with us into detailed engineering, further reinforcing our role as a trusted partner in achieving their objectives.