Lead Plant Transformations
169
the last few years. Nominally, 3–4 Mt/a of lead is produced using the SKS technology in China. Furnaces as large as 5 m in diameter and over 30 m long have been
constructed and operated in China.
All new lead production within China is reportedly to adopt this technology including the new reduction SKS technology to minimise impact of smelting operations
on the environment and improve the economics of the operations.
Process Modelling
In many of the studies that Worley has completed, the technology vendor has provided
a process model that covers only their core technology. To ensure that the total
flowsheet holds together with all the recycle streams and that all the design criteria are
consistently used in the development of the process, Worley has built an independent
process model of the entire facility.
This assists the client in understanding the interactions with the new plant and can
be used to model the impacts of different feed stocks, different recycle configurations.
It is also important for the peripheral equipment sizing, like the acid plant, oxygen
plant, and the off gas handling process equipment.
Worley uses the Metsim modelling package as the tool to complete this modelling
and has built sophisticated models that can be used and adapted for both TSL and SKS
technologies. The models can incorporate both the oxidation and reduction process,
pyrometallurgical refining processes, and off gas cleaning processes. In some of the
project work, these models have been used to complete technology trade-offs and
comparisons to allow our customers to make process selections.
Worley works with the client and technology vendor to determine:
• Suitable online time for the process
• Heat loss parameters for the process
• Oxygen enrichment targets
• Feed blends, and
• Target slag compositions and metal grades.
Control parameters are built into the model, like how the plant would be operated,
so that it becomes a realistic representation of the process. Other packages have
been used at different times; however, Worley has invested significant time in the
development of specific process related models that it represents a valuable resource
to fast track process modelling and to ensure that our clients have tools that can assist
them make decisions. In many cases, the client continues to use the model in same
format as the project develops.
169
the last few years. Nominally, 3–4 Mt/a of lead is produced using the SKS technology in China. Furnaces as large as 5 m in diameter and over 30 m long have been
constructed and operated in China.
All new lead production within China is reportedly to adopt this technology including the new reduction SKS technology to minimise impact of smelting operations
on the environment and improve the economics of the operations.
Process Modelling
In many of the studies that Worley has completed, the technology vendor has provided
a process model that covers only their core technology. To ensure that the total
flowsheet holds together with all the recycle streams and that all the design criteria are
consistently used in the development of the process, Worley has built an independent
process model of the entire facility.
This assists the client in understanding the interactions with the new plant and can
be used to model the impacts of different feed stocks, different recycle configurations.
It is also important for the peripheral equipment sizing, like the acid plant, oxygen
plant, and the off gas handling process equipment.
Worley uses the Metsim modelling package as the tool to complete this modelling
and has built sophisticated models that can be used and adapted for both TSL and SKS
technologies. The models can incorporate both the oxidation and reduction process,
pyrometallurgical refining processes, and off gas cleaning processes. In some of the
project work, these models have been used to complete technology trade-offs and
comparisons to allow our customers to make process selections.
Worley works with the client and technology vendor to determine:
• Suitable online time for the process
• Heat loss parameters for the process
• Oxygen enrichment targets
• Feed blends, and
• Target slag compositions and metal grades.
Control parameters are built into the model, like how the plant would be operated,
so that it becomes a realistic representation of the process. Other packages have
been used at different times; however, Worley has invested significant time in the
development of specific process related models that it represents a valuable resource
to fast track process modelling and to ensure that our clients have tools that can assist
them make decisions. In many cases, the client continues to use the model in same
format as the project develops.