742
C. Zschiesche and I. Bauer
The project was approved in 2012, and the erection time was approximately
1.5 years. The hot commissioning was finished in December 2014. For the first phase,
the utilization of 8 kettles was aimed, whereas the facility was already prepared to
install four further kettles as required.
The main objectives to enhance the environmental performance and occupational
health and safety of the lead refinery were carefully defined and considered as
key aspects during the conceptualization and execution of the project. These are
summarized as follows:
• Reduce the emissions at their source (the kettle) by an improved sealing with a
proper ventilation system,
• Reduce the emissions which could leave the facility by planning the right position
for the ridge turret system to ensure a proper circulation of the air,
• Design a plant layout which allows a proper access to all kettles for cleaning and
maintenance and which allocate solutions to minimize the storage of intermediate
bullions or dross on the kettle floor,
• Plan an energy efficient kettle heating system to minimize the heat losses while
increasing the contact area [2].
Improvement of Occupational Health and Safety
and Environmental Protection
The old lead refinery with its capacity of 30,000 t/a crude lead processing had 8 kettles
in operation, arranged in a very busy environment. As can be noted from Fig. 3, the
kettles had a secondary ventilation system which was placed at the outer corner of
each kettle. The suction was limited with 80,000 N m
3 /h filtered in a baghouse.
The valid limits in air circulation were critically reviewed and had to be improved
during planning of the new facility. Also according to the strive for minimization of
fugitive emissions, the new refinery was planned with a different concepts of ridge
turret system. Figure 3 shows the plant layout of the new refinery if all 12 kettles
Fig. 3 Left: Old lead refining facility; Right: New lead refining capacity with expansion setup
where 12 kettles could be utilized
C. Zschiesche and I. Bauer
The project was approved in 2012, and the erection time was approximately
1.5 years. The hot commissioning was finished in December 2014. For the first phase,
the utilization of 8 kettles was aimed, whereas the facility was already prepared to
install four further kettles as required.
The main objectives to enhance the environmental performance and occupational
health and safety of the lead refinery were carefully defined and considered as
key aspects during the conceptualization and execution of the project. These are
summarized as follows:
• Reduce the emissions at their source (the kettle) by an improved sealing with a
proper ventilation system,
• Reduce the emissions which could leave the facility by planning the right position
for the ridge turret system to ensure a proper circulation of the air,
• Design a plant layout which allows a proper access to all kettles for cleaning and
maintenance and which allocate solutions to minimize the storage of intermediate
bullions or dross on the kettle floor,
• Plan an energy efficient kettle heating system to minimize the heat losses while
increasing the contact area [2].
Improvement of Occupational Health and Safety
and Environmental Protection
The old lead refinery with its capacity of 30,000 t/a crude lead processing had 8 kettles
in operation, arranged in a very busy environment. As can be noted from Fig. 3, the
kettles had a secondary ventilation system which was placed at the outer corner of
each kettle. The suction was limited with 80,000 N m
3 /h filtered in a baghouse.
The valid limits in air circulation were critically reviewed and had to be improved
during planning of the new facility. Also according to the strive for minimization of
fugitive emissions, the new refinery was planned with a different concepts of ridge
turret system. Figure 3 shows the plant layout of the new refinery if all 12 kettles
Fig. 3 Left: Old lead refining facility; Right: New lead refining capacity with expansion setup
where 12 kettles could be utilized