Focus on the Copper Market

Cinque Terre
P.B. Panda, MD, TRL Krosaki

"Copper is one of the focused industries for TRL Krosaki and we are investing in know-how and technology, to be a valuable future oriented partner for our customers....."

TRL Krosaki is a proven refractory supplier to the Copper Industry with achieved top benchmark performances in international smelters from Chile to Australia. We have experience of working in all kind of copper smelting processes e.g. Outotec, Isasmelt or Mitsubishi technology.

Our state of the art production facility based on an integrated plant ensures a high-volume supply of different brands and shapes in shorter delivery time. The base are top grade raw materials from international suppliers carefully selected for the needs of copper process technology.

TRL Krosaki is worldwide the first refractory producer that has established a risk based quality control system in its Basic plant in order ensure constant high quality standards.

Due to the focus of TRL Krosaki on the copper industry a trained team of sales/marketing, design and supervision experts is servicing the customers.

The close relationship with local Indian copper smelters supports the continuous development of new refractory products, design solutions, efficient installation procedures and creation of performance based contracts.

TRL Krosaki has therefor a complete range of refractories required for the copper industry e.g. high quality direct bonded Magnesia Chrome, Alumina Chrome and high Alumina bricks plus all types of Monolithic Refractories including Alumina Chrome Castable.

 

TRL CRAL 25P and TRL CRAL 30P - Newly developed Alumina Chrome bricks for the copper industry

TRL CRAL 10P SL - Hydration resistant, cost effective Alumina-Chrome bricks for the use in the safety lining of Copper Furnaces

TRL Krosaki has developed two special quality of DBMC Bricks for Non Ferrous Metal Industry

Why TRL Krosaki is a Reliable Refractory Supplier for the copper industry ?

  • - have an Integrated production facility

    All products for a project are produced in one location

  • - have installed a Risk Based Quality Control system

    We take care that all production risks are constantly monitored

  • - use the best raw materials available on the market

    We are independent in our sourcing

  • - have a growing reference list with satisfied customers

    We have and we want long term relationships

  • - are focused on the copper industry

    Our staff is trained and specialized for the needs in your industry

  • - constantly develop our products based on latest copper producing technologies

    We have cooperation's with innovative technological companies in order to be close to the trends of the industry

Flash Smelting

Flash Smelting - Technology

A dry, fine concentrate is charged together with fluxes through the concentrate burner on the top of the reaction shaft into the furnace. Since it is mixed efficiently with oxygen enriched air the feed starts to react immediately based on the exothermic oxidation of sulfur. In the few seconds of free fall until the contact with the surface of the liquid bath in the rectangular settler zone the solid particles are melted and pre-reacted. In the bath, the slag layer is readily formed and the calm movement supports an efficient and good separation of matte and slag. At the end of the settler the gas flow is again redirected to the top into the uptake shaft to minimize losses caused by fine material escaping the furnace into the waste heat boiler.

During the last decades, more and more intensive cooling elements were introduced in the sidewall and roof design of flash smelter units. From a refractory point of view the perfect connection between refractory material and cooling elements is of outmost importance to allow a long-lasting uniform heat transfer.

TRL Krosaki has developed the matching brick and castable solution to this challenging application. Further TRL Krosaki has optimized the refractory design and heat up calculations. Therefore, a 3D thermal profile and CFD-model is essential for a correct expansion calculation.

TRL Krosaki balanced lining concepts for Flash Smelting Furnace

  • Roof :
  • TRL CRVV
  • TRL CRVV 2
  • Reaction Shaft :
  • TRL CRXS
  • TRL DBMC 3
  • Bottom :
  • TRL CR XV1
  • TRL CR XS
  • TRL CRAL 10P SL (Bottom Safety)
  • Settler:
  • TRL CR-XS
  • TRL SW HSR 1
  • Uptake Shaft :
  • TRL CRXS
  • TRL CRVV 2

TSL Technology

TSL (Top Submerged Lance) - Technology

The TSL process is characterized using a vertical lance that is submerged in a metal/slag bath that is surrounded by a vertical fixed cylinder. The feed (concentrate, fluxes and recycling material) is charged from the top and all process gases are injected through the lance in the center. Thereby a high intensive turbulent bath movement is created leading to fast chemical reactions. In some cases, a so-called splash block that is water cooled prevents the liquid material to be lifted into the upper part of the furnace.

The high erosion caused by discontinues contact with a slag and matte suspension above the liquid bath level is creating structural stress and chemical attack to the refractory lining.

Between 2 and 4 weeks the lance must be removed due to wear and maintenance needs. Therefore, the whole cylinder is regularly subject to large temperature changes in the refractory lining.

In the bath area, the refractory material is confronted by a matte/slag mixture with changing chemical and physical properties depending on the stage of metallurgical process.

TRL Krosaki has optimized its refractory products for the different zones of the lining to resist the high demands of this metallurgical process in the best possible way. Additionally, a concept of combined copper cooling and refractory lining is now part of the portfolio of TRL Krosaki.

TRL Krosaki balanced lining concepts for TLS Furnace

  • BOTTOM:
  • TRL CRXV
  • TRL CR XS C
  • TRL CRAL 10P SL
  • CYLINDER:
  • TRL CR XV
  • TRL SW HSR 1
  • TRL SW HSR 2
  • TRL CRAL 10P
  • TRL CRAL 25P
  • TRL CRAL 30P
  • OFF GAS AREA:
  • TRL CRXV 1

SLAG CLEANING

Slag Cleaning Process

The fayalitic slag coming from smelting or converting that has still a copper content too high for disposal, is further treated in a Slag Cleaning Furnace. Since heating is required, it is necessary to use an electric arc furnace that can be round or rectangular. This unit allows enough settling time for the physical separation of small matte droplets trapped in the viscous slag and allows also due to adding of reducing agents the reduction of copper oxide present in the slag.

The lower sidewall is in constant contact with corrosive slag and experiences high pre-wear especially in the interface area between bath and hot furnace atmosphere.

TRL Krosaki offers complete furnace linings for long lasting lining life. To achieve a balanced refractory wear, it can be necessary to use intensive cooling solutions in the side wall and in the tap hole area. In close cooperation with providers of cooling elements the correct refractory design and material selection was developed by TRL Krosaki.

TRL Krosaki balanced lining concepts for Slag Cleaning Furnace

  • Side Wall Lower Bath:
  • TRL CRXS
  • TRL CRVS
  • TRL DBMC-TF
  • Bottom:
  • TRL CRXS A
  • TRL CRAL 10P SL
  • TRL 42D
  • TRL RAM M95
  • Side Wall Upper Bath:
  • TRL CRVV
  • TRL CRVS
  • TRL CRVV
  • Roof:
  • TRL HIAL 60P
  • Tap Hole:
  • TRL CRXV 1
  • TRL CRAL 10P

CONVERTING

Converting Process

In the conventional Peirce Smith converter reactor, a horizontal cylindrical vessel, a two-stage process in performed.

In the first step – slag blow – the iron in the matte is oxidized and reacts with fluxes to form a fayalitic slag. For an efficient and fast reaction, the necessary oxygen is injected into the bath via a row of tuyeres that is placed below the bath level. The vessel can be rotated to follow the correct level of white metal in the bath.

In the second step - copper blow: the remaining copper sulfide is reduced again because of injected air forming finally blister copper with a low sulfur and oxygen content.

TRL Krosaki balanced lining concepts for Converter -

  • Tuyere Area:
  • TRL CRXS
  • TRL CRXV T
  • TRL SW HSR 1
  • TRL SW HSR 2
  • Mouth Area:
  • TRL CRXV
  • Slag Line Area:
  • TRL CRVV
  • End Wall:
  • TRL CRVV

REFINING

Refining Process

Since the sulfur content is still too high for electrolytic refining, it is necessary to further oxidize it to sulfur dioxide. This reaction step and the afterwards necessary reduction of the oxygen level in the copper is done in a drum type vessel. Heat is externally added by a burner and the process gases are injected via 2-4 tuyeres from the side. The whole process kinetic can be accelerated by the use of a bottom blowing purging system.

TRL Krosaki has developed the right refractory products for the complete lining in order to achieve multi-year lifetime. The tuyere zone is offered in resistant Alumina-Chrome brick qualities. The complete purging technology can be offered together with an experienced international technology company.

TRL Krosaki balanced lining concepts for Anode Furnace

  • Tuyere Area:
  • TRL CRXS
  • TRL CRXV
  • TRL CRAL 10P
  • TRL CRAL 25P
  • TRL CRAL 30P
  • Barrel & End Wall:
  • TRL CRVV
  • TRL CRXV
  • TRL CRXV1
  • Slag Zone:
  • TRL SW HSR 1
  • TRL SW HSR 2
  • Mouth Area:
  • TRL CR XV1
  • Skimming Port:
  • TRL CR XV1

ROTARY HOLDING FURNACE

Rotary Holding Furnace

The rotary holding furnace is used in combination with a TSL reactor. It is used as a buffer between the smelting reactor and the discontinuous Peirce Smith converter. The residence time in the rotary holding furnace allows for a good separation of matte and slag. Since it is closely connected to the smelting unit it is of outmost importance to reach the same refractory life time as in the smelter.

Otherwise the whole process line would be interrupted and cause a loss in production. Therefore, also high grade DBMC bricks are applied to withstand the corrosive attack of the charged matte/slag mixture during settling.

TRL Krosaki balanced lining concepts for Rotary Holding Furnace

  • End Wall Burner Side:
  • TRL CRXS
  • TRL CRXV 1
  • End Wall Inlet Side:
  • TRL CRXS
  • TRL CRXV 1
  • Off Gas Area:
  • TRL CRXS
  • TRL CRXV 1
  • Bath Area:
  • TRL SW HSR 1
  • TRL SW HSR 2
  • Tap Hole:
  • TRL CRXV 1
  • TRL CRXS ISA

Important international Copper Smelters trust in our quality

RISK BASED QUALITY CONTROL SYSTEM

TRL Krosaki has an active integrated Management system (ISO 9001, ISO 14001 and ISO 18001) since years. High product quality, environmental concerns and employee health are important pillars of the company strategy.

2017 the quality control procedures were further developed in the direction of a risk based quality control system.

In the whole production chain from the raw material to the final packed pallets every single step is analyzed for the probability and consequences of risks and counter measures are set already prior to.

CUSTOMER FEED BACK:

"......we have rated your responses at 92,06% which is an excellent rating. We congratulate you for an excellent performance and we look forward

towards an equally favorable relationship between your company and PASAR."

Cetificates