Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Introduction 1
In Pursuit of an Ideal Smelter 3
Basic Concept of the Mitsubishi Process 5
Advantages of the Mitsubishi Process 7
Environment /Recycling 9
Cost Competitiveness 11
Process Reliability and Control 13
Typical Plant Layout and Design Parameters 15
Mitsubishi Process Smelters in Operation around the World 17
Naoshima 19
Kidd Creek 21
Onsan 23
Gresik 25
Port Kembla 27
Company Profile 29
Available Services 30
Our atmosphere, the air we breathe, is common to all of Earth's inhabitants. Our planet provides The "Mitsubishi Continuous Smelting and Converting Process" which we have evolved from years of
us with abundant natural resources........clear waters........bountiful seas........fertile lands........ and research and production experience, is the world's only commercially proven pyro-metallurgical
verdant forests. All must be carefully nurtured, widely enjoyed, understood, appreciated, and most process to produce blister copper continuously from concentrates.
important of all, must be protected and sustained for the benefit of future generations. Since the
inception of the Mitsubishi Process, we have constantly challenged our own technology, striving to It is "THE PROCESS" for the 21st Century.
make it more efficient, and ever friendlier to the environment.
The Mitsubishi Process ensures environmental protection of the surrounding community, clean and
safe workplace conditions, and the highest copper, gold, silver and sulfur recoveries in the copper
industry. Its operating costs are low and the cost of plant construction is keenly competitive. These
are but a few of the many technological aspects, which we will cover more fully in the following
pages.
2
1
IN PURSUIT
OF AN IDEAL SMELTER
The Mitsubishi Process: from furnaces and ladles. Thus the Mitsubishi furnace Half a century of development
A step ahead of the rest arrangement consists of three stationary furnaces, 1959 Testing of injection feeding began, one of the 1991 New larger Mitsubishi Process line with production
Copper has been recognized as a valuable resource connected by enclosed launders, continuously cornerstones of the Mitsubishi Process. capacity of 200,000 MTPY started operating in
since ancient times. Mitsubishi Materials has sought to producing blister copper from concentrates. 1970 Successful completion of continuous smelting and Naoshima, replacing operations using the reverberatory
optimize the smelting of this valuable resource for many Furnace charging and tapping are eliminated, so no converting pilot plant testing. furnace + P.S. converters and the original Mitsubishi
years. We believe the ideal smelter should be environ- ladles and cranes are required, and there are no 1974 First commercial scale Mitsubishi Process plant with Process line.
48,000 MTPY production capacity, commenced opera- 1998 New Mitsubishi Process smelter started at Onsan,
mentally friendly, highly efficient, and inexpensive to fugitive emissions. These are the basic reasons why
tions in Naoshima. Korea, with production capacity of 160,000 MTPY.
build and operate. Our Mitsubishi Process attains all of the Mitsubishi Process is so clean to operate, and why it
1981 Second commercial scale Mitsubishi Process plant with 1998 New greenfield Mitsubishi Process smelter started at
the above goals. has such an unique structure. As demonstrated daily by
60,000 MTPY production capacity, commenced opera- Gresik in Indonesia, with production capacity of
our family of smelters at Naoshima, Kidd Creek, Onsan,
tions at Kidd Creek Smelter in Canada. 200,000 MTPY.
Unique structure that stresses and Gresik, the use of the Mitsubishi Process has
1982 Production capacity was doubled at Naoshima to 2000 The first stand alone Mitsubishi C-furnace started
environmental friendliness elevated their copper smelting to "clean industry" status. 96,000 MTPY. operating at Port Kembla Copper, in Australia in place
From the start of its development, the Mitsubishi An important and lasting advantage in complying with 1988 Production capacity at Kidd Creek doubled to 125,000 of previously used P.S. converters.
Process has aimed at eliminating fugitive emissions more stringent environmental regulations in the future. MTPY. 2000 Naoshima's production capacity increased to 270,000
MTPY of anodes from new source.
2001 Naoshima Smelter accredited with ISO 14001.
3 4
As mentioned previously, the Mitsubishi Process con- 150 to 200 m/s. The concentrates are bath-smelted two pairs of three. Here the mixed matte and fayalite slag researched, and pioneered the use of limestone for the
sists of three stationary furnaces in cascade, connected instantly, producing a high grade matte of around 68% (2FeO SiO2) separate by difference in specific gravity. continuous conversion of matte to blister. This lime-
by launders. By adopting this multi-furnace system, copper and silicate slag. The use of top blowing lances The lighter slag contains about 0.6% copper, and ferrite slag (Cu2O-CaO-Fe3O4) has a lower viscosity and
smelting, slag cleaning, and converting operations can ensures that the melt is always well mixed and makes continuously overflows from the CL-furnace into a fast a much higher solubility for magnetite than silicate type
be carried out continuously under "ideal conditions" for the Mitsubishi S-furnace one of the most efficient and flowing flume of water where it is instantly granulated, and slags. The choice of limestone as the C-furnace flux was
efficient copper recovery and removal of impurities. compact copper smelting units in the world. It also can then be either sold or discarded without any additional one of the key factors in the successful develop-ment of
Furthermore, the adoption of top blowing lances, and a ensures very high capture of the feed solids, with less treatment. Meanwhile the heavier matte sinks to the bottom the Mitsubishi Process, still the only technology to
special type of slag for the C-furnace are integral items than 3% solids (plus volatiles) carried over with the of the furnace and siphons continuously embody continuous converting. The relatively small
Scrap copper
Offgas
Lance
Anode scrap
Slag & matte Electrode Offgas
Lance
S-furnace
CL-furnace
CL-furnace C-furnace
Anode copper Anode
Anode casting
C-slag recyled to Anode furnace
Discard slag Anode casting wheel
S-furnce
S-furnace lances
that make continuous operations possible. furnace offgases into the waste heat boiler. The main from the bottom of the furnace to a covered launder, tonnage of converter slag (carrying about 14% copper)
The following section describes the Mitsubishi heat source for smelting comes from the oxidization of flowing continuously into the C-furnace. overflows the C-furnace, and is water granulated, dried
Process in more detail. and recycled to the S-furnace. Blister with about 0.6 to
iron and sulfur in concentrate, and the balance made up
C-furnace 0.7% sulfur siphons up out of the furnace, and is
S-furnace by coal. The matte and slag formed continuously The Converting furnace (C-furnace) removes the continuously delivered to the anode furnaces for pyro-
Dried concentrates (containing roughly 30% copper, overflows together from the S-furnace, down an remaining iron and sulfur from the copper matte, refining to anode copper. Anodes for the tankhouse can
25% iron, and 30% sulfur, and moisture content about enclosed launder into the CL-furnace. producing "blister" copper (about 98.5% Cu). The C- be cast in moulds mounted on a large diameter wheel,
0.5%), are mixed with coal, silica sand and recycled furnace is similar to the S-furnace, but smaller in or through a Hazelett Twin-Belt caster and
converter slag. The mixed feed is injected into the
CL-furnace diameter, and uses identical vertical blowing lances to Mannesmann "flying" shear.
Smelting furnace (S-furnace) through vertical lances, The slag cleaning furnace (CL-furnace) is a quiescent inject limestone flux, coolant, and oxygen enriched air.
together with oxygen enriched air, at a velocity between electric furnace powered by 6 electrodes arranged in Over 30 years ago, Mitsubishi carefully selected,
5 6
Today, Pierce-Smith converters (P.S. remelting of anode scrap and purchased copper
converters) coupled with various types of scrap, while avoiding the associated fugitive
smelting units, are used in most of the world's emissions of traditional reactors like P.S. converters.
smelters. However, due to "batch" processing
and problems associated with fugitive
Steady state operation
emissions during the transfer of melt and "Steady State" furnace operation at constant bathline
blowing stages, this arrangement will not be contributes to furnace integrity and simplifies
acceptable in the future. refractory design. Since the bathline is constant,
protection is only required for a small area to counter
Modern day alternatives include the the "wave" motion of the melt. In contrast, all tapped
Mitsubishi Process, Outokumpu Flash furnaces require protection over
Smelting and Flash a much wider area, since the
Converting Process, the bathline changes during opera-
Noranda Process, and tions. Our C-furnace bathline,
the Ausmelt Process. will now give 3 or 4 years
Only the Mitsubishi operation between bathline
Process is a "truly con- repairs, due to advances in
tinuous" smelting and furnace design and refractory
converting operation cooling.
producing a constant
flow of blister without Simplicity of scale-up
tapping, and is eco- The S and C furnaces can also
nomically proven by be tailored to accommodate
long term commercial operations. Its low capital and various annual production
operating costs are well demonstrated over many years. capacities. The table headed
"Typical plant design pa-
High reliability rameters" on page 16, shows S
While processes like the Flash Process have some also allows materials such as coal, flux, and granulated and C furnaces diameters for
advantages from the decoupling of their smelting and slag particles as large as 3mm in diameter to be 100,000 MTPY increments in
converting operations, its operating and capital costs charged to the bath. Feed materials need not be finely production. To move up to
are quite high. The Mitsubishi Process is a continuous ground and specially dried as in flash processing. Conversely, in areas where the cost of oxygen is high, 200,000, 300,000, and 400,000
"pipeline" with greater cost efficiency, and higher lower enrichment levels can be used, and additional MTPY production levels, the
reliability of operations makes decoupling unnecessary.
Effective heat utilization furnace diameters are increased by 1 meter only.
energy credits recovered as steam.
Although the Mitsubishi C-furnace is normally operated However, all Mitsubishi Process smelters currently in
Effective bath smelting with an oxygen enrichment around 32 - 35%, the level
Ideal for scrap melting operation, have increased production levels by
Furthermore, in the Flash Process, solid materials react can be adjusted freely to suit the need of each individual In contrast to quiescent furnaces, which are not suited increasing oxygen enrichment, while keeping the same
in the gas phase, and consequently dust carryover smelter. For instance, in order to reduce the size of gas towards the re-melting of scrap materials, the Mitsubishi furnace dimensions. This clearly illustrates the simplicity
rates are high. However, in the Mitsubishi Process, the handling facilities, oxygen enrichment can be increased, S and C-furnaces, with their efficient agitation the melt of our scale-up, and underscores the compactness and
injected solids are pinned down into the bath, with little and excess heat absorbed by charging additional by the top blowing lances, have excellent heat transfer high intensity of our furnaces, and our low capital cost
carryover. Effective bath-smelting by top blowing lances copper scrap, sludge or recycled C-slag as coolant. characteristics, making them ideally suited for the and low operating costs.
7 8
ENVIRONMENT RECYCLING
The recycling of scrap materials will continue to play an Similarly, ordinary market scraps can be pressed into
C-furnace
9 10
Continuous operation saves costs
Since the Mitsubishi Process always operates at or near
optimum mode, there is no need to build excess
capacity in main facilities like the furnaces, and
ancillaries such as gas handling, oxygen and acid
plants. These can all be designed very close to the
smelter's nominal capacity, greatly reducing construction
and operating costs.
Simple ventilation system Additional slag
Just one converter is enough! Occasionally gases escape from the furnace melt inlets
treatment unnecessary
and outlets. These fugitive gases contain only minor Most smelters around the world charge molten slag
In conventional processes using batch reactors,
usually three or more P.S. converters are required. The traces of SO2, and can be vented directly to the stack, from P.S. converters into electric furnaces, in order to
after de-dusting by bag filters. This simplifies the gas recover the matte portion, and discard the slag portion.
Mitsubishi Process uses just one C-furnace,
cleaning process, and greatly reduces costs. However, it is still difficult to keep copper content in
which operates continuously for 40 or 50
discard slag low, even when magnetite in slag is
months between bathline brick repairs. In
contrast, P.S. converters need tuyere line To achieve the same in-plant environment with a reduced. Therefore, some smelters in Japan have slag
rebricking every 3 months. Thus big conventional process, costs would be prohibitive, since crushing and flotation facilities, to keep copper content
savings can be achieved in labor and the huge gas volumes captured by a roof plenum would in discard slag low. In contrast, slag from the Mitsubishi
relining costs. have to be passed through a large scrubber before C-furnace can be recycled to the S-furnace without any
being released to the atmosphere. additional treatment, and copper loss in discard slag still
kept low, even while operating with a high matte grade,
Comparison of Manpower Requirement Production300,000(MTPY) about 68%.
Smeltiing
28
Converting
28
Anode furnace
16
Acid plant
Management,staff
reasonable assumption that to maintain the same
Since operations are continuous and straightforward,
environmental quality as the Mitsubishi Process, two acid
and the three furnaces are easily patrolled by a few
plants and complicated scrubbing facilities will be required
operators, manpower requirements are low compared to
efficient acid plant can be designed and operated. This for the conventional smelter. As can be seen, the
conventional processes.
saves considerable power and maintenance costs, as Mitsubishi Process requires about 33% less operators than
well as reducing capital. the conventional process. A considerable advantage in
The figure on page 11 compares the number of operators
countries with expensive labor.
Low manpower requirement required for a 300,000 MTPY smelter. It makes the
-Cu)
large overhead cranes and their expensive
1200 costs for Mitsubishi smelters
support columns. The smelter building has of varying production capac-
cost($/T
no crane aisle, no ladle skulls storage area,
1000 ities, assuming a double
contact acid plant is used,
and no skulls crushing facilities. Therefore, 36
and that oxygen is purchased
Construction
800
the building can be compactly designed. This
cost of just under US$300
and the savings on all the facilities from an adjacent supplier. The
mentioned above, results in markedly 600 graph shows a construction
reduced capital expenditures compared with 400 million for a 300,000 MTPY
16
other copper smelting processes. Apart from
24 12 smelter, plus acid plant. This
the odd spill and some boiler accretions, Others
there are almost no reverts to be recycled, 200 is much lower than other high
8 8 temperature processing tech-
resulting in very high overall copper and
10 9 0 nologies. We estimate these
precious metals recoveries. All of the above 100 150 200 250 300 350 400
Total 122 81 50 to be anywhere from 30% to
contribute to Mitsubishi's commendably low Production capacity(x1,000 MTPY)
copper cost per pound. double our cost.
12
11
First five years of production at Naoshima
PROCESS RELIABILITY
AND CONTROL
simple reliable systems working together. Therefore, combined total of over seven
engineering's focus was on using simple systems, with million tonnes of blister copper.
All are operating cleanly, eco-
built-in spares in critical process areas and good plant
nomically, and at levels well
layouts, giving easy access for repairs or replacement, to
above original design. This is the 280,000
minimize downtime should it occur. Thus now online
Process Reliability times above 92% are routinely logged, and decoupling of
most compelling evidence we 240,000 Process Control
have of our strength in research,
Critics of continuous processing are quick to point out furnace operations is not necessary. Control of the Continuous Process is like simple
engineering, process operations,
/ year
200,000
that..... "When any one item fails, everything stops." Turn "pipeline" control "inlet" conditions are measured,
this negative thinking around and you get..... "Let's make However, engineering is only one factor in the high control, and operator training changes in the "middle" monitored, and the resulting
tonnes
programs. 160,000
sure that everything runs together all the time." Always reliability of our operations. Research continues to find "outlet" flow analyzed.
better sensors, control systems, and a clearer under- The graph on right shows 120,000
ready to challenge conventional thinking, Mitsubishi,
standing of the Process fundamentals. Mitsubishi's production rates for the first five
cognizant of the clear advantages of continuous In plant practice, the matte quantity and grade is the
current family of smelters have now produced a years at our Naoshima smelter. 80,000
processing, understood the vital importance of having stable "middle." Various adjustments can be made to
As can be seen, full design ca-
the S-furnace "inlet" conditions, (for example the ratio of
oxygen to copper in feed). Then with constant matte
entering the C-furnace, blister quality (the "outlet") is
S-furnace
controlled largely by holding the C-slag copper content
CL-furnace
to around 14%. ined, similar to those developed in the Steel Industry and the training of new operators for Naoshima, and C-furnace
elsewhere. (See diagram below) providing experienced guidance for the operators of
Mitsubishi's process control has developed as a new Mitsubishi designed smelters overseas, especially
fascinating combination of operator input and experi- Starting in 1990, the Mitsubishi Operation Support during the early stages of operation.
ence, data logging, computerized analyses, on line System ("MIOSS") was gradually developed and tested
chemical assaying and lab support. As sensors and at Naoshima. It has now been used in routine operations For example, assisted by MIOSS, LG-Nikko Copper
computers improve, the variance amongst operators since 1995, working from a "digitized" input of the skills Inc., with operators used to "Flash" technology, were
becomes more significant. Therefore an "Artificial and experience of the best operators, selected able to adapt quickly to Mitsubishi Process control
Intelligence" or "Expert System" approach was exam-
metallurgical data, and rapid data analyses. For any plant during their exemplary start-up at Onsan in 1998.
operating condition, it provides vocal guidance to the
Control Room operator, and a printed copy on a Similarly, at PT Smelting, Gresik, after overcoming
computer screen. some ancillary plant problems, the smelter has
operated steadily at and above design capacity since
Presently, just as in Chess, MIOSS cannot always out June 2000.
perform a "Master" operator, but it has made process This outstanding accomplishment, with a locally
control more uniform between shifts, and over extended Indonesian workforce, totally devoid of "hot metal"
time periods given important gains in process reliability. experience, was due to the combination of Mitsubishi's
excellent training programs, including MIOSS.
MIOSS has also been invaluable in helping to speed up
feed back
Operator
The Mitsubishi Process
numeric
al data
DCS
Display
pacity was reached in the second 40,000 4th 5th Supporting Expert
3rd year information System
year of production, and produc- 0 2nd year
year
tion rates have exceeded design 1st year Anode scrap
capacity after that. year New anode
13 14
TYPICAL PLANT DESIGN PARAMETERS
TYPICAL PLANT LAYOUT
Typical operating parameters of The Mitsubishi Process for various copper production rates were
estimated and the results are summarized as follows.
Blowing condition
S-air 3 8,900 17,500 25,700 33,800
(Nm /H)
8 S-O 2(99.5%) 3
(Nm3/H) 7,000 13,800 20,200 26,600
7 S-total 15,900 31,300 45,900 60,400
22 (Nm /H)
S-O 2 enrichment (%) 56.0 56.0 56.0 56.0
4 Diameter 6.5m 8m 9m 10m
[C-furnace]
5 6
(T/H) 1.1 2.1 3.2 4.3
Limestone feed rate
Anode scrap feed rate (T/H) 2.3 4.6 6.9 9.2
Coolant feed rate (C-slag) (T/H) 2.0 6.3 11.4 16.0
15 16
MITSUBISHI PROCESS SMELTERS
IN OPERATION AROUND THE WORLD
17 18
In 1991, the existing reverberatory+P.S. converter line The main features of Naoshima's
Control room
19 20
Falconbridge Limited's Kidd Creek Metallurgical Division A point noteworthy of mention is that in 1990, the The main features of Kidd's copper
is located in Timmins, Ontario, Canada. Ore is railed from Canadian Government issued a control order requiring operations are:
the mine to the plant site for milling and concentrating, that by January 1994, all smelters must reduce SO2 Smelter: Mitsubishi Process
copper smelting and refining, zinc roasting and electro- emissions by at least 50%. Kidd Creek was the only Oxygen plants: Air Products
winning, and other operations. copper smelting operation exempted from this control Casting: Hazelett twin-belt caster
order, since Environment Canada judged the site's Tankhouse: Onahama Jumbo Tank
Around 1975, Texasgulf Inc., Kidd Creek's original owner, control of SO2 emissions to be more than adequate. This + Kidd Process with stainless steel
decided to process their copper concentrates to cathode justified the 1975 selection and avoided the enormous cathodes
copper. After examining several competing processes, refit costs required of the older smelting operations. Acid plant: Monsanto double contact
Texasgulf selected the Mitsubishi Process for smelting
and Onaha-
ma's "jumbo tank" refin-
ing technology.
Operations started in
1981, with 60,000 MTPY
production capacity.
Then in 1985, with test
work and design recom-
mendations from Mitsu-
bishi, production was
progressively increased
to 125,000 MTPY by
oxygen enrichment.
In 2001, the Kidd smelter
produced 131,000 tonnes
of "new" anodes from
concentrates, its highest
annual production record-
ed to date.
21 22
Currently LG-Nikko Copper Inc. is Korea's
sole copper producer. Their Onsan
smelter is located 50 km north-east of
Pusan on the eastern seaboard of the
Korean Peninsula. Since 1980 they have
operated an Outokumpu flash smelter
with three P.S. converters, and a
production capacity of 140,000 MTPY. In
order to meet the rising need for copper
in their domestic market, they decided to
expand their total production capacity to
300,000 MTPY, by installing another
smelting line and tankhouse. Considering
their long experience with Outokumpu
flash smelting, after careful study, we
were particularly pleased that they
selected the Mitsubishi Process.
23 24
GRESIK,Indonesia
25 26
PORT KEMBLA,Australia
Lance air
&
oxygen Molten matte
Matte
holding Lance furnace
27 28
The Mitsubishi Group Significant dates Mitsubishi Materials Corporation, as a nonferrous metal producer
maintaining a long history of highly advanced technology, and undertaking
By the early 1940's, the original Mitsubishi zaibatsu 1871
a diverse range of activities worldwide, can provide all or part of the
(Mitsubishi Company), founded in the early 1870's, had Mitsubishi Company established.
following services upon your request.
expanded into virtually every sector of the economy, 1896
including mining, heavy industry, oil refining, chemicals, Start of metal smelting in Osaka Refinery following
banking, trading, real estate, insurance, even aircraft 1.Feasibility studies
transfer from the government.
manufacture. It was the biggest most powerful industrial 2.Test work
1917
combine in pre-war Japan. 3.Licensing 4.Basic
Naoshima Smelter established as the central smelter of
engineering
Mitsubishi by Mitsubishi Company.
5.Detailed engineering
Then, with the advent of World War , everything 1918
changed. After the war, the single organization was 6.Training
Mitsubishi Mining Co., Ltd. established as off-shoot of
dissolved into scores of independent companies that 7.Start-up assistance
the Mitsubishi Company metal and coal mining division.
were no longer subject to central control. 8.Supervision of plant erection and construction work
Naoshima Smelter started operation of a reverberatory
9.Supply of machinery, equipment, and facilities
furnace.
The common misconception abroad however, is that 10.Guidance during early operating years
1950
Mitsubishi is still one giant company. This is not so. It is Post World War , allied break-up of Mitsubishi Mining Mitsubishi Materials Corporation
a collection of dozens of autonomous companies. Some Co., Ltd. 1-5-1 Ohtemachi, Chiyoda-ku, Tokyo
of them have been around for more than a century, 1990 100-8117, Japan
while others have grown up in the last few years. Merger between Mitsubishi Metal Corporation and
Mitsubishi Mining and Cement Co., Ltd. to form Metals Company Online
Mitsubishi Materials Corporation. URL http://www.mmc.co.jp
Mitsubishi Materials Corporation 1992 TEL +81-3-5252-5323
Mitsubishi Materials Corporation was created on (Process & Technology Dept.)
The completion of the new headquarters building
December 1st, 1990 by the merger of Mitsubishi Metal FAX +81-3-5252-5426
(Otemachi First Square) in Ohtemachi.
Corporation and Mitsubishi Mining and Cement Co., Ltd. E-mail mip@mmc.co.jp
which had been established after World War by the allied
breakup of the old Mitsubishi Mining Company.
Mitsubishi Materials Corporation is one of the world's
largest materials companies, employing more than
25,000 people in 19 countries. The company has built
strong positions in metal smelting and refining, cement
manufacturing and metal fabricating, and is now also
regarded as a technical leader in areas such as silicon
wafer, electronic components and advanced materials.
29 30