Lead Plant Transformations
171
Plant B
Worley was engaged to carry out several concept studies (on TSL smelt/reduce and
SKS smelt/reduce technology), a pre-feasibility study (on TSL and SKS technology).
The technology providers were engaged as part of these studies included ENFI,
Outotec, Xstrata, and MECS. Worley also executed the final feasibility study for the
replacement and upgrade of the plant (feed preparation, sinter plant, acid plant, blast
furnace, and feed system) with process plant based upon non-ferrous TSL oxidation
technology.
The studies included TSL oxidation and reduction, TSL oxidation and blast furnace reduction, SKS two stage processing, and SKS oxidation with blast furnace
reduction. With the TSL process, both Outotec and Glencore technologies were
compared and costed. The various studies were completed over several years as the
client developed the business cases to progress to project execution.
The study showed that all processes can treat the various feed blends that were
being considered by the client. Parcels of concentrate were sent to China for process
testing, and Worley provided technical assistance during the plant trial with ENFI
SKS technology. To minimize the capital cost of the project, a strategy to utilise Chinese equipment supply including materials handling, coal grinding, TSL furnace,
waste heat boiler, electro-static precipitator, gas cleaning and sulfuric acid, demineralised water, sea water pumps and slag caster, and fabrication where possible in a
China based Module Yard fabrication was developed.
On completion of these studies, the customer engaged Worley to undertake part
detailed engineering for the preferred option, subsequently engaged to initiate project
specific PCM activities, including supplier purchase orders, site establishment, early
works construction, and module yard contracts.
Ultimately, the client selected the Outotec TSL technology after completing the
trade-off studies that took CAPEX and OPEX to ±30%. The ultimate decision was
to install only one TSL furnace to produce synthetic slag to feed the existing modified blast furnace. The facility was constructed in a brownfields location, and the
modification included the installation of a new acid plant to incorporate both the TSL
and existing blast furnace off gas.
The new facility was developed to unlock a greater proportion of the value contained in a wider range of high margin feed materials including internal zinc smelter
residues and concentrates. SO 2 capture was designed to increase from 50 to 98% for
the new plant. Acid production was to increase significantly from ~200 to 1000 t/day.
Conclusions
The paper has outlined the approach that Worley has developed to execute lead
smelting transformation projects. It discusses two recent projects that have advanced
from conceptual studies to executed projects. The approach involves close liaison
171
Plant B
Worley was engaged to carry out several concept studies (on TSL smelt/reduce and
SKS smelt/reduce technology), a pre-feasibility study (on TSL and SKS technology).
The technology providers were engaged as part of these studies included ENFI,
Outotec, Xstrata, and MECS. Worley also executed the final feasibility study for the
replacement and upgrade of the plant (feed preparation, sinter plant, acid plant, blast
furnace, and feed system) with process plant based upon non-ferrous TSL oxidation
technology.
The studies included TSL oxidation and reduction, TSL oxidation and blast furnace reduction, SKS two stage processing, and SKS oxidation with blast furnace
reduction. With the TSL process, both Outotec and Glencore technologies were
compared and costed. The various studies were completed over several years as the
client developed the business cases to progress to project execution.
The study showed that all processes can treat the various feed blends that were
being considered by the client. Parcels of concentrate were sent to China for process
testing, and Worley provided technical assistance during the plant trial with ENFI
SKS technology. To minimize the capital cost of the project, a strategy to utilise Chinese equipment supply including materials handling, coal grinding, TSL furnace,
waste heat boiler, electro-static precipitator, gas cleaning and sulfuric acid, demineralised water, sea water pumps and slag caster, and fabrication where possible in a
China based Module Yard fabrication was developed.
On completion of these studies, the customer engaged Worley to undertake part
detailed engineering for the preferred option, subsequently engaged to initiate project
specific PCM activities, including supplier purchase orders, site establishment, early
works construction, and module yard contracts.
Ultimately, the client selected the Outotec TSL technology after completing the
trade-off studies that took CAPEX and OPEX to ±30%. The ultimate decision was
to install only one TSL furnace to produce synthetic slag to feed the existing modified blast furnace. The facility was constructed in a brownfields location, and the
modification included the installation of a new acid plant to incorporate both the TSL
and existing blast furnace off gas.
The new facility was developed to unlock a greater proportion of the value contained in a wider range of high margin feed materials including internal zinc smelter
residues and concentrates. SO 2 capture was designed to increase from 50 to 98% for
the new plant. Acid production was to increase significantly from ~200 to 1000 t/day.
Conclusions
The paper has outlined the approach that Worley has developed to execute lead
smelting transformation projects. It discusses two recent projects that have advanced
from conceptual studies to executed projects. The approach involves close liaison