Outotec® Ausmelt TSL Process
The Outotec® Ausmelt TSL Process is an efficient,
We have the world’s leading smelting technology
environmentally
flexible
portfolio which includes the Outotec® Ausmelt TSL
pyrometallurgical process for treating a wide range of
Process, the Outotec® Flash Smelting Process, the
feed materials:
Outotec® Kaldo Process and other complementary
nn copper, nickel, lead, tin and polymetallic
offerings. This extensive array of technologies and
concentrates
expertise ensures you receive not only the best possible
nn copper and lead secondaries
solution, but one that is tailored to match your specific
nn zinc bearing residues
requirements.
friendly
and
highly
nn various waste materials and ferrous feedstocks
002 Outotec Ausmelt TSL Process
Outotec® Ausmelt TSL Process in brief Based on Top Submerged Lance (TSL) technology, the Ausmelt TSL Process has become a leading smelting technology due to its versatility, cost effectiveness and environmental benefits. It is equally suitable for new
Gas Offtake/Boiler
installations and for modernization of existing smelting plants. Standby Burner
The Ausmelt TSL Process
Fuel, Air & Oxygen
is based on injecting air,
oxygen and fuel directly into the molten slag bath via a
Lance Sealing Device
vertically suspended lance. Critical process phenomena,
(optional)
such as feed material dissolution, energy transfer,
Feed Port
reaction and primary combustion, take place in the intensely agitated slag layer. As a result, the Ausmelt TSL Process is extremely efficient with high specific smelting rates. Outotec’s commitment to the continuous
Protective Slag Coating
development of the Ausmelt TSL Process - in close collaboration with our customers - ensures you receive a best practice solution.
Benefits of the
Patented Lance
Furnace Shell
Outotec Ausmelt TSL Process Low investment and operating costs Environmentally friendly Flexibility to process a wide range of
Forced Cooling
feed materials
(optional)
Compact furnace system - ideally suited
to retrofit into constrained plant area
Rapid ramp up to full production
Furnace Taphole
Outotec Ausmelt TSL Process 003
Superior environmental performance
The Ausmelt TSL Process is one of the most energy
Outotec® Ausmelt TSL Furnaces are fully sealed and
efficient smelting technologies available. In the Ausmelt
operate under a slightly negative pressure to eliminate
TSL Process the direct injection of fuel into the slag
fugitive emissions to the environment. As a result, the
bath and ability to utilise the energy released during the
lower offgas volumes and higher strength SO2 also offers
oxidation of the feed (e.g., sulphides, plastics) reduces
significant savings, as a smaller offgas handling system
the fuel requirements compared to alternative processes.
is required. In addition to these benefits, the Ausmelt
The addition of post combustion air with the Ausmelt
TSL Process provides significant improvements in
Lance Shroud System is used to maximize the recovery of
occupational health and safety.
energy available in the system. This energy may be used in other sections of the plant or for electricity generation.
The Weser-Metall GmbH Nordenham lead smelter
This further reduces the plant’s energy requirements
is a prime example of how the Ausmelt TSL Process
and minimises green house gas emissions.
can
dramatically
improve
a
site’s
environmental
performance. This modernization project, which involved The Ausmelt TSL Process offers a range of process
replacing an existing sinter plant/blast furnace process
solutions for the treatment of various metallurgical
with the Ausmelt TSL Process, significantly reduced SO2
slags, residues and waste materials. Unlike other
and heavy metal emissions from the site.
smelting
technologies
the
Ausmelt
TSL
Process
produces a benign slag that meets Toxicity Characteristic
12000
Leaching Procedure (TCLP) requirements. The slag does not require any downstream processing and is simply
Environmental benefits of the Outotec Ausmelt TSL Process Reduced offgas and SO2 emissions
SO2 Emissions (t/y)
before discarding.
Dust Emissions (kg/y)
granulated to vitrify and lock in metallic components
10000
8000
6000
4000
2000
High strength SO2 offgas Reduced energy consumption Ability to treat waste materials and
heavy metal residues
Ability to process secondary materials
0
SO2 Emissions Sinter Machine/Blast Furnce (1995)
Dust Emissions Ausmelt TSL Process (2008)
Emissions at Weser-Metall before and after the installation of the Ausmelt TSL Process (U. Kerney, “The Nordenham Pb Smelter and its
Challenges”, International Science and Technology Conference: Lead Metallurgy – Achievements and Problems Conference, Legnica, 2010 (preprint).)
004 Outotec Ausmelt TSL Process
Versatility of the Ausmelt TSL Process The flexibility of the Ausmelt TSL Process allows us
Secondary copper
to tailor a processing solution to suit your specific requirements. This versatility, combined with Outotec’s
With increasing competition for high grade primary
extensive metallurgical knowledge and experience,
concentrates and pressure for sustainable development,
enables us to deliver an optimized plant design.
producers are looking for technologies to process secondary copper materials. The Ausmelt TSL Process
The Ausmelt TSL Process can handle a wide range
is suitable for a wide range of secondary copper feeds,
of feed materials including low grade concentrates,
ranging from low grade slags and residues, to materials
complex polymetallic ores, materials with high impurity
with high impurity and organic contents such as
contents and secondary and industrial waste materials.
e-waste, through to high grade metallic scrap.
These materials, which are often problematic for conventional smelting technologies, are becoming increasingly important feed sources. The Ausmelt TSL Process has been widely adopted in commercial operations and successfully implemented worldwide. Outotec has a strong track record of projects achieving rapid ramp-up to design capacity or even exceeding design production capacity.
Copper smelting and converting The Ausmelt TSL Process offers an integrated solution for copper smelting and converting or it can be coupled with existing site processes. The Ausmelt TSL Furnace can process copper concentrates with a wide range of copper contents and high impurities contents. For copper smelting the Ausmelt TSL Process has been installed in relatively small operations through to large scale operations processing in excess of 1.5 millions tonnes of concentrate per year.
Outotec Ausmelt TSL Process 005
HCHM (Hulunbeier) Russian Copper Company (Chelyabinsk) Weser Metall (Nordenham)
Intertrust (Kurdjali)
Carat-TSM (Sorsk) Chifeng Jinjian Copper Group (Chifeng) Jinchuan Nonferrous Metals Corp. (Jinchang City)
KCM SA (Plovdiv)
Hindustan Zinc Ltd. (Chanderiya)
Global Resource and Materials (South Korea)
China Tin (Laibin)
Nickel
Aluminum
Yunnan Tin Corporation (Gejiu City)
Birla Copper (Dahej)
Copper
Zinc
Huludao Copper Group (Huludao) Jilin Nickel Group (Panshi) Mitsui (Hachinohe) Dowa Mining Co. Ltd. (Akita) Korea Zinc (Onsan) Young Poong Corp. (Sukpo)
Wuxin Copper (Urumqi)
Empresa Metalurgica Vinto (Oruro)
Lead
MAPO Project (Seoul)
Zhong Tiao Shan (Houma City)
Minsur (Pisco)
Votorantim Metais (Juiz de Fora)
Anglo American (Bindura)
Namibia Custom Smelters (Tsumeb)
Rio Tinto Zimbabwe (Eiffel Flats)
PGMs
Anhui Tongdu Copper (Tongling City) Daye Non-ferrous (Daye) Portland Aluminium/Alcoa (Portland)
Anglo Platinum (Rustenburg)
Tin
Ausmelt (Whyalla)
Waste Treatment Not in Operation
Ausmelt TSL Furnaces around the world Nickel smelting and converting Ausmelt TSL Furnaces have been designed, built and
Small-scale lead producers can now also benefit from
operated to handle nickel concentrates with nickel
the flexibility and superior environmental performance
content as low as 5%. Nickel converting is also available
achievable with the Ausmelt TSL Process. The
to upgrade low grade mattes before refining. PGM
consistency of secondary lead materials, especially
recovery can be targeted specifically using the Ausmelt
lead acid batteries, has allowed Outotec to offer ‘off the
TSL Process. Similarly, concentrates with high MgO
shelf’ small scale secondary lead plants to meet the
levels, unsuitable for other processes, can also be
needs of this competitive market.
treated using the Ausmelt TSL Process.
Tin
Lead Today, approximately a third of the world’s tin is The Ausmelt TSL Process has been rated the BAT (Best
produced with the Ausmelt TSL Process. The Ausmelt
Available Technology) for the production of lead. The
TSL Process can be used to smelt tin concentrates or
emergence of the Ausmelt TSL Process as the preferred
as a fuming operation to recover tin from low grade
lead smelting technology has been driven by the search
concentrates or slags.
for environmentally friendly technologies to process low grade concentrates and secondary materials. Ausmelt
Other
TSL Furnaces can process up to 100% secondary lead materials such as lead acid batteries, metallic scrap,
The Ausmelt TSL Process has also been adapted
low grade slags and residues.
to successfully process polymetallic concentrates, zinc bearing residues, ferrous materials and various industrial waste materials including spent pot linings (SPL), municipal waste incinerator ash (MWIA), electric arc furnace (EAF) dust and various residues.
006 Outotec Ausmelt TSL Process
Complementary Outotec technologies Outotec’s technology portfolio covers the entire production chain from mine to metal. This broad range of technology offerings and industry experience, combined with our comprehensive understanding of equipment and process requirements, ensures you
Complementary Outotec technologies Smelting technologies Refining
receive fully integrated process solutions customized to
Casting
your specific needs.
Electro-refining Precious metal recovery
This unique ability to supply comprehensive plant
Slag cleaning
solutions allows us to provide plant and process
Offgas handling
guarantees for key performance measures including throughput, metal recovery, energy consumption and emissions. In addition to building new capacity, Outotec
Sulphuric acid plants Automation and process control
delivers technology and services for the expansion,
In addition, Outotec’s technology portfolio
modernization,
also extends into the mineral processing,
hydrometallurgical, chemical, energy and
water industries.
optimization
and
maintenance
of
existing plants, processes and equipment. Outotec is dedicated to supporting you at every stage of a project lifecycle. From conceptual studies and process development
through
to
project
implementation,
training or ongoing technical and maintenance support, Outotec can help.
Outotec Ausmelt TSL Process 007
Outotec services improve process performance
Outotec aims to maintain long-term working partnerships
Plant and process support services
with its customers to ensure the full value of their operations and equipment is realized. Outotec’s global
Outotec's advanced plant and process assessment tool,
network of service centres are dedicated to providing
ef-X® Efficiency Explorer, indentifies areas with the most
ongoing specialist technical and maintenance support.
potential for improvements, e.g. equipment, automation
This support maximizes productivity and optimizes
systems, metallurgical processes and complete plants. Our
customer plants and processes.
intimate knowledge of the process demands and equipment requirements ensures that any modifications or upgrades
Through these local service centres, customers have
are seamlessly integrated into your existing operations.
unparalleled access to Outotec’s broad expertise base and extensive operational experience. Additionally, customers can tap into the latest technological
Benefits of Outotec services
developments from Outotec’s extensive research and
Critical original spare parts in stock
development programs. Outotec delivers solutions from spare parts procurement and support, preventative maintenance programs, plant audits, through to
Comprehensive process and equipment expertise
optimization and upgrades, project management and
Minimize downtime and unscheduled
training.
stoppages Maximum operating performance
Equipment services As the original equipment manufacturer (OEM) you are assured that Outotec’s spare parts and consumables are of the highest quality and specifically designed for the application. Through Outotec’s specialized manufacturing, procurement and logistics channels you will have the peace of mind of timely access to genuine parts whenever required. Outotec’s team of specialists understand the pressures of production. Our specialists will work with you to develop preventative maintenance programs and with regular involvement, offer optimal availability and reliability minimizing downtime.
Total service package from Outotec: Process support services nn Troubleshooting nn Optimization nn Simulation nn Integration nn Design nn Technology transfer nn Commissioning nn Process control analysis nn Training
Equipment services nn Spare parts and spare parts management nn Equipment inspections and maintenance nn Training Plant services nn Plant assessments nn Operation and maintenance support services nn Upgrades and modernizations nn Shutdown maintenance services
Finland, October 2011.
Outotec develops and provides technology solutions for the sustainable use of Earth’s natural resources. As the global leader in minerals and metals processing technology, Outotec has developed over decades several breakthrough technologies. The company also offers innovative solutions for the chemical industry, industrial water treatment and the utilization of alternative energy sources. Outotec shares are listed on the NASDAQ OMX Helsinki. www.outotec.com
[email protected] www.outotec.com Copyright © 2011 Outotec Oyj. All rights reserved.
