Saturday, November 1, 2014

Productivity in Copper Smelting and Refining


The ISASMELT™ process delivers clean, cost-effective, high intensity smelting using a Top Submerged Lance (TSL). Xstrata Technology’s ISASMELT™ process provides an innovative, high intensity, yet
low cost submerged lance smelting process that is easy to operate. It can be used for a range of applications including primary and secondary copper smelting and copper converting, primary and secondary
lead smelting, primary nickel smelting and converting, and tin, zinc and precious metals smelting.

After more than 25 years of continuous development, the ISASMELT™ design provides all licensees with clean, effective and low cost smelting.

ABB wins five-year Full Service agreement for copper smelting plant in Africa
Contract with Namibia Custom Smelters to improve maintenance, production planning, and equipment reliability
Zurich, Switzerland, July 17, 2012-- ABB, the leading power and automation technology group was recently awarded a five-year ABB Full Service® contract with Namibia Custom Smelters (NCS), to manage and improve all maintenance activities at their copper smelting and converting plant in northern Namibia. The full service total plant maintenance agreement includes the transfer of NCS maintenance and reliability staff to ABB, as of July 1, 2012. ABB’s Full Service model, which involves the complete management and operation of a plant’s maintenance function, development and implementation of expert measures to improve productivity and equipment reliability, will be employed at NCS. In this manpower-intensive environment, ABB’s performance agenda will include a strong focus on Occupational Health and Safety (OHS) standards for the workplace.

NCS is located in Tsumeb, Namibia. The plant, which was commissioned in 1963, is owned by Dundee Precious Metals Inc. of Canada. It consists of two primary smelting furnaces, three converters, and has an annual production capacity of 200,000 tons of copper concentrate from the treatment of complex copper concentrates containing gold, silver and arsenic

Model Helping Jhagadia Copper Limited  reduce cost of production by 8 – 10 %
TRDDC (TCS) proposed a model based optimization of JCL’s  Kaldo furnace resulting in a new furnace operating regime.
The solution has improved productivity by 10% and the refractory life by 50-60%. This has led to direct cost savings to the tune of 8-10%, enhancing the cost competitiveness of the company.

Jhagadia Copper Limited (JCL) is the largest producer of LME Grade “A” Copper Cathodes in India using secondary smelting route. The company was set up in technical collaboration with Outokumpu Technology
AB (formerly Boliden Contech AB), Sweden. The capacity of its plant is 50,000 MT per annum of copper cathodes (conforming to LME Grade “A” specification) and 20,000 MTA per annum of copper anodes. In terms of production, JCL has the largest secondary copper smelting plant and is the third largest copper producer in India.

Innovation, Productivity Growth, and the Survival of the U.S. Copper Industry
John E. Tilton and Hans H. Landsberg
Discussion Paper 97-41
September 1997



India's largest copper producer with its integrated facility in Gujarat comprising of copper smelters, captive power stations, utilities and captive jetty.
Hindustan Copper
Sterlite Sesa Goa
Jhagadia Copper Limited

Indian Copper Smelting Industry - Details

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