Lead Plant Transformations
167
Technology Alternatives
All operations have different drivers for considering a change in process technology. Two of key drivers relate to lead and SO 2 emissions. The operating costs and
efficiency of the sinter plant/blast furnace can also be a contributing factor when
considering a process change. Also, key feed stock material including internal and
external recycles can also contribute to the selection criteria when considering a
new technology. The new technology must also be able to integrate with regards the
existing equipment and has a suitable capacity to ensure success of the modernisation.
Determining the best alternative technology for a particular operating site involves
determining how the technology can be incorporated at the plant and also determining
what impact the technology will have on the remaining plant. During this stage,
Worley works through a process of collecting the plant data that is relevant to the
particular project goals. This can include the following tasks:
1. Review and updating of the process design basis for the area of the plant—
including nominating the name plate capacity that the client requires for the
future upgraded facility
2. As-building PFDs for the plant—in many cases, a total new plant has not been
built, and much of the existing plant infrastructure, for example, feed preparation,
feed conditioning, hygiene off gas systems, molten metal handling facilities, and
pyrometallurgical refining of the bullion can be re-used with only minor upgrades
required
3. Collect plant operating data and assess the plant and equipment performance and
condition to ensure that the plant reaches the name plate capacity and that none
of the equipment will become a bottleneck for the redeveloped site.
Worley has completed this process by generating area concepts that describe the
area of the plant, the issues that are seen in the plant area, condition of the equipment,
and the throughput of the plant in its current format. It identifies work that would
need to be carried out in the area to overcome the issues in the plant and to determine
how the different technology can be implemented and integrated at a particular site.
For example, does the facility only install an oxidation process to replace the sinter
plant, or do they consider replacement of both the sinter plant and the blast furnace
operation.
With the answers to these questions, information on the blend of concentrates and
secondaries to be treated, information on the supply of utilities like oxygen, plant
air, electricity, and water, a trade-off study can be completed to determine the ideal
technology for the plant.
Top Submerged Lance Technology
There are two technology vendors—Outotec and Glencore. Primarily, the technology,
however, is a bath smelting process. The Top Submerged Lance consists of an upright
167
Technology Alternatives
All operations have different drivers for considering a change in process technology. Two of key drivers relate to lead and SO 2 emissions. The operating costs and
efficiency of the sinter plant/blast furnace can also be a contributing factor when
considering a process change. Also, key feed stock material including internal and
external recycles can also contribute to the selection criteria when considering a
new technology. The new technology must also be able to integrate with regards the
existing equipment and has a suitable capacity to ensure success of the modernisation.
Determining the best alternative technology for a particular operating site involves
determining how the technology can be incorporated at the plant and also determining
what impact the technology will have on the remaining plant. During this stage,
Worley works through a process of collecting the plant data that is relevant to the
particular project goals. This can include the following tasks:
1. Review and updating of the process design basis for the area of the plant—
including nominating the name plate capacity that the client requires for the
future upgraded facility
2. As-building PFDs for the plant—in many cases, a total new plant has not been
built, and much of the existing plant infrastructure, for example, feed preparation,
feed conditioning, hygiene off gas systems, molten metal handling facilities, and
pyrometallurgical refining of the bullion can be re-used with only minor upgrades
required
3. Collect plant operating data and assess the plant and equipment performance and
condition to ensure that the plant reaches the name plate capacity and that none
of the equipment will become a bottleneck for the redeveloped site.
Worley has completed this process by generating area concepts that describe the
area of the plant, the issues that are seen in the plant area, condition of the equipment,
and the throughput of the plant in its current format. It identifies work that would
need to be carried out in the area to overcome the issues in the plant and to determine
how the different technology can be implemented and integrated at a particular site.
For example, does the facility only install an oxidation process to replace the sinter
plant, or do they consider replacement of both the sinter plant and the blast furnace
operation.
With the answers to these questions, information on the blend of concentrates and
secondaries to be treated, information on the supply of utilities like oxygen, plant
air, electricity, and water, a trade-off study can be completed to determine the ideal
technology for the plant.
Top Submerged Lance Technology
There are two technology vendors—Outotec and Glencore. Primarily, the technology,
however, is a bath smelting process. The Top Submerged Lance consists of an upright