Furnace Integrity – A Holistic Approach to face todays Challenges

10,00
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DI. S. Wallner, Dr. A. Filzwieser, Dr. M.B. Hanel, Dr. I. Filzwieser, S. Ruhs

Non-Ferrous Metallurgical companies, especially toll smelters are nowadays under extreme economical pressure caused by reduced metal prices and competitive treatment and refining charges. This situation is additionally worsened by degrading concentrate conditions with increased amount of impurities that have to be treated with the same smelter setup. Therefore, an increase in the annual production and an extension of the maintenance intervals is of vital economic importance for all smelters especially in the Western hemisphere. Process parameters as there are for example feeding rate, amount of recycling material, process temperature, blowing time, fuel consumption are changed in order to increase the throughput in the smelter. At the same time, environmental regulations and health/safety standards are tightened which further increases the responsibility and the legal pressure on the operating staff and the management. This very complex system with a lot of parameters that influence each other requires professional expert know how and a dynamic risk management in place in order to be properly, responsibly handled. In case of process changes all available tools as there are CFD, FEM modelling, online parameter measuring (temperature and other important process data), complete 3D design including furnace shell, refractory and cooling have to be applied together with a risk analysis based on HAZOP and FMEA to improve the visibility into the continuous metallurgical processes. Since unknowingness is never an excuse it is of importance to be informed about latest technologies not only for process improvements but also concerning tools that have strong impact on the plant safety. The new Quality management norm 9001-2015 requires the implementation of an active risk management system which can now be made use of also as a competitive edge because of the potential in case of implementation of running a process in a more stable way on its limits.

Diese Kategorie durchsuchen: Process Control