copper smelter projects & services - dickinson … smelter projects and... · furnace and...
TRANSCRIPT
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COPPER SMELTER
PROJECTS & SERVICES
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Presentation Contents
1
2 Products and Services
3 Primary and Secondary Vessels Services
4 Isasmelt, Ausmelt & Reverb Furnaces
Introduction
Anode, Converters, Matte Settling, Six & Three-in-line Furnaces
Copper Recovery –Vacuum Services
5
6Package Benefits and Partnership7
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IntroductionDickinson Group of Companies was founded in 1910 followed by the
establishment of its furnace service business in 1928. The company has
more than 85 years experience in providing Specialist Furnace and
Industrial Services to the mining, metals smelting, mineral processing,
thermal power generation and petrochemical refining industries.
VISION
Dickinson Group of Companies’ Vision is to be a Leading provider of
Furnace and Industrial Services
MISSION
Dickinson Group of Companies’ purpose is to provide an integrated and
multidisciplinary “One Personalised Solution” by offering essential
furnace and industrial services, which increase productivity and
performance together with reducing costs for our customers.
CERTIFICATION
Dickinson Group of Companies is certified to OSHAS 18001
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Dickinson Geographic Presence
Office Locations
• Dickinson South Africa
• Dickinson Mozambique
• Dickinson Zambia
• Dickinson Mauritius
• Dickinson Tanzania
• Dickinson Indonesia
• Dickinson Tianjin China
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Dickinson Office & Workshops
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Services
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Products
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Industrial Sectors
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Industries we serve
Aluminium
Glass
Platinum
Iron ,Coke and Steel
Copper and Cobalt
Ferrochrome & Ferromanganese
Heavy Sands
Nickel
Power Plants
Lead Smelter
Cement & Lime
Chemical & Petrochemical
Power Generation
Vanadium
Ceramic
Refractory Manufacturing
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Global References
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Copper Smelter Projects and Services
Turnkey Furnace Rebuild Project Service - Project and construction management
Salamander tapping and controlled furnace decommissioning and cool down
Mechanical, structural, steel and piping dismantling, fabrication and erection
Refractory materials and Industrial Plant Spares management, including selection, procurement, and testing
Quality assurance and control systems
Demolition of furnaces, removal of refractory linings, and waste management
Design, manufacture and installation of anchor systems
Manufacture of customised precast refractory shapes
Installation of refractory materials
Hot and cold furnace repairs
Hot sealing and insulation
Drilling and installation of thermocouples
Drying and curing of refractory linings
Industrial Vacuum & Silo Cleaning Services
Furnace start-ups and commissioning
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Dickinson Group offers the complete range of services on the following Copper & Ferro-Nickel smelter vessels
Isasmelt , Ausmelt & Smelting Furnaces
Anode Furnaces
Matte Settling Electric Furnaces
Flash Furnaces & Slag Cleaning Furnaces
Six-in-Line / Three-in-line / Two Electrode Furnaces
PS Converters / Teniente Converters
Mould Twin Casting Wheel
Primary & Secondary Vessels Services
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Isasmelt & Ausmelt Furnaces
Partial, major or full demolition of refractories
Partial, major or full refractory installation
Refractory materials supply & coordination
Shell repairs or replacements
Tap hole repairs or replacements
Cleaning service on the boiler and transition piece
Launder replacements
Stack cleaning and maintenance
Platform repairs or replacements
Cleaning Copper & Ferronickel spills
Precast launder tiles
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Isasmelt Demolition utilizing Brokk Machine
Only 48 hours for complete demolition
Isasmelt Refractory Demolition
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Isasmelt Demolition utilizing Brokk Machine
Isasmelt Refractory Demolition
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Isasmelt Refractory Installation by use of 6061-T6 Aluminum Multi-point Suspended
Platform
Isasmelt Refractory Installation
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Isasmelt Refractory Installation with Suspended Platform
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Isasmelt Refractory Installation
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Partial, major or full Demolition on refractory
Partial ,major or full Refractory installation
Material supply and coordination
Gooseneck repairs or replacements
Maintain spare gooseneck units
Charge door repair or replacements
Charge door platform repairs
Maintain spare charge door units
Tuyere plate repairs or replacements
Shell plate repairs or replacements
Tap hole shell repair
Lip repairs or replacements
Anode Furnaces Maintenance
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Anode Furnaces Maintenance
Copper cooler replacements
Lip maintenance
Lip cleaning with the Brokk
Tuyere maintenance
Porous plug maintenance
Diesel ,water, air and nitrogen line repairs or replacements
Slag settling chamber repairs and maintenance
Slag settling chamber cleaning
Growth monitoring
Cleaning copper spills
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Full Reline Brick Removal : 3.5 days
Partial Repair Brick Removal :2.5 days
Full Reline Refractory Brick Installation:13 days
Partial Reline Refractory Brick Installation: 8 days
Full reline on Anode Furnace :16.5 days
Anode Furnaces Reline Statistics
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Partial, major or full Demolition on refractory
Partial ,major or full Refractory installation
Material supply and coordination
Shell repairs or replacements
Structural repairs or replacements
Tap hole repairs/maintenance
Matt launder repairs or replacements
Supply of precast launder blocks
Matte Launder blocks installation
Matte Launder maintenance
Feeding chutes repairs/maintenance
Electrode repairs/maintenance
Slag launder head maintenance
Roof cleaning and maintenance
Matte Settling Furnaces
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Growth monitoring
Cleaning copper spills
De-bricking of MSEF furnace roof
Removal of roof brick suspension members
Installation of new members and alignment
Installation of new roof bricks where necessary
Demolition of furnace side and end walls up to the base of
furnace
Bricking of new side walls and the repair of the DR System
where necessary
Last reline completed in 33 days including demolition mechanical
& refractory installation
Removed working Hearth and sidewalls from Skew back up of the
permanent lining
Matte Settling Furnaces
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Matte Settling Furnaces Precast Launders
Pre-dried up to 650 oC
Ready to use with no drying out required
Ease of Installation and removal
Reduce time required to replace the blocks
Reduce Labour required for launder maintenance
Increases refractory lining life cycle
Reduces need to constantly repair Launder refractories
Modular design with capability to remove only damaged sections
Less skill require as installation & removal is rigging activity
Ability to keep pre-cast launders in stock
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Matte Settling Furnaces Precast Launders
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Precast Matte Launder Life Time of 9 months
Matte Settling Furnaces Precast Launders
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Flash & Slag Cleaning Furnaces
Partial, major or full demolition of refractories
Partial, major or full refractory installation
Refractory materials supply & coordination
Shell repairs or replacements
Tap hole repairs or replacements
Matte launder repairs or replacements
Supply of precast launder blocks
Matte launder block installation
Matte launder maintenance
Feed chutes repairs & maintenance
Electrode repairs & maintenance
Slag launder head maintenance
Roof cleaning & maintenance
Growth monitoring
Cleaning copper spills
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Flash & Slag Cleaning Furnaces – Recent Projects
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Flash & Slag Cleaning Furnaces – Recent Projects
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Six and Three-in-line Smelting Furnaces
Partial, major or full demolition of refractories
Partial, major or full refractory installation
Refractory materials supply & coordination
Shell repairs or replacements
Tap hole repairs or replacements
Matte launder repairs or replacements
Supply of precast launder blocks
Matte launder block installation
Matte tap hole deep repairs
Feed chutes repairs & maintenance
Electrode repairs & maintenance
Slag launder head maintenance
Roof cleaning & maintenance
Growth monitoring and Cleaning copper spills
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Six & Three-in-line Furnaces
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Six and Three-in-line Furnaces
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Partial, major or full Demolition on refractory
Partial ,major or full Refractory installation
Material supply and coordination
Hood inspection and repairs(Hood door, hood rails and water leaks)
Cleaning of hang ups
Protection plate repairs or replacements
Apron repairs or replacements
Pouring lip ,gable and invert arch liners supply and replacements.
Converters
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Converters
Retaining plate and mounting plate repairs
Replacements on the mouth area
Shell repairs or replacements
Burner hole repair or replacement
Tuyer line base plate repairs
Tuyer boxes maintenance
Distribution pipe installation
Supply of tuyer pipes and installation
Repairs on tuyer mounting plates
Discharge chute’s repairs
Swivel and bustle repairs and maintenance.
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Auxiliary maintenance (handrails, walkways)
Off gas maintenance and repairs
Growth monitoring
Cleaning copper spills
Pouring lip cleaning with the Brokk
Converters
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Full reline hot to hot rebuilds :15 days
Partial repair hot to hot repairs :12 days
Converters
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Converters
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WE COMPLETED OVER 80 CONVERTER REBUILDS IN PAST 9 YEARS
Converters – Rebuilds Track Record
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Converters - Mechanical
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Converters - Mechanical
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Maintain the refractory on the
receiving launder
Maintain the refractory on the
long lasting launder
Maintain the refractory on the
Y-Piece
Maintain the refractory on the
launder tip
Maintain the refractory on the
intermediate ladle
Maintain the refractory on the
spoons
Mould Twin Casting Wheel
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Mould Twin Casting Wheel
Maintain the refractory on all the
spares units
Maintain the refractory on the
pouring spout
Supply of pre cast shapes on the
spoon tips
Curing facility for the units
Mechanical repairs on units
(Anchors, Base plates ext.)
Material supply
Demolition on the units with the
Brokk machine
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Mould Twin Casting Wheel
Our company currently carry out maintenance
on spoons, launders and intermediate
launders utilizing recycled brick lining grog to
reduce refractory consumption up to 50%
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CU
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ON
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AC
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Copper Recovery – Vacuum Services
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CU
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T C
ON
TR
AC
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Copper Recovery – Vacuum Services
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CU
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Copper Recovery – Vacuum Services
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Copper Recovery – Vacuum Services
Recovery of copper concentrate from Ducts, Conveyor Spillages,, Walk ways and Plant Floor Space
Solid and Liquid Recovery and disposal
Recovery from Slag Pits
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Business Alliances
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Dickinson Group Attributes and Benefits
Dickinson Group Attributes Benefits
OSHAS 18001 Certification Enhanced safety and health record
World class maintenance practices
Company :More than 85 years’ experience in specialist
furnace and industrial services
Quality, guaranteed,
Reduce down time and frequency of short shutdowns on an annual basis
Enhanced Preventative Maintenance planning
Over 1 million man working hours per year on maintenance services
Global Alliances Latest technology applications
State of the art maintenance equipment
Competitive pricing on refractory materials ,equipment and spares
State of the Art Equipment Increased shutdown efficiency
Reduce down time
Global Footprint Access ,experience and availability across the world
Priority service convenience
ISO9001 Certified products Quality guaranteed
Specialist and experienced personnel Reduced shutdown duration
Confident budgeting
Maintains highest level of optimum equipment performance
Inherent Innovative Culture Continual focus on product and methods development
One Personalised Solution Consolidated and Integrated Plant Maintenance Services
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Dickinson Group of Companies provides a “One Personalised Solution” and strives to be your
preferred partner and supplier.
www.dgrpint.com
DICKINSON GROUP OF COMPANIES
Corporate Head Office
10 Smuts Avenue
P.O. Box 63
Vereeniging
1930
South Africa
Tel: +27 16 421 3720
Fax: +27 16 422 1038
Email: [email protected]