JANUARY/FEBRUARY 2017 VOLUME 7 | 1

See Buyers Guide pp26-27

n Key Words: Innovation and sustainability n News: Głogów Smelter Kamoa-Kakula More copper mined Project issues n Smelting features: Converting (2 of 3) Two-step method at Dongying n Spotlight: Electrorefining progress UMMC n Optimisation: A 4-step process n Copper in Germany: Jonathan Barnes on Europe’s copper major n Copper semis: Producers and capacity survey n Events: 30th Intl Copper 16th World Copper Conference Copper/Cobre 2016 Coming up in 2017 n Contracts: Outotec re-orders Toquepala Steerhorn Chuquicamata n Buyers Guide - In search of added value

ISSN 2046-9438

www.copperworldwide.com www.copperworldwide.com CONTENTS | 1 We transform … Key Words the world of copper 3 Innovation and sustainability News Kamoa-Kakula progress; Rise in mined 4 copper; Głogów starts up flash furnace; Project acceptance study; IWCC Technical Seminars; MIDAS undersea research results; The MD issue around commissioning; MKM into e-mobility; Market in surplus; Aurubis update; Glencore knowhow; Peru output Spotlight Electrometallurgy 2016 review; 6 UMMC tankhouse Contracts & People Outotec re-ordering and Toquepala 20 contract; Steerhorn cathodes; Gas management in France; Iran and Indonesia The Głogów Copper Smelter (see page 5) items; Chuquicamata acid plants ordered; Copper crucible restoration Inside this issue ELECTROREFINING/ 16TH WORLD ELECTROWINNING COPPER CONFERENCE The SX-EW cost burden; G Corner top Preview and latest CRU analysis 9 in refining; Dias d’Ávila milestone; 19 Ion exchange processing SAFETY AND Copper working process – from the melting bath to the fi nal product PLANT INTEGRATION MAINTENANCE AND CONTROL Stories relating to these SMS group has been active in the copper fi eld for more Our integrated solutions are a byword for robust and reli- Optimisation of control systems via the two key operational areas than 50 years. Our business partners benefi t signifi cantly able state-of-the-art technology. And we never stop trying 24 10 BBA 4-step method from our comprehensive portfolio. Our employees know to become even better. The raw material prices for copper EXTRUSION every step in the copper working process, from the melting are high – which is why we are continuously looking for GERMANY TECHNOLOGY MECS state of the art metallurgical sulphuric acid technology COPPER STUDY bath to the fi nal product. We connect individual machines new ways to reduce material use and material loss during (see page 21). Photo: DuPont Clean Technologies Banyard LFi keeps up billet heating to form integrated systems which meet all requirements production. Close tolerances, top quality and effi cient pro- Jonathan Barnes on 25 profile of the customer. At the same time we off er our customers cesses – that is what you can expect from our plants. Rod, Tube and Wire 14,15 making it in Germany confi gurations in which all the components are ideally Front Cover A snapshot of producers and capacity 21ST CENTURY Earth, air, fire and water - Find your element - coordinated – both technically and economically. 16 across these sectors SMELTING Continuous innovation is required to achieve ongoing sustainability in mining and processing The Dongying Two-step SMS group GmbH Buyers Guide of copper and its alloys: ‘Earth’ image - Ohlerkirchweg 66 Phone: +49 2161 350-0 Suppliers who give added value 17,18 process; Arsenic reduction; Chuquicamata open pit mine in Chile. 41069 Mönchengladbach, Germany Fax: +49 2161 350-1667 Photo: Codelco; ‘Air’ image - Oxygen generation. 26 Oxygen supply [email protected] www.sms-group.com Photo: Messer Group; ‘Fire’ image - Głogów EVENTS Copper Smelter in Poland. Photo: KGHM; Daily Lives ‘Water’ image - Carlsbad desalination Reviews and Previews Detlef Neumann is plant in San Diego. Photo: International 28 Director of Sales at Danieli Fröhling 22,23 of key conferences into 2017 Water Association

Copper Worldwide Vol 7 No 1

Kupfer_A4_e.indd 1 19.12.16 07:54 2 | COPPER WORLDWIDE A-Z www.copperworldwide.com www.copperworldwide.com KEY WORDS | 3

Companies COMPANY NAME PAGE NO COMPANY NAME PAGE NO COMPANY NAME PAGE NO Where to find markets for innovations Volume No: 7 Issue No: 01 Data released in February by the International Copper Association, Ltd. (ICA), shows that continued economic Date: January/February 2017 ABB...... 19 G Corner...... 9 Mines and Money Americas...... 7 Air Liquide...... 18, 19, 20 Glencore Plc...... 3 Mining on Top: Africa Summit (AME Trade)..... 5 development in Asia may drive significant growth in several key markets, resulting in an estimated additional Publisher: ALTA 2017...... 4 Glencore Technology...... 8, 20 Montanwerke Brixlegg...... 6 31 million tonnes of demand for copper up to 2030 in the region. The study highlighted urban infrastructure, Chris K Holding BSc BEng Amec Foster Wheeler...... 19 Hatch...... 4, 6 NICICo...... 8, 20 clean power, electric vehicles and rail transportation to fuel the projected growth. Anglo American...... 3, 6, 19 Publishing Consultant: IARC 2017 (ICM)...... 5 NORAM...... 21 John Clarke Antofagasta Plc...... 23 IERC 2017 (ICM)...... 7 Outotec ...... 8, 20 The study, commissioned by ICA from The Warren Centre, examined • Significant basic infrastructure investments are expected to be 12th Asia Copper Conference (MB Events)... 23 key economic sectors to determine the expected level of investment US$ 11 trillion through 2030 Circulation & Subscription IIMCh...... 3 Paranapanema...... 9 Manager: and activity in the region. Amongst other sources, it used census data • Asia is predicted to account for 50% of the world’s electricity by Asia Copper Week...... 23 Inductotherm Group (Banyard) ...... 25 [email protected] PDAC 2017...... 7 from the United Nations Department of Economic and Social Affairs 2030 (2/3 from China) and there will be an overall need for increased Aurubis...... 7 International Copper Association...... 3, 8 P. J. Mackey...... 6, 17, 22 to define demographic indicators in these areas to determine expected availability of energy BBA, Inc...... 10, 11, 12, 22 IT/www Contact: 30th Intl Copper Conference (MB Events).... 23 PolyMet Solutions GmbH...... 4 population and density. • Copper demand from clean power generation is expected to be [email protected] Bechtel...... 19 International Copper Study Group..... 4, 5, 8, 16 The study found that India is expected to see a 17% increase in total 6.5 million tonnes from solar photovoltaics and 3.6 million tonnes Rautomead...... 21 Beijing Antaike Information Development.... 8, 21 International Lead and Zinc Study Group...... 5 population from 2015 through 2030, with a significant jump in urban from wind Managing Director: RHI...... 20 BHP Billiton...... 4, 23, 24 population from 420 million to 583 million, or a 39% increase. China • The future of electro mobility is likely to be light vehicle solutions and Chris K Holding International Wrought Copper Council (IWCC).... 5 BMI Research...... 8, 21 Rio Tinto...... 23 is expected to see an overall increase in population of 3% over the more extensive public transport solutions to combat urban congestion [email protected] Interwire 2017...... 16 Butech Bliss...... 21 Samarco...... 24 same timeframe, but the shift to urbanisation is significant, with 70% • Cumulative production of electric vehicles and plug-in hybrids in Asia Published by Iontech Engineering...... 9 of the population expected to live in urban areas by 2030. The growth between 2016 and 2030 is expected to be 75 million. This will result in CEEC Medal...... 20 Sepon Copper...... 9 Ivanhoe Mines...... 4 in population and shift towards urbanisation play critical roles in the 6.4 million tonnes for light EVs alone, with additional copper demand CESCO Week...... 3, 19 SIPS 2017 (Flogen)...... 23 Metallic Media Ltd J. Barnes...... 13, 15 expected use of copper. in charging equipment. 5 Dennis Road China ENFI...... 17, 18 SKS bottom-blown technology...... 17 Both India and China are travelling down parallel tracks as they The International Copper Association (ICA) brings together the global Jiangxi Copper Corporation...... 16 Wimborne, Dorset BH21 3NF Codelco...... 3, 21, 23 SMM...... 8 plan to satisfy a population that is growing in size and wealth, with a copper industry to develop and defend markets for copper and to make United Kingdom JSC Uralelectromed (UMMC)...... 6 Copper / Cobre 2016...... 22 SMS group...... 4, 8 migration towards urban environments. Increased material and copper a positive contribution to society’s sustainable development goals. Its Kansanshi...... 8 use is forecast as their governments look towards clean technologies Copper Alliance® programs and initiatives are executed in nearly 60 CRU Consulting...... 8, 9, 16, 19 SNC-Lavalin...... 19, 21 Tel: +44(0)7731 784798 KGHM...... 1, 4, 5 such as electric vehicles and renewable energy to mitigate urban countries. ICA will be a featured presenter during the CRU 16th World CRU Events...... 19 e-mail: [email protected] Southwire Company...... 16 KME...... 15 pollution, according to Colin Bennett, Market Analysis & Outreach, Copper Conference (see page 19) held during CESCO Week in Santiago, www.copperworldwide.com Danieli Fröhling...... 28 Sulphur 2017 (CRU Events)...... 23 ICA. Some parameters for development of demand for copper in Chile from 3 - 5 April 2017. La Farga...... 20 Dongying Fangyuan...... 17 Warren Centre...... 3 Asia are: www.copperalliance.org Distribution: free to managers involved in the DuPont MECS...... 21 LME ...... 19 various stages of the copper industry: Weir Minerals...... 4 Ecometales...... 21 Mansfelder Kupfer und Messing (MKM)..... 7, 20 Production of primary or secondary copper MEC 2017 (IMN)...... 5 Wire & Tube China...... 4 and associated refining; recycling, melting Electrometallurgy 2016...... 6 Wire & Tube Russia...... 7 Holding onto innovation leadership MECS...... 1 and casting operations; processing of copper ENAMI ...... 3 World Bureau of Metal Statistics...... 7 by extrusion, rolling and tube/wire drawing Escondida...... 4 Metal Bulletin Events...... 23 The IIMCh Smelter and Refinery Seminar which took place in Calama, Chile on 20 -21 October 2016 asked for the manufacture of semi-finished products EUnited Metallurgy...... 5, 7 Metal Expo...... 4 16th World Copper Conference or fabrications; or involved in the manufacture ‘Does an environmental standard lead to economic development?’ To remain competitive the Chilean domestic Metso...... 21, 24 (CRU Events)...... 3, 19 of components and structures from copper First Quantum...... 8 smelter industry has to collect at least 95% of the sulphur and arsenic entering in the smelter feed at each facility. alloys; and who are involved in the buying Flogen Technologies Inc...... 23 METTOP...... 4, 6 Zijin Copper Company...... 4, 21 process for equipment and materials. Freeport McMoran Inc. (FCX)...... 20 MIDAS project...... 5 ZIMEC 2017 (AME Trade)...... 5, 11 It is advantageous to view the the four Codelco, one ENAMI, Chagres is possible to achieve full optimisation by avoiding the duplication of All other categories of reader are invited to (Anglo American) and Altonorte (Glencore) smelters and the refineries in equipment (e.g. one production line processes 100% of output) and subscribe at £75.00 to UK, and non UK is: terms of a new business model on a case-by-case basis. The leaders are reaching full capacity (maximum availability and utilisation) with online Surface £90.00, e125.00, $165 USD there, as is the wealth. To safeguard and capitalise on its knowhow and controls. Automation and remote control of operations are the essential Airmail: £107.50, e150.00, $195 USD overseas. Advertisers expertise in employment and research, Chile now feels it must develop tools to facilitate this. The development and qualification of smelting/ Single copy £25.00, e40.00, $55 incl. p&p. policies and regulations that avoid the outflow of copper concentrates refining specialists at the level of plant operators and maintenance COMPANY NAME PAGE NO COMPANY NAME PAGE NO COMPANY NAME PAGE NO to other countries. engineers is a compelling need. The articles within Copper Worldwide are ACCS...... 26, PW exma...... PW Polymet Solutions...... PW A smelter trade association could assist in bringing the smelters and www.iimch.cl copyright and are the property of the publisher Agellis...... 26 G Corner...... PW Primetals Technologies...... 27 refineries up to their nominal capacities. They really need to expand Alex Stewart International...... 27, PW hpl-Neugnadenfelder...... 27 RHI...... 27, PW Metallic Media Limited and cannot their business into recovering up to ten additional elements and stop Andritz MeWa...... 26 30th Intl Copper Conference (MB)...... 14 Saint Gobain...... 27 be reproduced in any media form without being limited to just anodes, cathodes, smelter dust, anode sludge and permission of the publisher. Application should Banyard (Inductotherm)...... 25 Kumera Corporation...... 26, 27, PW Schenck Process...... 26, 27, PW sulphuric acid. Strategic alliances and joint ventures with other world be made in writing to the above address, Combilift...... 26 Küttner GmbH...... Cover 1, 24, 26, 27, PW SMS group...... Cover 2 or by e-mail to [email protected] Continuus Properzi...... Cover 4 Metalex...... 26, 27, PW Weir Minerals...... 26 producers and processors were recommended. Danieli Froehling...... 27 Mettop...... 26, 27, PW 16th World Copper Conference (CRU).... Cover 3 An apparent low availability and utilisation of furnaces and equipment Reprints of articles and advertisements are EBNER Industrieofenbau...... 26 Oschatz...... 26 ZIMEC 2017...... 11 at some state-owned installations was cited as causing low productivity. available, allow 28 days for delivery. PDF pages Maintenance programs on facilities due for a ‘someday’ upgrading available by e-mail. Prices on application to can suffer, so exchange visits and cross-audits were proposed to the publisher. 2017 is going to be an interesting year – enable benchmarking and activation of improvement programs. It Members of the International Organising Committee for Copper 2016 (see page 22)

Instead of Reader Reply cards, we are now including Discover the ISSUES affecting copper now! a contact website address with stories at the sole discretion of the Editor. You may submit your The next Vol 7 No 2 issue of Copper Worldwide is published enquiries with the item titles, page and your full Ranking sustainable economies in April/May 2017. Scheduled features include 21st Century / address, telephone, fax using the contact form on: The 5th edition of the Global Sustainable Competitiveness Index while countries from Northern Europe, the Baltic States and www.copperworldwide.com Primary Smelting, Materials Handling, Melting and Casting / (GSCI) was released in December 2016. The GSCI is based on an Eastern Europe dominate, including Germany (14). Of the BRICS countries, inclusive competitiveness model, analysing 109 indicators. All are China scores highest (37), with Brazil (41), Russia (45), India (153), Magazine Production Molten Metal, South America Study, New Copper Movers, and Toni Barrington, measurable, quantitative indictors derived from the World Bank and and South Africa (158). From the Americas, the top performers The Magazine Production Company more. Supporting website www.copperworldwide.com features UN databases. The only non-European economies in the top 20 are are Canada (22), Peru (30) and USA (32). Other copper nations ranked Shoreham-by-Sea, West Sussex, BN43 5EG, UK issue summaries and event updates. Thank you to all advertisers New Zealand (12) and Japan (15). Japan has been adept at setting and include Poland (25), Australia (26), DR Congo (61), Chile (62) and Tel: +44 (0)1273 467579 working towards its Sustainable Development Goals. The GSCI 2016 Zambia (120). [email protected] once again. All correspondence welcome. is topped by Sweden, followed by the other 4 Scandinavian nations, www.solability.com

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 4 | NEWS www.copperworldwide.com www.copperworldwide.com NEWS | 5

In brief… Copper 2016 the perfect platform Significant rise in Upcoming IWCC Welcome to the In brief… BHP Billiton and Hatch have entered mined copper output Technical Seminars The International Copper Study Group into a collaborative technology as well as tank house Głogów flash furnace era has released its 2016 Statistical development partnership to accelerate technology to numerous The International Copper Study The 2017 IWCC Technical Seminar A special launch ceremony Yearbook covering world copper supply the development and deployment of clients. PolyMet Group (ICSG) released preliminary will be held in Munich from 5 - 9 took place at the Głogów and demand data for the 2006-2015 key technological advances in the fields Solutions welcomed data for October 2016 world copper March. The subject of the Seminar Copper Smelter/Refinery period. The Yearbook is included as part many customers to their supply and demand in its January will be ‘Melting, Refining & Casting’. on 20 January of its new of mining and mineral processing. of the ICSG Monthly Bulletin annual booth and presented 5 2017 Copper Bulletin. World mine The Seminar itself will be held on state of the art facility for Hatch sees this collaborative approach subscription and is also available at papers covering their production is estimated to have 6 - 7 March with up to 24 papers blister copper production as the future of technology development EUR 200 for orders originating from knowhow with regard increased by around 5% (815,000 presented, sub-divided into five with a rectangular in the mining industry. ICSG member countries and EUR 300 to complete copper t) in the first ten months of 2016 with sessions: electric furnace. The for other orders. www.hatch.com plants solutions, the concentrate production increasing • Introduction and overview technology combines www.icsg.org new revolution in by 7% and solvent extraction- • Scrap for the circular economy three stages - concentrate Commissioning of the Głogów Copper Smelter/Refinery ALTA 2017, now in its 22nd year, vessel cooling by ILTEC- electrowinning (SX-EW) declining • Melting and casting roasting, smelting of matte 28 September with the firing of ICSG projections for 2016 released takes place from 20 - 27 May 2017 in Technology, as well by 1.5%. There was a 43% (590,000 • Consumables copper and converting - into a the electric furnace, and the firing in October indicated the market Perth, Western Australia. The Nickel- The PolyMet Solutions Team at Copper 2016 as a highly innovative t) rise in Peruvian output from new • Modelling. single process. Commissioning of the flash furnace on 1 October should remain essentially balanced, Cobalt-Copper conference, including The Kobe event was the perfect tank house technology. The and expanded capacity brought on The Seminar programme is designed of the modernised Głogów I 2016. Timeline: while in 2017 ICSG forecasted around Pressure Acid Leaching Forum & platform for PolyMet Solutions, PolyMet Solutions Team looks stream in the last two years. Canada, to provide ample networking Copper Smelter/Refinery took •17 July 1971 - shaft furnaces 160,000 tonnes surplus in view of Panel, runs from 22 - 24 May. At time SMS group and Mettop to forward to being part of Copper Indonesia, the United States and opportunities throughout the place in the middle of October launched better than expected actual growth, of publication there were 67 papers demonstrate their competences 2019, which is being held in expanded capacity in Mexico also event. On 8 - 9 March there will 2016. After a series of full-scale trials •16 July 2016 - shaft furnaces compares with a deficit of 55,000 t from 21 countries and Short Courses in the field of pyrometallurgical Vancouver, Canada. contributed positively, but a 4.5% be a programme of plant visits to: of the flash furnace’s feed loading extinguished and a surplus of 20,000 t for 2016 on copper SX-EW (21 May) and Heap copper production technology www.sms-group.com decline in production in Chile, and • Diehl, to visit the brass rod system, continuous feed of the •1 October 2016 - flash furnace and 2017 respectively forecast at Leaching (27 May) scheduled. a 6% decline in DRC where output plant located in Röthenbach an concentrate and its smelting in fire-up process started its March 2016 meeting. www.altamet.com.au is being constrained by temporary der Pegnitz, which is close to the reaction shaft of the flash •15 October 2016 - first kilograms www.icsg.org Kamoa-Kakula Copper Project options outlined production cuts, affected the growth Nuremberg furnace commenced. After a of concentrate fed into the smelter MIT Enterprise Forum Poland in The Kamoa-Kakula Copper Project Kansoko Mine at the adjacent figure negatively. Regional production • Wieland, at Vöhringen, where the three-month shutdown, the •20 January 2017 - flash furnace The 7th Annual Zambia International partnership with KGHM, represented is a joint venture between Ivanhoe Kamoa Deposit. The pre- rose by 6% in the Americas and 10% focus will be on the manufacture production of unrefined copper launch ceremony. The ribbon was Mining and Energy Conference and by Cuprum Research & Development Mines and Zijin Mining Group Co., production capital cost would be in Asia, but declined by 4% in Africa. of rolled products. was recommenced at the Głogów cut by Mr. Andrzej Duda, President Exhibition (ZIMEC 2017), under Centre, is one of the 10 winners of the Ltd. and the Government of the US$ 1.0 bn with an average annual World refined production It is also planned to have visits to I Copper Smelter/Refinery, but of the Republic of Poland. the theme of ‘Mining and Energy Scale up pilot contest organised by the Democratic Republic of Congo. production rate of 292,000 t of increased by about 3% (540,000 the wire drawing operations of in a completely new technology. Commissioning of further facilities Development in Zambia - Increasing Polish Industrial Development Agency. It has been independently ranked as copper at a mine-site cash cost t) in the first ten months of 2016 Leoni and the technical application The first discharge of blister copper and production circuits is ongoing to Economic Activities’, will take place A grant of 5.9 MEUR will support the world’s largest, undeveloped, of US$ 0.42/lb copper during the with primary production (including laboratories of Linde. The IWCC was achieved several hours after achieve the new target production from 22 - 23 June 2017 in Lusaka. acceleration projects in four key sectors high-grade copper discovery by first 10 years of operations, and Electrowinning) increasing by 2.5% has also announced that the 2018 feeding the concentrate. The capacity of the installation. The 2016 event in Lusaka saw 300 visitors, 235 delegates, 43 exhibitors of the Polish economy including Wood Mackenzie. It lies within peak production of 370,000 t by and secondary production (from Technical Seminar on ‘Hot & Cold commissioning process started on www.kghm.com.pl and 35 speakers. energy and raw materials. the Central African Copperbelt, year seven. scrap) by 6%. China increased Deformation’ will be held in the www.ametrade.org/zimeczambia www.kghm.pl approximately 25 km west of Kolwezi The Kakula 2016 PEA was output by 7%, followed by the USA in March 2018. (Katanga Region). independently prepared by United States (+12%) and Mexico www.coppercouncil.org Project acceptance high on Study Group agenda The next Mineral Engineering Conference In December 2016, Ivanhoe Mines OreWin Pty. Ltd., Amec Foster (+18%), where expanded SX-EW Metals study groups the International October 2016 included copper Metal Expo 2017 takes place from (MEC2017) organised by the Institute announced results of an independent Wheeler E&C Services Inc. and capacity is contributing. Other Lead and Zinc Study Group (ILZSG), plants and projects, including 14-17 November 2017 at the VDNkH of Non Ferrous Metals (IMN) and KGHM preliminary economic assessment SRK Consulting Inc. (the same team country changes were Chile (-1%), Commissioning versus International Copper Study Group mining, smelting and refining copper. in Moscow, Russia. This will be the Cuprum Sp. z o.o will be held on 20 - 23 (PEA) of initial options for the start- worked on the Oyu Tolgoi Project Japan (+4%), and DRC and Zambia and International Nickel Study A 62-page Report entitled ‘Social 23rd International Industrial Exhibition. ‘putting into service’ September 2017 in Wisla, Poland. The up of world-scale copper mining on in Mongolia.). (-13% jointly). Refined output Group have been working on Acceptance for Mineral and Metal Around 530 companies from 32 clarity sought Chairman of the Organising Committee the Kakula and Kamoa deposits in Recent drill results have increased in the Americas (+3%), community and social acceptance Projects’ has been prepared by the countries across the ferrous and non- of MEC2017 is Prof. Andrzej Wieniewski the D.R. Congo, namely: significantly expanded the Kakula Asia (+6%) and Oceania (+3%), EUnited Metallurgy has worked out of new copper projects and also University of Queensland-based ferrous production sector participated, from IMN. The 2016 event saw 112 • An initial option for development Copper Discovery and resource but declined in Africa (-12%) and a Position Paper that provides existing plants, in particular copper Centre for Social Responsibility in and 27,000 professionals visited the participants from 14 countries. of a 4 Mtpy Kakula Phase 1 Mine at estimate and preliminary economic in Europe (including Russia) (-3%). concrete suggestions to establish smelters with air emissions of Mining. The document is relevant exhibition during the four day event www.imn.gliwice.pl the Kakula Deposit with an average assessments are being fast-tracked World apparent refined usage a common understanding for a impurities such as arsenic, and on for all non-ferrous metals and in 2016. annual production rate of 216,000 to examine expanded Kamoa-Kakula is estimated to have increased by complementary, coherent and the management of the hazardous industry stakeholders. It is available www.metal-expo.com The 4th edition of the Mining On Top: tonnes of copper at a mine-site development options. There is around 3% (515,000 t) in the first consistent interpretation of the wastes and precious metals (as a pdf via e-mail) from the ILZSG Africa Summit, which is taking place cash cost of US$ 0.37/lb copper exceptional continuity of high-grade ten months of 2016. The world MD regarding ‘commissioning’, and sometimes related to equipment at EUR 500 to companies in member At least six new mega ports have been on 6 - 7 July in Frankfurt, Germany, will for the first 10 years of operations, copper mineralisation and relatively refined copper balance for the ‘putting into service’ (CE marking) capturing air pollution. countries and EUR 750 to companies cleared to be built under the ambitious have the aim of building shared value and peak copper production of flat-lying geometry. A follow-on PEA, period indicates a deficit of around of metallurgical machinery/plant. The Joint Study Groups’ Seminar in non-member countries. Sagarmala Project, taken up by the across the extractive supply chain 262,000 t by year three. The pre- expected in 1Q 2017, will assess 64,000 t. This is mainly because of These two steps in the life cycle entitled ‘Social acceptance of the Ministry of Shipping. The National www.ilzsg.org so that the African mining sector can production capital cost would be the potential for an 8 Mtpy stand- a 5% increase in Chinese apparent of metallurgical machinery/plant mining and metals industry’ in www.icsg.org Perspective Plan (NPP) for the much realise its full potential. The two day US$ 1.0 billion. alone Kakula Mine, plus expanded, demand in the analysis period. The must be clarified, because different conference is expected to attract over talked about project envisions these • A second initial option for a two- combined mining scenarios of refined copper market balance for points of understanding regarding new infrastructural facilities as part of Keeping in touch with MIDAS 200 participants from over phase sequential expansion of 12 and 16 Mtpy from both the Kakula October 2016 showed a surplus of commissioning (as a period of 20 countries. its multi-pronged strategy to enhance production to 8 Mtpy from the Deposit and the adjacent Kamoa around 48,000 t. time, e.g. in situ manufacture, The MIDAS project ran from 2013 to Black Sea, and the Norwegian and www.ametrade.org/miningontopafrica India’s cargo handling capacity. proposed Kakula Phase 1 Mine Deposit’s Kansoko Mine. www.icsg.org trial operation, performance test, 2016, covering a wide array of topics Svalbard continental margins (gas www.economictimes.indiatimes.com at the Kakula Deposit and the www.ivanhoemines.com without the machine having to all aimed at helping the nascent hydrates). Additionally, the Canary The 17th International Automobile Workers at Escondida Copper conform to the MD) and putting deep-sea mining industry, regulators Islands, Palinuro Seamount (central Recycling Congress IARC 2017 The wire and Tube China 2016 trade fair Mine in Chile began strike action into service (as a point in time, i.e. and civil society to understand the Mediterranean), Norwegian fjords organised by ICM AG will be held saw 1,645 exhibitors from 31 countries Specialist pump maker hails brand milestone on 9 February as expected over CE marking) according to the MD potential impacts of mining on deep- and Portmán Bay in Spain were from 22 - 24 March 2017 in the Hotel and in excess of 42,000 trade visitors Weir Minerals can celebrate manufactured its first sulphuric acid the amounts due under a new pay exist. Metallurgical machinery/plants sea ecosystems. A final summary used as proxy sites for various Palace in Berlin, Germany. Delegates in Shanghai, which was a new record. 125 years of developing and valve. In recent years it has added and bonus deal. Several mine labour are assembled and commissioned pdf publication ‘MIDAS Research mining impact experiments. A will discuss and present news and From 26 to 29 September 2018, wire manufacturing its Lewis® Pump gate, globe and butterfly valves with deals are due for re-negotiation this on site. In this context, the Highlights’ has been published, and more comprehensive and technical challenges of the manufacturing and and Tube China will once again be held range used primarily in the Sulphur, the proprietary Lewmet® austenitic year. Escondida is currently the question who is responsible for the is available from Vikki Gunn summary of the project results end-of-life vehicle (ELV) business. for the eighth time at the Shanghai Sulphuric Acid and Phosphoric Acid nickel-chrome alloys, proven to be world’s largest copper mine, with commissioning phase and putting MIDAS study areas included will be available in early 2017 as Over 250 international industry leaders New International Expo Center (SNIEC). industries. The firm developed and highly effective in sulphuric acid BHP Billiton owning 57.5 percent and into service (CE marking) always the mid-Atlantic Ridge (SMS), the part of the ISA’s Technical Series will be expected. www.wirechina.net manufactured its first sulphuric acid pumps. Rio Tinto 30 percent respectively. needs to be answerable. Clarion Clipperton Zone (CCZ) publications. www.icm.ch pump in 1914. In 1975 the company www.global.weir www.reuters.com www.eu-nited.net/metallurgy of the central Pacific (nodules), the www.eu-midas.net

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 6 | SPOTLIGHT: ELECTROMETALLURGY www.copperworldwide.com www.copperworldwide.com NEWS | 7

Investing in forecast EUnited Metallurgy elects new Board In brief… Refining electrolysis operations growth in e-mobility Mines and Money is coming to New York for the first time from 3 - 4 May 2017. MKM was successfully certified in The Electrometallurgy 2016 conference at the Annual Conference of Metallurgists (55th COM) and XXVIII International Using the Meetmax system, attendees November 2016 for the ISO/TS will be able to schedule meetings with Mineral Processing Congress (IMPC) held in Quebec City, Canada yielded some interesting presentations. 16949 quality system, of critical qualified investors and a selection of importance for automotive and mining companies. The exhibition gives capital goods industries. Seeing delegates face-to-face access to the further scope for development senior executives of over 50 global opportunities within the growing mining companies. e-mobility market, MKM is www.newyork.minesandmoney.com investing in production technology, development of new products, The PDAC 2017 International Convention, quality and works processes to Trade Show & Investors Exchange capitalise on them, according takes place in Toronto from 5 - 8 to CEO Roland Harings. There March 2017. In addition to over 900 is already up to 6 km of copper 1 METTOP-BRX Installation at Xiangguang Copper, China (www.mettop.com) exhibitors and 22,000 attendees from cable in the electrical system of 125 countries, there are also technical Some 4 million tonnes (21%) of world mined standard cars, and this is set to sessions, short courses and networking copper comes from leaching followed by solvent rise significantly. In hybrid cars The new EUnited Metallurgy Board events. The four day annual convention extraction-electrowinning. Several papers this quantity doubles, in electric The General Assembly of EUnited Andreas Flick, Primetals began in 1932. presented related to copper electrowinning cars the demand is three times as Metallurgy unanimously elected Technologies, Germany; Fabrice optimisation came from Hatch (Toronto) high. Compared to conventional their new Board in Brussels in Orban, CMI Industry S.A., www.pdac.ca and Colorado School of Mines, whilst CSIRO cars using around 24 kg of copper, December 2016, who expressed Belgium; Georges Rassel, Paul ESI’s 26th Solidification course runs (Melbourne) delivered simulation results in this means a rise to 75 kg per car. their will to further engage with Wurth S. A. Luxembourg; and 2 The trend in average current density in copper electrorefining over the period 1869 to 2013, with key events. (1) from 30 April - 5 May 2017 in two presentations. The Missouri University According to the Fraunhofer- the directorate: Dieter Rosenthal, SMS Siemag Switzerland and is designed for of Science and Technology discussed lead- As discussed at Electrometallurgy 2016, a Filzwieser et al. in a paper entitled, “FAQs Institut, by 2050 around 20 per • Chairman: Benoît Caratgé, Fives AG, Germany. engineers and scientists from industry based anodes, and anode composition, while recent breakthrough in technology now at with regards to operating a copper tankhouse cent of the global demand for Group, France The theme ‘The digital manufacturing and research centres who wish to a paper from China covered permanent stainless the commercial scale has allowed a jump in above 400 A/m² using the METTOP-BRX- copper will be from the automotive • Vice Chairman: Dr. Anthony revolution and what it means for the improve their knowledge in the field steel cathodes. current density to 420 A/m2 virtually overnight Technology”. It is believed that this technology industry. MKM has recently had its Tropeano, FATA HUNTER, Italy machinery and equipment business’ High current density operating data came - a further increase relative to that at a typical will gradually be embraced by the industry as it ISO 9001:2008 renewed. • Board members: Dr. Heinz was the subject of the EUnited of solidification. Participants should from Los Bronces courtesy of Anglo American, modern plant today by a factor of about 1.2 to means a smaller footprint for a given tonnage, www.mkm.eu Autischer, Andritz AG, Austria; Competitiveness Review and have a degree in materials science, while a Sepon (Laos) supplier presentation 1.4. By introducing fresh electrolyte with active or in some cases a significant increase in copper Axel E. Barten, Achenbach Dinner Debate after the elections. metallurgy, mechanical engineering, from Scantech International summarised the inhibitors at a high flowrate parallel to the output ( by 1.2 to 1.4 times) at an existing plant. Buschhütten GmbH, Germany; www.eu-nited.net/metallurgy physics or chemistry. successful application of an on-belt analyser to cathode, METTOP-BRX Technology of Austria www.com2016.metsoc.org Market in surplus www.esi-group.com/company/events improve ore blending ahead of processing. A has significantly increased the present limiting www.impc2016.org for January to Results analysis and Aurubis projects snapshot International Electronics Recycling Short Course on Electrometallurgy with around step with, in effect, a ‘disruptive’ technological References: November 2016 six top instructors including Dr. Mike Moats breakthrough. METTOP has now successfully Congress IERC 2017 e-waste 1. A.E.Wraith, P.J.Mackey and R. Protheroe-Jones, The Aurubis Group (Aurubis) (organised by Consultant Michael Agnew) was installed this system at two commercial plants - According to WBMS Market generated a result within the recyclers meeting in Salzburg discussed Origins of electrorefining: Birth of the technology and the the predicted increase from 15 to run. A one-day tour to Canadian Copper Refinery the copper refinery of Xiangguang Copper Co. world’s first electrorefinery, in Proc. Conf. Cobre Copper Balances released in January, company’s expectations, achieving and Canadian Electrolytic Zinc also took place. Ltd., in China (Figure 1) and the copper refinery 2013,Vol 5 - Electrowinning and refining (Eds. R. Abel The copper market recorded operating earnings before taxes 50 billion devices in the IoT (Internet of Montanwerke Brixlegg in Austria, with each and C. Delgado), pp 259-273, Santiago, Chile, IIMCh. a surplus of 17 kt in January to (EBT) of EUR 213 million in fiscal of Things) by the year 2020, including Electrorefining update plant operating at 420 A/m2. November 2016, which follows year 2015/16 (ended 30 September wearables, consumer electronics and Primary and secondary copper production by New developments and advances in this a surplus of 35 kt in the whole 2016). Reduced refining charges for vehicles. While consumers get more Author: Phillip Mackey copper electrorefining totalled over 16 million interesting system were discussed by Andreas of 2015. Reported stocks fell copper scrap accompanied by a convenience, the recycling companies’ tonnes in 2014. The typical current density at during November and closed lower copper scrap supply, and a Panoramic view of the Aurubis Belgium production site challenge increases. a modern copper refinery today is of the order 23.2 kt lower than at the end of weaker sales price for sulphuric acid at Olen www.icm.ch of 300 to 350 A/m2. This is a key parameter Tankhouse renovation program at UMMC December 2015. No allowance due to a surplus, a lower metal gain on the copper scrap market has establishing the copper output for a given size of is made in the consumption accompanied by decreased metal also improved slightly, as the copper Russian metal trade fair quartet wire plant). The upper value of current density while JSC ‘Uralelectromed’(metallurgical enterprise and even exceeded its 150 ktpy design capacity. calculation for unreported stock prices, a lower cathode premium prices increased after the end of Russia, Tube Russia, Metallurgy Russia still giving a smooth deposit is essentially set by of UMMC Group) is setting about realising Construction of the second stage started in changes, particularly in the Chinese and the scheduled shutdown in fiscal year 2015/16. Aurubis says it and Litmash Russia will take place the limiting rate of convective mass transfer of a major investment project in its copper July 2014. The new production facility partly government stockpile. Pirdop, Bulgaria all negatively wants to close-the-loop with more in Moscow from 5 - 8 June 2017, copper ions to the cathode. refining facilities at Verkhnaya Pyshma. After occupies areas of the old tankhouse. Baseless World mine production in the impacted profits. Some positives product customers. The result of Q1 organised by Messe Düsseldorf GmbH, As seen in Figure 2, there has been a steady, building a new copper tankhouse in three cathode production technology is used in period was up 7.0 percent y-o-y to were higher treatment and refining 2016/17 is negatively impacted by a Messe Düsseldorf Moscow and the slow increase in current density in copper stages, by around 2018 UMMC aims to achieve the second stage as with the first stage. The 18.78 Mt. Global refined production charges for copper concentrates three-week maintenance shutdown Russian partners Joint-Stock Company refining since 1869 - when the world’s first production capacity of 450-500 ktpy. The first technology provides application of permanent rose 2.7 percent y-o-y to 21.37 Mt, with an improved input mix, stable carried out in Hamburg in October/ VNIIKP for wire Russia and Metal Expo copper refinery began at Pembrey, Wales. and second stages are to have 150 ktpy capacity stainless steel sheets instead of disposable with China up 422 kt and Spain sales volumes for continuous cast November 2016. This shutdown is for the other three fairs. The current density at that time was of the order each, and the third, depending on the market starting sheets. After starting up of the second up 14 kt. Global consumption for wire rod and shapes, and the strong legally mandated every three years. www.wire-russia.com of 90 A/m2 (1). There was an initial increase to and raw material balance, will have 150-200 stage, baseless cathode production capacity January to November 2016 was US dollar. The EUR 44 million In the FCM (Future Complex about 200 A/m2 over the first 80 years up to about ktpy capacity. Baseless technology (see below) is will increase from 150,000 to 300,000 tonnes 21.35 Mt compared with 20.78 shutdown at Pirdop, completed in Metallurgy) project, Aurubis will ITPS 2017: International Thermprocess 1940. Over the 50 year period from 1940 to 1990, used in the process. annually. The total capacity including the Mt for the same months of 2015. budget in 54 days, was a notable continuously develop its unique Summit takes place in Düsseldorf the average current density further increased Conceptual and basic engineering was made starting sheet technology will be 400,000 tonnes. Chinese apparent consumption in achievement according to Jürgen expertise in processing complex on 27 - 28 June 2017, with a high- from 200 A/m2 to about 300 A/m2 - an increase by Outotec (Finland), with detail engineering Construction is planned to be completed in the period rose by 273 kt to 10,515 Schachler, Chief Executive Officer materials. In Hamburg, Aurubis has quality programme for stakeholders of about 1.5 times. These increases were provided by ‘Uralmekhanobr’ design institute 2017. According to UMMC, the budget of the kt y-o-y and represented just over of Aurubis AG. started the MSO (Metallurgical Slag in the automotive, aviation and metal achieved by mainly incremental improvements (the structural division of UMMC). The new second stage tankhouse project will exceed 4.5 49 per cent of global demand. EU28 Uncertainties will continue Optimization) project with the goal industries, covering the general in a number of areas such as improved anode tankhouse is in accordance with state of the bn rubles. At the same time within this project, production fell by 2.1 per cent and to influence fiscal year 2016/17, of reducing unwanted elements in economic and political conditions uniformity, better electrolyte and addition art world standards concerning equipment JSC ‘Uralelectromed’ is carrying out design demand was up 2.2 percent y-o-y to although positive factors include the iron silicate with an additional around the world, climate protection, agents control, and better quality starting sheets, and working environment. In February 2012 work for its copper sulphate and chemical- 3,165 kt. In November 2016, refined the good ongoing supply of preparation stage. Another objective carbon footprint, energy, and resource among other factors. The basic cell design Uralelectromed commissioned the first stage metallurgical plants, copper smelter shop, copper production was 1,969.0 kt and copper concentrates, as well as a of the project is to expand the efficiency fields. and electrolyte flow system remained of the new tankhouse at a cost of over c.US$ 70 storage and railroad facilities. consumption was 1,931.3 kt. relatively high level of treatment company’s granulation capacities. www.itps-online.com essentially unchanged. million (4.4 bn rubles). The first stage reached www.elem.ru www.world-bureau.com and refining charges. The situation www.aurubis.com

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 8 | NEWS www.copperworldwide.com www.copperworldwide.com ELECTROREFINING / ELECTROWINNING | 9

In brief… Glencore knowhow applied Sulphuric acid plants The cost burden of SX-EW only mines Chang’ge City government of to Iran from Outotec Henan province signed a cooperation to Kansanshi smelter In mid-2016, Piotr Ortonowski, Senior EW mines were cashflow negative compared agreement with Jiangxi Tungsten Outotec has agreed with National Consultant - Copper Supply Analysis at CRU, to concentrates mines (18%). Industry Group Co., Ltd., Henan Iranian Copper Industries Company noted in a CRU Insight that two thirds of Overall, average SX-EW mine costs were Economic and Technical Cooperation (NICICO) on the delivery of two 2016 production cutback and closure losses 86% higher than the equivalent concentrates Group and Henan Futong Co., Ltd on state of the art sulphuric acid plants were mooted by SX-EW mines, while SX-EW mine when compared on the above net basis. 7 September, aiming to build a 600 ktpy for the Sarcheshmeh and Khatoon only constitutes a fifth of global mined copper On average, site costs ran 10% higher at SX- secondary copper rod and wire project Abad copper smelters in the Kerman output. At the time, CRU’s Copper Mining Cost EW mines than at concentrates mines, power in Dazhou Town, Chang’ge City of province in Iran. The value of the Model indicated that on a net of by-product costs (EW tankhouse) were 58% higher, and orders is approximately EUR 50 cash cost basis, 76% of SX-EW mine capacity consumables costs 18% higher (sulphuric acid Henan Province. Kansanshi Smelter ramp up. Source: Glencore www.antaike.com million. Scope of delivery includes features in the top half of the copper mine cost for leaching). On top of this, Electrowinning commissioning it had achieved over engineering, main process equipment curve, with only 5% placed in the first quartile cathode producers also have low by-product China’s exports of unwrought copper 100% of its nameplate capacity. Within and instrumentation for the acid compared with 30% of concentrates mines. credits compared to a large proportion of including copper alloy jumped to 6 months of startup on 1 July, it had plants, as well as spare parts and CRU estimated that at the 2015 LME cash price concentrate producers. The Sepon tankhouse in Laos - in 2016 Sepon (LXML) produced 78,492 declared commercial production! supervisory services for installation low of US$ 4,516 /t, twice as many (36%) SX- www.crugroup.com tonnes of copper cathode (capacity 85 kt) by Leach / SX-EW operations 57,265 tonnes in August, four times the The Kansanshi Smelter at night. Photo: Glencore 2015 equivalent period amount, China Copper recoveries have been and commissioning. Deliveries will Customs reports. The G20 Summit was One recent example where consistently between 97 to 98% take place in mid-2018. The off-gas given as the reason why China’s refined knowhow was tangible was the - a great effort for the Kansanshi cleaning systems and sulphuric acid Bespoke refining solutions copper output was down 645,000 recent startup of the IsaSmelt™ operations. Glencore Technology plants complement earlier deliveries tonnes in August, though still up copper smelter at First Quantum provided Kansanshi with hands on of Outotec Flash Smelting technology being developed at that time. This expertise in • Main trunk DC Busbars busbars 0.62% y-o-y, an SMM survey found. Minerals Kansanshi operations. training and mentoring at Mount for NICICO’s two copper smelters, electrowinning design has allowed G Corner to • Intercell and endcell busbars www.smm.com The smelter was designed to treat Isa Mines IsaSmelt™ operation, as which will have full compliance with develop cost effective designs for larger electro- • Watercooled Equipotential busbars 1.2 Mtpy of concentrate, with the well as supporting the operation the latest environmental standards refinery tankhouses using complex cell-bank • High current electrowinning At the 2nd China Nonferrous Metals first startup in early 2015. After through the commissioning period. as a result. Manchester-based G Corner is a global leader in and DC switching busbar formats. Shorting frames Forum on 1 November there were 3 months from startup and www.glencoretechnology.com www.outotec.com the supply of DC Electrical systems and The company works with customers on • High Current DC switches around 120 attendees. Mr. Shang other specialist refinery equipment to the base specific process issues to do with plant operation • Expansion flexibles Fushan, Vice President of CNIA, said Market acid price benefits some smelters Peru copper output metal refining industry. and develop products such as electrowinning The company is also widely known for being an there was a 13% growth in Chinese In the early 2000’s, the refined production of shorting frames, which are able to increase effective source for replacement tankhouse refinery nonferrous metal processing company Since 2007, global smelter revenues international price benchmark, and remains on track copper saw a substantial amount of growth from plant operational performance by reducing equipment, including copper cell top busbars, usage in H1 2016 - copper saw a have increased, but the contribution relating an international delivered According to BMI Research from around 17 million tonnes (Mt) in 2000 to just plant downtime. copper flexibles, contact rings for copper foil- 4% consumption increase and made by acid has varied from price of $80/t CFR to an FOB price October 2016, Peru’s significant copper over 20 Mt by 2005. A significant proportion The G Corner HQ in the UK co-ordinates plating plants, cell-top capping boards, stainless aluminium an 8% increase in 47% to 15%, according to a CRU in a supply region by subtracting production growth will be driven by a of this growth was through the development of with manufacturing facilities in India and steel cathodes, rolled-lead anodes, and larger the period. Insight in October 2016 by CRU the freight, a regional differential strong project pipeline and competitive electrowinning refining capacity, as supposed representative offices in Chile, Mexico, machinery such as cathode stripping machines and www.chinania.org.cn Consultant Peter Harrisson, who impact on the change in revenue operating costs over the coming years, to the more traditional electro-refining process. Kazakhstan and Russia. G Corner now offers transformer rectifiers. To date G Corner exports found the global trend of decline in can be estimated. in contrast to decelerating copper G Corner was able to develop designs that design and engineering solutions for large and of bespoke refinery solutions have been delivered SMS group reports that compared to acid prices had not cut the average Chile, India and China, which production growth in top producer were ideally suited for the higher DC currents small base metal refinery projects, including to over 30 countries around the world. 5,250 jobs at the beginning of 2014, revenue from acid at smelters to have little or no exports, show Chile. Peru is set to emerge as a copper required for the electrowinning processes the supply of: www.gcorner.co.uk the workforce in Germany will be cut the same degree regionally. Two essentially no change in revenue outperformer, as output increased by 1,200 to some 4,050 by 2017. key factors are: as international prices vary. In SE by 47.8% y-o-y over the first seven In 2015, the average number of • Share of acid sold to export Asia, where the major share of months of 2016. This production Dias d’Ávila reaches cathode milestone employees including apprentices in versus domestic markets sales is exports, revenues change growth will be supported by a number SMS group totalled 14,342 (2014: • Relative pricing of those export significantly. With a 25% increase of large-scale projects. On 22 December 2016, the Dias d’Ávila unit 28% copper. Pyrometallurgical processes are 14,003), primarily as a result of the and domestic markets. in the global benchmark price, acid While Chile will remain the largest of Paranapanema in Brazil reached the 6 subdivided into seven furnaces: a flash furnace, expansion of the service business and Smelters with a greater share of revenues in SE Asia increased by global producer of copper by a million tonnes of copper cathodes production an electric furnace, three converting furnaces more jobs abroad. sales within the domestic market 66%. This increase seems dramatic significant margin, the country’s milestone. To commemorate the occasion a and two refining furnaces. The plant operates www.sms-group.com have more stable and generally but it is partially a function of SE growth outlook will lag. BMI forecasts special cathode displaying the number was fixed a sequential molding wheel with a capacity of higher revenue from acid sales Asia having a particularly low acid Peru’s copper production growth at the entrance of the administrative building 80 t/hr. The Dias d’Ávila plant has an annual The International Copper Association, than exporting smelters. Domestic price in 2015. West European to average 9.5% over the period of the plant. With around 1,000 employees, the production capacity of 280 kt of cathodes. The Ltd. (ICA) says projections based on prices set on a contract basis can revenues increased 11% for a 25% 2017 to 2020, producing an additional company is the only one in Brazil to produce plant generates coproducts with the copper, China’s 13th Five-Year Plan (FYP) reduce exposure to international increase in the global benchmark, 629 kt, while Chile averages just 99.99% pure electrolytic copper, certified by namely sulphuric acid, oleum, anodic sludge show the potential for 15% growth trade price risk. Using actual with Japanese revenues increasing 1.5% annual growth, producing an the London Metal Exchange. The concentrates and granulated slag. in the Chinese copper market. ICA annual prices for export and by 28%. additional 290 kt. imported from Chile and Peru contain around Dias d’Ávila Refinery in Brazil celebrates 6 Mt of production www.paranapanema.com.br commissioned the study (conducted by domestic markets in 2015 with the www.crugroup.com www.bmiresearch.com All China Marketing Research Co., Ltd.) to analyse potential demand in China China’s refined copper exports double in 2016 Time for an ion exchange? under the country’s most recent FYP. www.copperalliance.org The ICSG has looked into Raw significant growth in imports of blister and Peru accounted for 76 percent Of the alternative processes, the most likely • Large volume and significant cost of Leaching, Ion exchange, Solvent Extraction Material Flows in 2016. China now and anode (+45.5% y-o-y) and ores of concentrate imports into China challenger to conventional SX-EW for large the required organic compounds. and Electrowinning. According to Iontech, UGOL ROSSII & MINING 2017, produces 60 percent of all scrap and concentrates (+34% y-o-y) in 2016. scale operations appears to be IX/EW, One method which offers to overcome these is despite the wide acceptance of SX, it does use the 24th International Trade Fair refined worldwide, but this amount into China, the research indicates. The International Copper Study particularly for low grade solutions. Metal the combined L/IX/SX/EW process using Ion large quantities of volatile organic substances, for Mining Technology, Preparation, is only 30 percent of Chinese refined Reasons postulated for the doubling Group currently has 24 member recovery by solvent extraction (SX) is practiced Exchange and Solvent Extraction as developed SX extractants have to be handled with Material Handling and Safety & Security copper, so scrap refined worldwide in Chinese refined exports are: countries. Intergovernmental and commercially for the recovery of copper, by Iontech Engineering of Bulgaria. This environmental awareness, and organic losses will be held from 6 to 9 June 2017 at is less than 18 percent of copper • Some Chinese smelters were international organisations sharing uranium, nickel, cobalt, molybdenum method may be excellent for processing of from the liquid organic phase are a potential the Kuzbasskaya Yarmarka Exhibition refined globally, while scrap refined converting copper concentrate common interests may be granted and other metals. However, it does have PLS as well as in the decommissioning of spent hazard to ground water. Also, crud generation in Center in Novokuznetsk, Western in China represented over 10 percent into metal for traders, possibly to observer status by the Group. The some limitations: copper heaps and dumps, acid mine drainage / the SX process requires special facilities and has Siberia, Russia. There were over of world refined copper output at reduce the VAT and tax burdens. ICSG Copper Bulletin is produced • Leach solutions containing large quantities AMD/ and other industrial streams without any both an economic and downtime impact. Solvent 500 exhibitors from 25 countries, the end of 2016. China imported • Chinese refineries were tolling monthly and has a 500 EUR annual of suspended solids are unsuitable for preconditioning. An important factor will be the extraction is also sensitive to low temperatures, and over 27,000 visitors, in 2016. copper scrap from 78 countries in anodes and blister into cathodes subscription for new subscribers in solvent extraction processing availability of cost-effective resins with copper which can cause bad phase disengagement times www.ugol-rossii.com 2016, yet this may only represent for export in 2016. member countries. • The SX circuit has a relatively large selectivity comparable with SX extractants. and reduced process performance. around 1.3 Mt of metal. There is Australia, Chile, Mexico, Mongolia www.icsg.org plant footprint The method involves four major stages - www.ionteching.com

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 10 | PLANT INTEGRATION AND CONTROL www.copperworldwide.com www.copperworldwide.com PLANT INTEGRATION AND CONTROL | 11

• Be used according to its purpose, i.e. usage: The third phase will start when enough Before: Do you use it? equipment in a given area is performing well. Get the benefit from control systems • Perform as expected, i.e. performance: This third phase consists of tuning control loops Is it stable? and optimising control strategies. • Be optimised, i.e. Does it perform? The fourth phase consists of designing new Most plants do not track their systems’ performance. Optimisation is the easiest way to benefit from your control Do you derive the maximum benefit from it? control strategies and adding more equipment systems. A 4-step approach is demonstrated here by Michel Ruel of BBA Inc. in Québec. Do you need advanced control? to improve performance. If an advanced control system is used, this system will be optimised. If After (standard deviation reduced by a factor of 3, water usage reduced Taking a systematic approach performance is not sufficient, advanced control by 38%)): Maximising what you already have is the Table 1. Savings in production costs associated with different process control categories Prior to beginning a project, it is suggested will be added: advanced regulatory control, best investment to remain competitive. This Process control categories Savings in production costs to prepare a database with all instruments, model predictive control, or fuzzy logic control. article aims to show the benefits of a systematic Final control device performance and basic loop tuning 1.5% analysers, valves, variable speed drives, Finally, once all steps are completed, approach using modern tools to improve plant Unit operations control 0.8% and other equipment. All analyses, tests, monitoring tools are used to sustain performance. We at BBA suggest dividing the Advanced control 1.4% observations, performance results will be stored performance and results. work in four phases, and a subsequent phase can in this database. The database will be used begin when the previous one has progressed: to generate progress reports, planning and Instrument auditing Table 2. Typical control loop problems and performance issues 3 Valve repaired, density meter recalibrated, control strategy optimised Assess, Remediate, Stabilise, Optimise or add detailed reports. This objective under Step 1 is to audit every (graphs to same scale over a 24 hr period) advanced control. This approach has been Control valves of poor quality or in poor condition 30% The first step to ensure that all equipment is instrument in the selected areas. The following successfully applied to several sites. Examples Instruments not installed properly 15% adequate and properly installed is a thorough tasks must be performed: following tasks must be performed on the and illustrations from these plants demonstrate instrument audit of your facility. This • Visual inspection identified equipment: how this step-by-step method is applied and Controller in manual mode 30% assessment will also include tests and analyses. • Configuration generates results. Under the BBA method, there Poor loop design 15% If all equipment of a control loop receives a • Analyses using historical data Using regular maintenance budget are 4 questions to answer before moving to the Poor controller tuning (unacceptable values) 30% green card, the loop is put back in automatic • Analyses using specialised software (control • Review of calibration methods, installation next step. For each control strategy, you should Poor controller tuning mode. If the loop oscillates, default tuning performance software) or through testing practices, etc. ask the following questions: parameters will be used. If the loop is unstable, • Observations and recommendations o Drafting of new procedures if needed (not selected according to the performance goal) 85% • 1 Assessment: Does it work? it will be identified for the second phase. • Remediation needed: calibration, • Equipment calibration • 2 Remediation: Do you use it? Control loop not performing according to control objectives 85% Therefore this first phase will immediately configuration, reinstallation, repair, • Equipment configuration • 3 Stabilisation: Is it stable? Loops that perform better in automatic mode than in manual mode 25% generate results. replacement, or re-design. • Range change • 4 Optimisation: Does it perform? Do you need The second phase will remediate problems For example, see Figure 1. A magnetic • Equipment repair. advanced control? identified during the first phase. This second flowmeter with its grounding wire missing The first phase is to assess all equipment to practices in several different process control phase will begin simultaneously with the audit. means the signal will be noisy and erratic, so it Requiring extra budget determine the performances of instruments, categories. The savings are expressed as a The remediation will consist in recalibrating, is neither working normally nor performing • Replacement valves, variable speed drives, and other percentage of production costs. reconfiguring, repairing, or replacing the as expected. • Reinstallation equipment. To carry out the project, a The actual benefits will certainly vary from equipment. As in the first phase, if all • Redesign, when replaced by another database will be used to collect and store all the plant to plant and from industry to industry, equipment of a control loop receives a green Remediation process technology for instance. information. The second phase is to remediate but in every case the benefits are significant card, the loop is put back in automatic mode. In the second (remediation) phase, the Transferring to future projects instrumentation problems, including the ones and will undoubtedly impact the bottom line. pertaining to valves, variable speed drives, Reported benefits are most often based on analysers, transmitters, etc. When equipment is very specific case studies where a problem is in order, loops are put back in automatic mode. identified, a faulty steam valve for example, and If a loop oscillates, use standard default values then corrected, thereby resulting in savings. for this type of loop. Based on BBA’s experience, the main sources 7th ZAMBIA INTERNATIONAL MINING AND ENERGY CONFERENCE & EXHIBITION The third phase consists in validating the 1 A magnetic flowmeter with its grounding wire missing means the signal of control problems include: will be noisy and erratic control strategies, properly configuring 1. Valve performance issues the systems (control system, programs and Before 24hr: 2. Instrument problems parameters, HMI, alarms), and then tuning 3. Inappropriate tuning parameters the loops and control strategies. Soft sensors 4. Inappropriate control strategies should be validated also. The fourth phase 5. Lack of resources consists of analysing the process and expected 6. Absence of a proactive control loop performances to optimise the control loops optimisation program and control strategies. When mixing products 7.  Inability to link process control benefits for instance, each flow loop should move at to process performance the same speed to ensure proper recipe when After (reviewing algorithm, adjusting configuration): 8. Lack of process knowledge increasing the total flow. If performance is not 9. Lack of monitoring technology sufficient, a decision tree will be presented 10. Lack of necessary skills to implement SUPPORTED BY to determine the right approach: advanced control strategies regulatory control, model predictive control, 11. Changes in process and equipment wear. or fuzzy logic control. Once all steps have been completed, control The first items in this list relate to valves, performance monitoring software is used to instruments, and control loops. Statistics from 22-23 JuNE 2017|LusAKA, ZAMBIA 2 Passive sonar flowmeter (both 24 hr graphics have same scale THE MuLuNGusHI INTERNATIONAL CONFERENCE CENTRE sustain the results and pinpoint equipment and same filter) our experience and projects performed in many or loops not performing as stated. Also, plants are summarised in Table 2. after an audit on the alarm system, an alarm the process industry, they are often underrated. It is better to have a systematic approach management and rationalisation could be Since the 1980s, computer control has evolved to performance improvement rather than performed if needed. and the control algorithms used by control attempting to ‘cherry pick’ individual control engineers have become increasingly complex. problems. In most plants, maintenance is kept Basic control systems However, PID controllers still handle over to a minimum and equipment availability www.zimeczambia.com @ZIMEC_ZAMBIA|#ZIMEC Instruments, valves, control systems and other 90% of the control loops in operating plants. becomes an issue. To fully benefit from equipment can all be beneficial to the bottom Even if advanced control systems and expert instruments, valves and process control systems, line when set up, operated and maintained systems are used, the basic layer of process this equipment must: correctly. Although basic regulatory controls control is the control loop. Table 1 shows the • Work normally, i.e. be available: (PID controllers) are reliable workhorses in savings that can be made by achieving best Does it work?

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 12 | PLANT INTEGRATION AND CONTROL www.copperworldwide.com www.copperworldwide.com GERMANY COPPER STUDY | 13

System stabilisation Control project organisation The BBA approach in action The third phase will start when sufficient The consultant and client personnel should The 4-step approach was applied at a equipment in a given area is performing well. work together as a team, comprising: Copper makes it in Germany concentrator plant. Initially, four areas were This third phase consists of tuning control • Process and instrumentation control expert, selected, but all the other areas were added loops and optimising control strategies. also acting as project manager to the project later on. The project team Control performance and tuning software • Process control engineer responsible for With resilient consumption, Germany stands tall in Europe’s copper sector, or does it? - writes Independent comprised: is recommended. This will identify equipment tuning loops and reviewing control strategies Analyst Jonathan Barnes. • A process and instrumentation control expert, problems and control loops that are not • Engineers and technicians for assessment also acting as project manager performing well. If the loops are in automatic and remediation. • A process control engineer responsible for mode, the software will identify a model Estimation will require preliminary work Germany is the most important copper tuning loops and reviewing control strategies for many of these loops. This model will be (100 to 400 hours): consumer in Europe, and it is also the • One engineer from the plant (part time, used to determine tuning parameters for the • Collect data third largest in the world after the United management) PID controller. • Select and prepare the database States and industry leader China. Its • Four engineers and technicians from If no model is available for a loop, BBA will • Populate the database prominence as a consumer is just as relevant the consulting firm for assessment and conduct tests to tune the loop according to its • Connect the database to the network. for secondary purposes (direct use scrap remediation objective. Using a specialised tool, we conduct To estimate the time needed on a given by semis manufacturers) as it is for the • Six technicians from the plant for remediation these tests in automatic mode and many loops project for the assessment, remediation industry’s traditional benchmark measure This more than 25 year old plant had increased can be tuned at the same time. Alternatively, and optimisation work, BBA has developed of refined copper consumption (1.2 million its capacity and modernised its equipment these tests can be carried out in manual mode. metrics based on instrument age, complexity, tonnes in 2015). Germany’s status as a semi- through several projects. In the early years, Performances are evaluated before and after technologies used, control system, manufacturing giant is reflected by the fact that, maintenance of the plant equipment was using key performance indicators, for example: documentation system, control strategies. by a massive margin, it is the world’s largest performed according to best practices and • Service factor (% of time in normal mode, www.bba.ca exporter of copper and copper alloy products. an expert system was used at the grinding no saturation) The country is also the world’s eighth biggest circuit. Unfortunately, in the last 12 years, • Standard deviation of PV producer of refined copper (0.8 million tonnes maintenance was reduced and the expert system was abandoned. More than 40% of • Response time in 2015) entirely through the activities of loops were in manual mode at the beginning • Relative performance index (actual Aurubis in cathode production by both of the project. Approximately 38% of the versus expected) primary and secondary means. instruments required remediation. • Oscillation index. Steady economic growth 1 Germany’s quarterly semis output Table 3. Efforts required to optimise the concentrator (hours) Control optimisation The most recent release from the Federal The fourth phase will consist in designing Statistics Office reveals that the German Instruments (transmitters, valves, etc.) 760 new control strategies and adding more economy lost momentum in the third quarter Control loops and strategies 110 equipment to improve performance. If an of 2016. GDP only grew by 0.2% between July Preliminary work 235 advanced control system is used, this system and September compared to faster growth of Assessment (hours) 2,269 will be optimised. If needed, an advanced 0.4% during the second quarter. The slowdown Remediation (hours) 4,300 control system could be added using guidelines Author: Michel Ruel, P.Eng., Executive Director, was mainly blamed on the external sector, Engineering Practice / Optimization and Process Optimisation (hours) 345 to select the proper approach. For each with exports declining slightly quarter-on- area, all control strategies will be reviewed Control Principal, BBA Inc., Québec. Michel Ruel quarter and imports growing marginally. The Advanced control (hours) 100 to ensure that the process is under control. is a Process Control Engineer with over 35 years uncertainty caused by Brexit was attributed as Total hours 7,014 These control strategies will be designed for of expertise in process control and control the key element of blame, but it is just as likely Team (persons) 13 normal conditions, but also to handle abnormal performance monitoring. that the then unresolved political situation Equivalent full time 6.3 situations, start-ups, and shutdowns. The in the USA, one of Germany’s largest export Overall Project Duration 6 months strategies are optimised to achieve process References: markets, was probably just as significant to the goals. Once everything has been optimised, Brisk, M. L. (2004). Process control: Potential benefits overall effect. we will evaluate other alternatives: soft sensors, and wasted opportunities, 5th Asian Control Conference, Amid the slowdown in external trade, private The plot in Figure 4 is indicative of progress Vol. 1, pp. 20-23. measurement along the four steps in such a addition of equipment, advanced control, consumption has become the largest engine expert systems. Brittain H., Dewey D., & Ruel M. (2009, October). Closed loop of growth. With unemployment at its lowest project. The following are the main benefits tuning: Methodology, tools, benefits and common mistakes, ISA, derived from this particular project: 2009 Conference, Houston, TX. ever level, higher real wages and low interest • Significant reduction of water usage at the Brittain, H. & Ruel, M. (2008, October). Optimize your process rates are encouraging consumers to spend grinding circuit using normal operation data, NPRA Conference, Houston, TX more. The government is also doing its part 2 German trade flows in copper semi-manufactures • Reduced downtime Liptak, B.G. (Editor-in-chief) (2006). Instrument engineers’ through increased state spending. There is a • Increased tonnage handbook, Process control and optimization, (4th Edition, considerable rise in expenditure on the road • 97% of control loops now in their highest Boca Raton, FL: CRC Press,), Ruel M., et al. Chapters 2.20 network to alleviate congestion choke points brand registrations increased by 8% against picture of industrial activity in the downstream mode (automatic, cascade, ratio, etc.) Optimizing control; 2.35 Tuning PID controllers; 2.38 Tuning and to expand capacity on major haulage and only a 3% improvement in German brands. copper sector. Copper product statistics are • Use of all instruments except for 3 by computer; Ruel M., Chapter 2.37 Tuning interacting loops, commuter routes. It is also spending over With exports only flat against year-earlier levels, divided into the two categories of Leitmaterial Synchronizing loops flowmeters and 2 density meters UR 20 billion on additional housing the annual gain in German vehicle production (literally ‘conductive material’, such as wire rod, McNabb, C. & Ruel, M. (2009, February). Best practices for • Eleven procedures written for the managing control loop performances - Roadmap to Success, to meet the influx of over one million migrants was limited to only 1%. In the electrical and the main raw material for the wire and cable 4 Example graph of overall progress measurement maintenance team Paptac Conferences, Montréal, QC. to the country over the past 18 months. electronics industry, production fell by 5.3% industry) and Kupfer and Kupfer Legierungen • Three installation procedures prepared Patwardhan R.S. & Ruel, M., (2008, November). Best The government is forecasting GDP growth and incoming orders dropped by 4.2% in (copper and copper alloys, in tubes, bars and for sonic flowmeters, ultrasonic level Sustaining results practices for monitoring your PID loops - The Key to Optimizing of 1.8% in 2016, the fastest rate for five years. October, according to the latest newsletter sections, and plate, sheet, strip and foil), and measurement, and pinch valves. Proper procedures must be put in place Control Asset, ISA EXPO, Houston, TX. from the ZVEI. In the German mechanical both are measured in gross weight. • Plan in place to replace radioactive sources in to sustain the results. The most important Ruel, M. & Tremblay, E., (2008, November). Managing assets Key use sector struggles engineering industry (VDMA), orders in Output of copper and copper alloy products density meters for the next 5 years. measure is to keep the database updated, and with modern tools at White Birch Paper, ISA EXPO, While the overall economic indicators are October fell 10%, while production is likely is on a steady upward trend and totalled The project was extended to the entire plant for this, regular assessment and remediation Houston, TX. broadly encouraging, some key end use sectors to be flat in 2016 as a whole. approximately 729 kt in the first nine months after completion of this project. are essential. The degradation in performance Ruel, M., (1999, March, April, May). Loop optimization: of copper demand are suffering. Of these, the of 2016, and 6.2% higher than the 686 kt www.bba.ca Before you tune - Troubleshooting - How to tune a loop, will trigger actions. The second measure is Control Magazine German automotive industry is probably the Upbeat downstream reported in the prior year period. Leitmaterial to install control performance software to Ruel, M.., (2010, November). Control System Performance brightest. The latest data from the Verband German statistics on aluminium and non- output has been more variable, with a very • Addition of new equipment monitor performance and usage. The third Assessment - Best Practices, Automining, Santiago, Chile. Der Automobilindustrie (VDA) showing ferrous metals are compiled and published on a strong Q2 year-on-year increase followed • Modification of the process. measure is to implement an alarm management Ruel, M. (1995, 2006). Fundamentals of process control, preliminary full 2016 industry statistics reveals quarterly basis by the Wirtschafts Vereinigung by a sharp retrenchment in Q3 last year. Once remediation has been completed, a program. When properly done, alarm (English, Spanish, Portuguese, French) second Edition, 269 p. a healthy 5% year-on-year rise in new car Metalle (WVM) industry association (see Nevertheless, production in the first three performance assessment will be performed. management is the key to detecting process Ruel M., (2000, October). Control valve performance, registrations. However, digging a little below Figure 1). The latest data covers the first nine quarters of 2016 stood at 571 kt, some 4.5% and process control problems. Chemical Engineering, pp. 64-67 the surface paints a different story. New foreign months of 2016 and paints a more upbeat more than the 547 kt recorded in the same

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 www.copperworldwide.com GERMANY COPPER STUDY | 15

period in 2015. Therefore, total production of for inter-company transfers for local resale, indicators and the unusually cold winter now all copper products improved to 1,300 kt in or simply where the quantity or quality of been experienced, it is unlikely that the first the period, compared to 1,233 kt in the year- local production is insufficient relative to that quarter will see little if any expansion compared earlier, a noticeable gain of 5.5%, and much country’s demand. In copper wire rod and to the prior year period. If Germany is to better than the underlying macroeconomic drawn wire, Poland, Italy, Austria, Romania, remain one of the stronger performers amongst situation would appear to warrant. Saudi Arabia and France rank as the major European national consumers, then it must look export destinations. Most imports are attracted to secure further gains in its net trade position Net trade balance gains from Poland, Sweden, Belgium and Italy, some by remaining cost sensitive in its domestic Rod and wire and brass mill products trade is of which again may reflect inter-company market, while striving to be price competitive in the main explanation for stronger performance transfers or more competitive product pricing. its European and international export business. of German mills, as they have been gaining For brass mill products, the United States, market share both domestically and in the the Netherlands, Italy, France and the Czech export market (see Figure 2). Imports of copper Republic are the leading export destinations. wire rod and drawn wire into the German As sources of imports, Italy, the Netherlands, market have fallen while exports to third Poland, France, Belgium and Austria feature 30th markets have expanded. Similarly, imports of most highly. brass mill products have dropped slightly while exports have grown. In each case this has led Leading semis groups to a more favourable net trade position in 2016 In no particular order the leading companies compared to 2015. As the chart illustrates, this involved in German copper industry are International Copper is no one-year trend. German net exports of Aurubis, Wieland Group, KME Group, copper wire rod and drawn wire and those of Deutsche Giessdraht, Mansfelder Kupfer & brass mill products have been on a four-year Messingwerk, Diehl Metall, Schwermetall upward trend since 2012. This has improved Halbzeugwerk and Nexans Deutschland, as German’s net trade balance by almost 175 well as a host of smaller fabricators. Further Conference kt, helping to explain why the country has downstream, Nexans, Prysmian and the been Europe’s strongest performing copper Wilms Group are significant wire and consumer during this period of economic and cablemakers, while Germany is also Jonathan Barnes is now an Independent Analyst 13-15 March 2017 | Steigenberger Grandhotel, Leipzig, Germany political uncertainty. headquarters to Leoni, a major global player in the automotive harness business. Author: Jonathan Barnes has worked as a principal Trading partner variety consultant on copper demand for over 25 years Germany’s country trading partners in semi- Outlook for 2017 with CRU and Wood Mackenzie. He is now an Independent Analyst on the copper industry, manufactured products reflect many factors The German government expects GDP growth semi-manufactures and wire and cable markets. aside from simple geographic proximity. to slow a little in 2017 compared to 2016, E-mail: [email protected] Export destinations can sometimes be those and certainly based on the current end use Speakers include: Extruded profile KME plate coolers • Roland Harings, CEO, MKM Mansfelder Kupfer und • Panos Lolos, Commercial Director, Halcor, Greece About 50 per cent of all blast furnaces in use Messing, Germany worldwide today are cooled by copper staves. • Alexander Dehnelt, Member of the Management Board, Copper plate coolers have also been used for • Robert Morris, Vice President Marketing, Vale Base Diehl Metall Stiftung & Co, Germany many decades, but up to now these copper Metals, Canada cooling plates have solely been manufactured • Leonardo Botti, Global Head of Product Management by sand casting, which carries the risk of • Benedikt Zeumer, Partner, McKinsey & Co, Germany & Marketing, Power Conversion, Product Group Solar, blowhole formation in the material. A leak in ABB, Italy • James Jian Wu, Managing Director & Head of Global the cooling circuit may cause serious problems Metal Physical Trading, Mercuria (China) Metal • Max Brandt, Head of Sales, Marketing and R&D, MKM in manufacturing. Whilst KME has become a Resources Co Ltd, China Mansfelder Kupfer und Messing, Germany leading supplier of copper staves, it has always been keen to also solve the problems with Comparison of copper plate cooler designs • Nicholas Snowdon, Metals Analyst, Global Research, • William Berry, SVP and President SCR & International, plate cooling. Standard Chartered Bank, UK Southwire, USA In close cooperation with Salzgitter Flachstahl GmbH, KME Engineering has now developed • Michael Widmer, Metals Strategist, Bank of America • Rudolf van Rooyen, Business Development Manager, an economical production method for plate Merrill Lynch, UK TMS International, South Africa coolers made of copper profiles. Instead of • William Adams, Head of Research, FastMarkets, UK • Monica di Cosimo, Co-founder and Partners, Cu2 sand casting, these profiles are manufactured Consulting, Italy in a reliable extrusion and drawing process. • Robin Bhar, Head of Metals Research, Societe In addition to their fine grain and blowhole- The new KME copper plate cooler solution Generale Corp & Investment Banking, UK • Stefan Eitel, Director of Metals & Mining, KfW IPEX- free structure, the new products also offer Bank, Germany considerably improved thermal and mechanical • Significantly reduced water channel area • Carlos Risopatron, Director of Economics and properties. Practical application in blast reduces the water leakage risk and increases Environment, International Copper Study Group, furnace A at the Salzgitter Flachstahl plant the new plate cooler’s lifetime in the different Portugal in Germany has delivered outstanding results Blast Furnace zones since 2014, proving that the new plate coolers • High conductivity refractory to fill the gaps are a convincing alternative for furnace cooling. between the water circuits The main characteristics of the new plate cooler • Welded copper bottom plate and top plate compared to the sandcasted plate cooler are: design to protect the refractory inside the • Fine grain sized copper, no risk of blowholes plate cooler Easy ways to register • Higher thermal conductivity compared to • Simple water channel design avoids ‘dead as-casted material water’ or re-circulating water corners Asymmetrical copper profile for reinforcement of wear out zones • Use of asymmetrical copper profile to • Easy design change from sandcasted to new +44 20 7779 7222 [email protected] metalbulletin.com/events/copper reinforce the wearout zones plate cooler. www.kme.com

Copper Worldwide Vol 7 No 1 16 | ROD, TUBE AND WIRE www.copperworldwide.com www.copperworldwide.com 21ST CENTURY SMELTING | 17 Global copper use capacity update Two-step copper smelting process The capacity expected to be operational in 2016 with some certainty was less than 50.8 million tonnes (Mt), Dongying Fangyuan discussed its ‘Two-step Copper Smelting Process’ in a presentation at Copper 2016 in according to the ICSG Directory of Copper/Alloy Fabricators Capacity 2016, which also has found that copper November. Here in Part 2 of his copper converting story, Phillip Mackey briefly describes and illustrates the wire rod has 59 percent of the world share by product. process and provides the available operating data.

The next largest product group is copper and 11 countries with a total capacity of 42.4 Mt under-reported, e.g. in Germany and Japan. The first commercial application in China of alloy flat rolled PSS with a 14 percent share, or almost 80% of the capacity reported. China Finally in this brief roundup of what is an the SKS copper smelting technology developed Table 1. Key operating data for the Two-step Copper Smelting Process with Rod Bar RBS and Tubes both at reported nearly 21.9 Mt capacity (represented extensive 168 page document, 79% of new plant by ENFI of Beijing was at the Dongying Smelting Furnace 10 percent each. The total listed capacity by 582 plants), followed by the United States capacity in 2010 - 2016 started operations in Fangyuan copper smelter in Shandong One unit sized 5.5 m diameter by 28.8 m equipped with 23 tuyeres: is 53.52 Mt across 2,319 plants. Of these, a with up to 4.1 Mt (North America has around 63 plants located in China (representing Province, China. This 500,000 tonnes of Item Unit Recent Data total of 1,544 reported in the 2016 survey. 230 plants), then Germany at 3 Mt (there are more than 55% of all new plants reported concentrate per year plant, which commenced Concentrate rate t/hr 156 There were 114 new plants reported between approximately 318 plants in Western Europe), worldwide). Outside China the country with operations in December 2008, was based on the Total feed rate t/hr 180 (Max reached c.207 t/hr) 2010 and 2016 representing 10.04 Mt of new and Japan with nearly 2.86 Mt reported. Italy most new plants in the period was Japan use of a horizontal smelting furnace fitted with Coal rate t/hr 0 capacity. In contrast, the operational status (2 Mt) and the Korean Republic (1.8 Mt) follow, with 11 and over 273 kt of new capacity, but the SKS tuyeres - special concentric tuyeres Furnace temperature °C 1,180 of 51 percent of pre-2010 plants is uncertain. then India, Taiwan (China), Brazil, the Russian Brazil secured most new capacity with a which allowed the injection of tonnage oxygen Oxygen blowing rate Nm3/hr 25,668 The global leaders in terms of reported Federation and Turkey register greater than 1 518 kt increase. accompanied by a controlled flow of air via a Air blowing rate Nm3/hr 13,706 fabrication capacity in 2016 are a group of Mt capacity each. Substantial capacity remains www.icsg.org shrouded section of the tuyere. Total blowing rate Nm3/hr 39,374

The start-up of the Dongying plant followed Oxygen enrichment of %O2 73 the successful commissioning in 2001 of the blowing air Rundown of the top wire rod producers first SKS commercial smelter at the Shengquan Matte grade %Cu 73-78 copper smelter in Vietnam (rated at 50,000 tpy Dust make % of conc. <2 According to CRU Senior Copper Consultant technology and one Contirod technology, and North America copper mines. The company of concentrate). The SKS unit, which operates Iron-silica ratio in slag Ratio 1.8 to 2.0 Matthew Wonnacott in CRU Copper Market owns a 51% stake in a third mill. produced around 212,400 t of rod in 2015. akin to a ‘third generation’ Noranda reactor Copper content of slag %Cu 1.9 to 3.1 Outlook in July 2016, Aurubis took the top spot Third placed Jiangrun copper is the largest Large cable companies that maintain with high oxygen enrichment, top concentrate Sulphur capture % >99.5 as the world’s largest producer of wirerod in non-upstream-integrated wirerod producer in an upstream presence by owning wirerod feeding and side-tapping of high grade matte, 2015, having grown production by 30,000 tonnes the world with production of 620,000 t in 2015, mills in the top 10 include the LS Group of soon established itself as an important process SLCR Converting Vessels Two units sized 4.8 m dia. by 23 m equipped with 17 tuyeres: in 2015 to 779,000 t. The company has grown having grown output by 80,000 t in the year. As companies (6th), with LS Cabling and Systems adapted to conditions in China. The first vessel market share in Europe (including Russia) such, the company is estimated to be the largest maintaining a large 270,000 tpy Southwire line at Shengquan was sized (inside steel) at 3.1 m Item Unit Recent Data rapidly to reach 27% of total production, up buyer of copper cathodes on the open market to in Korea, and wholly-owned subsidiaries LS diameter by 11 m long with a rated capacity of Matte throughput t/hr 43 to 52 from 21% in 2012, also gaining market share in feed its two Southwire lines. Fourth is Walsin Vina Cable and Superior Essex also running 7 to 8 tonnes of concentrate/hr, while the larger Oxygen enrichment of %O2 21 to 30 Africa and the Middle East. Lihwa, which has its headquarters in Taiwan copper wirerod lines. Korea-based Gaon cable Dongying unit was sized 4.4 m diameter by 16.5 blowing air The next three largest producers Jiangxi but the majority of its production in China. also falls under the umbrella of the LS Group m long, with a rated capacity of 70 tonnes of Copper content of slag %Cu 8 to 10 Copper, Jiangrun Copper and Walsin Lihwa The company enjoyed a strong performance in of companies and produced 58,000 t of copper concentrate /hr. Sulphur capture % >99.5 are all based in Asia. After expanding capacity 2015 operating at 98.5% capacity utilisation. wirerod in 2015. Seventh placed Southwire and production of wirerod aggressively in recent Fifth placed FCX manufactures continuous consumes nearly all the wirerod it produces, Converting plant years, Jiangxi Copper’s production stabilised in cast copper rod at its facilities in El Paso, Texas, following its acquisition of Coleman Cable Dongying continued technology development 2015 at around 750,000 t. The company operates Norwich, Connecticut, and Miami, Arizona, which completed in 2014. of the SKS unit with the incorporation of two wholly-owned wirerod mills, one Southwire primarily using copper cathode produced at its www.crugroup.com a continuous converting process, with the integrated operation now referred to as the ‘Two-step Copper Smelting Process’. The plant, rated at around one million tonnes of Main tube producers concentrate per year, commenced operations In 2016 China reported to the ICSG Directory in October 2015 and was described in a paper of Copper/Alloy Fabricators Capacity around presented at the Copper 2016 conference (1), 2.53 Mt of copper and copper alloy tubes upon which this second article in the series production, followed by North America is based. (760 kt), Western Europe (713 kt), NE Asia The process flowsheet of the new plant is ex China (510 kt), SE Asia/India/Oceania illustrated in Figure 1, while Table 1 presents (387 kt), Eastern Europe and Central Asia typical operating data for the smelting and (173 kt), South and Central America (148 kt), the converting vessels. Figure 2 presents an Middle East and North Africa (114 kt), and illustration of the Two-step process steps,

Africa Southern and Central (25 kt). In the showing the single smelting furnace (SLS vessel) 1 Process flowsheet of Dongying Fangyuan smelting process period 2010 - 2016 around 579 kt of new copper and the two converting vessels (SLCR vessels). tube capacity was installed globally, or 6% Figure 3 provides a schematic illustration of overall continuous operation. A typical sequence of all new capacity by product. The operation of the Two-step process the smelting furnace (referred to as the SLS of the converter units is as follows: The No. Expansions and new plants scheduled in is described as follows:- furnace). The process off-gas is ducted to the 1 converter is charged with matte by launder 2016 included the CNMC Albetter Bronze Co. Separate bins are provided to hold copper acid plant following gas cleaning. The tapped transfer. When charging is complete, blowing Cedynia copper wire rod plant of KGHM in Poland has 230 kt of capacity using Contirod and Upcast technology. Photo: KGHM Ltd 110 ktpy Tube Plant Project, the Zhejiang concentrate, slag concentrate, silica flux, dust slag is cooled in 12 m3 ladles, and following commences to convert the charge to copper. Hailiang 25 ktpy Copper Tube Plant in etc. prior to feeding the smelting furnace. These slow cooling is treated by slag flotation for At this point, the No. 2 converter starts to receive Global Wire and Cable Industry in 2016 Guangdong Province, and a 15 ktpy expansion materials are then fed to the smelting vessel at copper recovery. The high grade matte flows high grade matte. After slag skimming at the No. at Mueller Industries in Bahrain. controlled rates through one of the three feed continuously by gravity via a launder to one of 1 converter, copper reduction commences and The wire and cable sector is producing and cable makers (with revenues of 1 to 3 bn euros) www.icsg.org ports located at the top of the barrel section and the two converting vessels (referred as SLCR when the analysis of a sample of copper shows using most of the wire rod worldwide. Reported includes some top Japanese and Middle East towards the vessel ‘feed end’. Oxygen and air vessels) which operate in parallel. The liquid the anode copper is ready, casting commences. 2015 revenues were down 15% on the 2014 level cable makers: Furukawa Electric, Fujikura, Interwire 2017 & The WAI’s 87th Annual are injected through the near-bottom mounted matte feed port in each converting vessel is At the end of casting, the No. 1 vessel is ready of 58.2 bn euros. Just six corporations including Hitachi, Leoni, Xignux, Riyadh Cable, Far East Convention take place in Atlanta, GA from concentric tuyeres. These injected gases react located at the centre of the vessel end-wall (also to receive high grade matte when the No. 2 Prysmian, Nexans, General Cable, Sumitomo, Cable, El Sewedy, Condumex, NKT Cables and 8-11 May, with the Exhibition running from with the added feed to form a high grade matte refer Figure 4). converter readies for finishing, followed by Southwire and LS Cable & Systems are making Tele-fonika Kable. 9-11 May 2017. containing 73 to 78 % Cu content, a slag averaging The two converting vessels, which operate in anode casting. Table 2 presents the average almost 50% of the revenues. The second tier of www.icsg.org www.interwire17.com 2.5% Cu and a high-strength SO2 off-gas. batch mode, function alternately to allow for an anode analysis (1).

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 18 | 21ST CENTURY SMELTING www.copperworldwide.com www.copperworldwide.com 16TH WORLD COPPER CONFERENCE | 19

Table 2. Average anode analysis (wt. %) Oxygen supply to Cu Fe S O Bi As Sb Pb Zn Ni All rising above C-level 99.2 0.003 0.013 0.198 <0.001 0.023 0.010 0.078 0.007 0.057 the Two-step process Soon CRU’s 16th World Copper Conference will be held in Santiago during CESCO Week Chile from According to the Copper 2016 paper as 3 - 5 April 2017. The three-day conference is widely regarded as the leading copper conference and referenced, the following improvements to regularly attracts nearly 500 delegates from over 40 countries. the new process are underway: Arsenic mitigation • Improved operation and scheduling of the Fangyuan Copper Smelter Phase I was At this annual event representing the complete slag and matte transfer stages commissioned in 2010 with the aid of ENFI, Air Liquide announced a long-term contract copper value chain from miners to smelters, • Improvement to the copper tapping step formerly known as China Nonferrous with Shandong Fangyuan, China’s leading traders and end-users, over 40 percent of • A new pyrometallurgical slag cleaning step Engineering and Research Institute, privately-owned copper smelter, in June attendees are usually C-level executives - to reportedly replace slag flotation with a wholly-owned subsidiary of China 2015. Air Liquide will invest around EUR Chief Executive Officers (CEO), Chief slag cleaning. Metallurgical Group Corp. It independently 60 million in a state of the art ASU (Air Operations Officers (COO), and Chief Overall the Fangyuan Process, protected by invented Oxygen Bottom-Blowing Separation Unit) with a capacity of 2,000 Financial Officers (CFO). Chinese Patent No. 20141023-7182.4, operates Continuous Copper Smelting Technology tonnes of oxygen per day, expected to be with two main steps instead of three steps in (SKS/BBS) and a two-step copper smelting commissioned by the second half of 2017. Conference preview: conventional processing (but a separate slag technology. With the SKS/BBS process, The new ASU, located in Dongying, The main sponsors of the 16th WCC at time of cleaning step is also required). The process over 90% of As in the high-As concentrate Shandong province, will be built by Air publication were: Gold - ABB, Anglo American, involves no crane transfer of matte in ladles and enters into offgas in the form of gaseous Liquide’s Engineering and Construction Bechtel, Fluor, Outotec, SNC Lavalin; Silver - CRU Chairman Robert Perlman founded the company in 1968. He is seen has reportedly good energy and environmental As2O3. The offgas is then cooled down and teams, using state of the art technologies Amec Foster Wheeler, LME, Proudfoot. here addressing the 14th WCC delegates in 2015 performances. Dongying Fangyuan Nonferrous quenched, where As2O3 powders can be that offer energy efficiencies as well as Metals Co., Ltd. is to be congratulated on the collected. The product is high purity, and optimal reliability and safety. It will support Monday 3 April Wednesday 5 April development of this ingenious new copper the whole process is safe and can be easily Shandong Fangyuan’s ongoing large-scale International Exploration Forum Metallurgical Sulphuric Acid Seminar smelting process and the copper world awaits controlled. The technology and its complete expansion plan to increase smelting capacity 12:30 - 17:30 14:30 - 16:30 news of further developments. equipment was successfully applied in the at the Dongying site from 400,000 tonnes to Covering strategies for the Chilean Government, Areas covered will include improvements in

www.sdfygroup.com Yuguang Copper Smelter commissioned in 700,000 tonnes per year by 2017. mid-size mining, technologies and productivity, SO2 capture in Chile - timing and effectiveness 2014, for example. The Dongying Fangyuan The oxygen supplied will boost productivity and Chinese demand. of proposed programmes, and changes in References: Nonferrous Metals Ltd Two-step line of the smelter while reducing overall CO2 smelting industry structure and investment 1. Z. Cui, Z. Wang, H. Wang and C. Wei, Two-step copper commenced operation on 1 October 2015. emissions and cutting maintenance costs. 14:30 - 16:00 in the Americas. smelting process at Dongying Fangyuan, Paper PY16-4, Copper www.enfi.com.cn Air Liquide will also provide support for an ICA Workshop 2016 International Conference, Kobe, Japan. MMIJ 2016. optimised usage of Shandong Fangyuan’s - Copper Demand and Substitution Grand exhibition oxygen injection technology. Oxygen Confirmed exhibitors in Santiago include: Codelco’s Ministro Hales Division (the concentrator control station is shown here) produced more than 238,000 tonnes of copper in 2015. injection is a strategic technology for the Tuesday 4 April • ABB - power and automation technologies In January 2016, Codelco CEO Nelson Pizarro said Ministro Hales had non-ferrous industry in which Air Liquide Case Study Collection / Innovation Showcase • Air Liquide - gases, oxygen solutions, ALSITM become their most productive operation, yielding 67 tonnes of copper per worker in just twelve months. Photo: Codelco has over 20 years of proprietary research and 14:30 - 17:00 (injector for smelters and converters) and several industrial references. Air Liquide has Showcase of technology, process and OXIALTM (Air Separation Unit) • Outotec - minerals and metals processing installed over 350 ASU’s worldwide to date. performance innovations. Last year’s presenters • Anglo American - copper and molybdenum technology, industrial water treatment www.airliquide.com included University of Concepción, Ecometals, operations Los Broncos, El Soldado, Mantos • Tsukishima Kikai - seawater-method flue Hatch, University of British Columbia, Next Blancos, Mantoverde, Chagres smelter, gas desulphurisation, water purification, Exploration, Brass, Olympic Dam Taskforce, Collahuasi mine (interest) in Chile, and sewage treatment. Government of South Australia and SolGold. Quellaveco project in Peru www.worldcopperconference.com

CRU analysis: Copper blister surplus emerging To conclude this roundup, here is an example strong growth in refined copper production most of its product to India, to be processed of an excellent piece of CRU Analysis by in 2017, regardless of constraints on mine at its facilities at Tuticorin and Silvassa. CRU Principal Consultant Christine Meilton concentrates production growth. CRU’s Glencore has also brought on stream released in December. It declared that in analysis determined that much of the stock additional smelting capacity at its PASAR Air separation unit operated by Air Liquide in China. 2015, global blister production from smelters build is in Zambia and China, and this is operation at Leyte in the Philippines. Photo: Air Liquide 2 Two-step vessels in the Dongying Fangyaun process totalled 16.1Mt contained copper against total supported by data on international trade flows. Production is now believed to be ramping electro-refined production of 18 Mt of cathode A major underlying factor has been the up but still below previous expectations. copper. The shortfall was filled by high-grade establishment of new smelting capacity with Much of the blister is processed to anode scrap. The recovery of copper from high-grade no associated refinery capacity. In Zambia, before selling to third parties, and CRU scrap is estimated to have totalled 1.95 Mt, and First Quantum’s Kansanshi smelter, which estimates that the year’s surplus blister/anode the intermediary market for copper blister was started operating at the beginning of 2015, will amount to 36,000 t, rising in 2017 to therefore approximately balanced. In 2016, has continued to ramp up and production 74,000 t. In the year to August, only an blister production growth outpaced that of is now close to its 300,000 tpy capacity. The estimated 6,500 t had been exported. refined copper production as new standalone blister is all processed to anode before export, Within China, domestic blister production blister production capacity has been brought with China being the main destination. has risen by more than refinery output, as the on stream and ramped up, while cutbacks Also in Zambia, both Glencore and Vedanta country’s small operations have responded to to electro-refined production in Africa have have ceased operations at their refineries, a good supply of concentrates with favourable not been matched with equivalent cutbacks but continue to operate their smelters. In TC/RCs. Secondly, imports have increased to blister production. CRU forecast 2016 Glencore’s case, this is at a reduced level sharply and in excess of requirements. Despite blister production at 16.86 Mt (up 4.6% y-o-y), due to the temporary closure of its Mufulira continued growth in global smelter capacity, compared to a 2.4% increase in electro-refined and Nkana mines in response to low prices, tight concentrate availability is expected to production to 18.41 Mt. although custom concentrates are still being restrict production from 2017 and CRU is An increase in blister stocks of some 300,000 processed. While all of Glencore’s production forecasting a 0.3% rise. t contained copper will support a continued is for the custom market, Vedanta is shipping www.crugroup.com 3 Depiction of SLCR converting vessels operation 4 Operational details of SLS single smelting furnace

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 20 | CONTRACTS & PEOPLE www.copperworldwide.com www.copperworldwide.com CONTRACTS & PEOPLE | 21

In brief… Services unit and Kontola Filtration plant for Codelco Chuqui New final acid tower for Chile In brief… Outotec has received an 18 million Peru’s Toquepala contracts for According to BMI Research, in part move by Outotec An extensive upgrade of a sulphuric euro order from Chile for the delivery SNC-Lavalin due to strong Chinese investment, the of concentrator process equipment, Outotec has been awarded a contract acid plant for a Chilean copper smelter DRC’s copper output will experience the Outotec is to establish a Services by Southern Copper Corporation, SNC-Lavalin of Canada has been included the supply of a new NORAM comprising grinding, flotation, thickening second fastest growth rate (6% p.a.) of business unit as of 1 April 2017. a subsidiary of Grupo Mexico S.A.B awarded an EPC contract by brick-lined final acid tower. The 1,300 and filtration equipment and engineering. all major global copper producers from Outotec will provide spare parts and Until the appointment of a Services de CV. (Grupo Mexico), for the Corporación Nacional del Cobre de MTPD double-absorption plant treats business unit head, CEO Markku delivery of a concentrate filtration Chile (Codelco) division Norte for off-gas from Teniente and Peirce 2017 to 2021, particularly now the sale installation supervision services and of Tenke Fungurume copper mine by training for the delivered equipment. Teräsvasara will lead the design plant to the Toquepala copper the construction of two sulphuric acid Smith converters. The acid tower, work for it. In addition, Outotec has project concentrator expansion in plants at the Chuquicamata Copper capable of increased gas throughput Freeport-McMoran and Lundin Mining Delivery is expected by the end of 2017. appointed Mr. Kimmo Kontola, MBA, Southern Peru. The contract value Smelter in Antofagasta, Chile. The and a lower pressure drop, allows is to be completed. www.outotec.com B.Sc. (Chemical Eng.), as President exceeds EUR 15 million. Outotec’s project incorporates sulphuric acid treatment of up to 150,000 Nm3/h www.bmiresearch.com The RHI Supervisory Board has appointed of its Minerals Processing business scope of delivery includes the production technology by MECS of metallurgical gases, to capture The 1st International Seminar on Dr. Gerd Schubert as Chief Operations unit and a member of the Executive engineering and supply of a filtration Inc., a wholly owned subsidiary of essentially all SO3 gas and to produce Board of Outotec as of 1 January plant consisting of automatic pressure DuPont, with whom SNC-Lavalin has commercial H SO of 98.5% purity. Mining and Sustainable Development is Officer and Chief Technology Officer of 2 4 the Management Board of RHI AG for 2017. Kimmo Kontola was leading filters, ancillaries and control as well successfully executed projects for over Environmental performance of the on 6 April 2017 in Santiago as part of a period of five years from 1 January the Beneficiation business line and as related installation supervision and 50 years. The plants will treat off-gas plant improved significantly, with a CESCO Week, with the theme ‘Impurities: prior to that was head of Outotec’s commissioning services, including from the Chuquicamata smelter, each greater than 95% reduction of SO 2017. He will support the Management 3 Regulatory trends, markets and Americas region. The company has spare parts. Delivery is mostly during producing up to 2,048 tonnes of market and acid mist emissions. NORAM The NORAM acid tower installed on a Codelco smelter Board team in the course of the planned technologies’. Over 150 are expected. two reporting segments according the second half of 2017. The expansion grade sulphuric acid per day. These provided basic design, detailed and acid distributors, was custom combination of RHI and Magnesita. The Organising Committee includes to IFRS 8: Minerals Processing and is expected to increase the annual new plants will replace those currently engineering, site services, fabrication manufactured in British Columbia for Mr. Franz Buxbaum has stepped down. Cochilco, Cesco, Anglo American, Metals, Energy & Water. The service production capacity by 100,000 tonnes in operation at the facility and are part advisory services, and start-up shipment to site. The contract was Codelco, EcoMetales Ltd and the www.rhi-ag.com business will continue to be reported of copper. of Codelco’s ongoing environmental assistance. Specialised equipment, completed in 2016. University of Chile. Vincent Nguyen will be overseeing the as part of the two reporting segments, www.outotec.com compliance plans. Construction is including some tower internals, www.noram-eng.com Minerals Processing and Metals, expected to begin in early 2017 with www.ecometales.cl finance department of MKM in his future Energy & Water. SNC-Lavalin performing basic and role as CFO and will report directly to Kimmo Kontola is the new President of Outotec’s Iran’s copper sector A line on restoration of copper crucibles Rautomead Chairman, Sir Michael Nairn, www.outotec.com Mineral Processing unit detailed engineering, procurement CEO Roland Harings. He will succeed looks to move forward of equipment, and construction of will be presenting a paper on Gerhard Bickmann, whose contract Mahan Company for Mines and the acid plants via their Santiago and ‘Developments in Vertically Up-Cast Rod expires in April. Vincent Nguyen started Steerhorn Cathodes added to IsaKidd™ range Industries Development (MACMID) Toronto offices. for Non-Standard Alloys using Rautomead working at MKM in January. Most plate was designed has two copper mines under Earlier in November 2016, SNC- Continuous Casting Technology’ at recently he was head of recycling at to enable operators development at Chah Firuzeh (20% Lavalin was awarded another EPC March’s IWCC Technical Seminar in Novelis Europe and managed their to achieve significant completed) and Daralou (35% contract by Codelco Chuquicamata Munich, Germany. Rautomead will later Nachterstedt foundry set-up. power savings. completed) in Iran. It wants to reach division for replacement of its effluent be exhibiting at Interwire 2017 in Atlanta, www.mkm.eu Reductions of up to around 26,000 tonnes per year output treatment plant at the Chuquicamata Georgia from 8 - 11 May. 1.7% total power in each mine by 2019. This will require Copper Smelter. SNC-Lavalin Glencore Technology has recently been www.rautomead.co.uk use can be expected around US$ 600 million investment will provide services for detailed awarded the inaugural 2016 METS with this cathode, in both the mines and associated engineering, supply of equipment Ignited Collaboration Award presented Amer International Group commissioned as was recently processing plants. The Managing and materials, construction, a 500 ktpy low-oxygen bright copper rod at the IMARC Gala Dinner in Melbourne, demonstrated in Director of MACMID, Ebrahim commissioning and start-up for the along with project partner Core continuous casting and rolling line from a South American Sadeghi, says it has a mandate to use new effluent treatment plant. The SMS Group in November 2016 to make Resources. The award recognises EW tankhouse. This only European technology in these new installations will replace the A copper hearth for titanium melting aerial conductors and foil products, the successful installation of the development can developments. existing plant and will bring more At the Butech Bliss facility in Ohio conditions that remove undesirable TM according to Antaike Copper Monthly Albion Process treatment plant for The new Steerhorn hanger be retrofitted into The National Iranian Copper efficiency to how effluents from the (USA), the copper-based melting elements during the melting process GeoProMining Gold LLC’s GPM Gold Glencore Technology’s IsaKidd™ existing plants, or can be designed Industries Company (NICICO) firms gas cleaning plant are treated. The equipment repair and replacement and greatly improves the quality of No.240. Amer installed a 225 ktpy ® Project in Armenia. business has released the Steerhorn into new projects, to provide produced 528,768 tonnes of copper project will be centrally managed business has been steadily growing and the metals. In the case of titanium, SMS group Contirod CR 3500 plant www.glencoretechnology.com Cathode Plate to the market, power savings from the start of concentrate, an 18% rise, in the from SNC-Lavalin’s Santiago gaining new customers. The melting the initial melting occurs in a copper to produce 8mm copper wire in 2008. consisting of a bar designed to the operation. It is ideally suited for first half of the current Iranian year (Chile) office, with support from its or re-melting of many specialty or hearth and the subsequent re-melting www.antaike.com Jordi Magnet has left his position as reduce the distance for the current Glencore Technology’s IsaKidd™ (20 March - 19 September 2016). Montreal (Canada) office for process exotic metals often takes place under in a copper crucible both under strictly General Manager of La Farga Tub, and to travel from the hanger bar to Cathode designs or HP Cathode Sarcheshmeh Copper Complex design, commissioning and start-up controlled conditions inside a water- controlled environmental conditions. Zhangjiagang United Copper Co., Ltd., will end his 35 years’ exemplary service the plate. Nigel Aslin, Technology Plate designs. produced 306,684 tonnes, Sungun services. The project is expected to cooled copper vessel. These vessels One of the interesting characteristics the Tongling Nonferrous Metals Group Co., in April 2017. The new General Manager Manager, said the new cathode www.glencoretechnology.com Copper Complex output was be fully operational in 21 months. are typically a key part of melting of these copper vessels is the amazing Ltd subsidiary, made gains in 2016 after of La Farga Tub is Manel Antequera, until 148,194 tonnes, and Miduk Copper www.snclavalin.com systems known as VAR (Vacuum Arc ability to conduct heat away from the three years of prior losses, according to recently Sales Manager (with 14 years’ Company made 73,890 tonnes Remelt), ESR (Electro-Slag Remelt), molten metals. Titanium, for example, Antaike Copper Monthly No.241. In 2016, service). Sales Management is now Gas management goes national for Air Liquide concentrate respectively, with a Metso change PAM (Plasma Arc Melting) and EBM melts at around 3,000oF. The molten Zhangjiagang United Copper produced under the direction of Victor Parellada, Air Liquide has inaugurated in France, operation and optimisation centre, 20% y-o-y rise recorded in the final The Board of Directors of Metso (Electron Beam Melting). Butech Bliss titanium is only separated from the 297 kt refined copper. The business for the past 4 years the company’s as part of its Connect project, located near Lyon in Saint-Priest, month of the period. Iran has nearly has appointed Chief Financial Officer has supplied both new components cooling water by as little as ¾” of revenue and gross profit reached 21.4 bn Export Manager. a unique operations centre that has a nationwide vision of customer 14% of Asia’s copper deposits and (CFO) Eeva Sipilä as Deputy to the and repair services for all of these copper. The copper would normally o yuan and 40 M yuan respectively. www.lafarga.es enables the remote management needs for oxygen, nitrogen, argon about 3% of the world’s reserves, CEO with immediate effect. Ms. Sipilä different systems. melt at a temperature (2,000 F) well www.lianhecopper.com of production for 22 of the Group’s and hydrogen. Capable of stopping at around 4 billion tonnes. has served as Metso’s CFO since 1 The copper crucibles, liners and below that of titanium, but copper is Applications for the CEEC Medal, an units in France, optimising their or restarting a site remotely, the www.nicico.com August 2016. Former Deputy to CEO, hearths are commonly used for the such an excellent conductor of heat The Zijin Mining 2.477 bn yuan Duobaoshan annual award intended to recognise and energy consumption and improving centre adapts the production level Harri Nikunen, will continue in his melting of titanium, nickel alloys, that the cooling water prevents a Copper Mine Stage 2 expansion project celebrate outstanding published papers, their reliability. With ‘technological of the plants according to customer PT Freeport Indonesia (PT-FI), current position as SVP, Mergers & select stainless steels and exotics such meltdown. These severe conditions was approved in January 2017, according articles or case studies describing showcase’ certification from the demand. Thanks to this centre, as of 3 February, awaits to export Acquisitions and Special Projects. Also, as tantalum and vanadium. Some of require frequent maintenance and beneficial strategies for energy-efficient Industry of the Future Alliance, the workflows of each unit are of its copper concentrates via the Metso Santa Ana de Bolueta Grinding these metals are initially melted in repairs to be performed. The copper is to Antaike Copper Monthly No.241, raising comminution, will close on 15 March Connect represents an investment of adapted in real time to the needs conversion from a COW to an IUPK Media SA located in Vizcaya, Spain, an induction furnace or electric arc often received in a distorted condition the capacity to 70,000t per day. Planned 2017. Studies on measured energy EUR 20 million. This project is based of each customer. The volume of operating licence. January 2017 has been awarded by the Basque furnace and poured into ingot molds. with gouges, scars and arc damage 2017 production volumes include 41 t of improvements and financial benefits, on the implementation of new digital production and the delivery of regulations permitted the export Government for its contribution to These ingots are then re-melted in requiring welding, straightening or gold, 221.8 t of silver, 200,000 t of copper, achieved or potential, are of key interest. technologies at French production gases to customers are optimised of anode slimes, necessary for PT the mining industry and economic copper crucibles as an additional machining in order to be returned 300,000 t of lead and zinc. www.ceecthefuture.org sites and on the creation of new skills. throughout the country. Smelting to continue operating. development of the local community. step in the refinement process. This to service. www.zijinmining.com Like a control tower, the remote www.airliquide.com www.fcx.com www.metso.com re-melting is often done under specific www.butechbliss.com

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 22 | COPPER/COBRE 2016 www.copperworldwide.com www.copperworldwide.com EVENT PREVIEWS | 23

Positive tone at the Kobe gathering Metal Bulletin marks 30th International Copper Conference This year’s International Copper which the value chain from up- With the world facing increasingly troubled times, the Copper 2016 conference concluded on a somewhat Conference in Leipzig, Germany to downstream could be brought positive note. There is a reasonable outlook on future copper demand and for mine-smelter-refinery sustaining from 13 - 15 March 2017 marks together to discuss common aims developments to match in the near to long-term. Summary by Phillip Mackey. a milestone: it is the 30th in the and objectives, but also gain series of gatherings which have insight into the challenges faced scrutinised the entire industry by other segments of the chain. outlined in plenary presentations chain from mine to market and Exploration, mine development and others given at Copper 2016 attracted delegates from across and finance, the mine-smelter included the following: the continents. While it is edition interface, fabricating industry • World copper demand is presently number thirty, the International health, recycling, technology and about 23 Mtpy and is expected Copper Conference has been of course, the end-markets, have to grow at 2.8% per year over the going for well over three decades, been key themes throughout, with next two decades. Brownfield as the early ones were held only additional timely topics finding expansions - some already every two years, the very first their way onto the programme each announced - will meet part of this conference taking place in 1982 year. E-commerce, substitution, 1 Copper 2016 in Kobe attracted over 747 delegates demand, but new mines will need in Copenhagen. The delegate and inventory financing have all from 31 countries to be developed. This growth rate list from that event reads very made appearances, and of course The Copper 2016 Conference (9th suggested the equivalent of a new differently from today’s, but many China, which is now very much a Executive Industry Panel at the 29th International Copper Conference in Lisbon in March 2016 Edition) held on 13-16 November 300,000 tpy smelter-refinery each company names still feature permanent feature. field trips visited El Teniente, in response to changing industry in Kobe, Japan was the first to be year over the period (see below strongly, and some industry Apart from bringing together all Los Pelambres and Chuquicamata. dynamics, notably the annual held in Asia in its 30 year history and Figure 3). stalwarts such as Christian the links of the value chain, the The conference has tracked the Asia Copper Conference in (see Table 1). Hugely successful, 2 Refined copper production, 1990 to 2015 (‘000s of tonnes). Asia was the leading region in the world in 2015 • With growing demand Schirmeister of Amalgamated conferences have moved each year vicissitudes of the global copper Shanghai, African Copper and there were 272 papers in total on (12 Mt). Source: ICSG in mind, several plenary Metal Trading have attended if to locations that are intrinsically market: in 1998 in Phoenix the Copper Concentrates, and of all key areas of copper metallurgy. speakers highlighted the role not all, then the great majority linked to copper production of some industry was getting excited course the popular and unique The conference attracted over of sustainability in all areas of of the conferences. kind, or major areas of copper usage. about prices breaking through Copper Recycling Conference, 747 delegates from 31 countries. copper operations. This rotation of venues has provided the dollar per lb mark (thank you but it is the International Copper Around 70% of the delegates were • The conference was informed that Binding force some notable associated field trips, Mr Hamanaka); in 2009 it was Conference that continues to be from Asia, with the balance from wind turbines, electric and hybrid The copper industry has been ranging from the Highland Valley looking on tearfully as prices sunk the event that embraces all aspects Europe (15%), North America cars will all require significant marked for many years by a mine high in the Rockies to Atlantic back to not far off that level. Then of the business, living up to its (7%), Central and South America amounts of copper. relative lack of vertical integration, Copper’s smelter and refinery in there were the heady heights of the rubric: Linking up the value (4%), and Australia (4%). New The copper requirement in which to some degree has led southern Spain, from Cananea in mid-1990s and 2011 (with prices in chain to foster debate and global and improved technologies in all electricity generating systems is to a disconnect between supply the north Mexican desert to KME’s the latter year almost at US$ 4/lb). industry growth. production areas were presented graphically illustrated in Figure 4. side planning and consumption state of the art fabricating plant It is fair to say attendance at www.metalbulletin.com and discussed. In 2015, installed generating power requirements, and the price near Florence, Italy. In the late the conference has not been as Author: Ann-Marie Moreno, in China was 1,505 GW, and this volatility that brings with it. 1990s, after an explosion in mine volatile as the market itself! Table 1. Last five and upcoming Copper Senior Conference Programme Conference venues is expected to grow to over 2,100 From the outset Metal Bulletin’s production, Chile’s Santiago became A number of successful offshoots Manager, Metal Bulletin GW by 2030. Based on the data in aim was to provide a forum in the venue for the conference, and to the event have been spawned Year City/Country 3 World mined copper to 2030 (N.B. OT is Oyu Tolgoi). Source: Copper 2016 Figure 4, this will require of the 2003 Santiago, Chile order of over 7 million tonnes 2007 Toronto, Canada of copper. 2010 Hamburg, Germany There will be slowly expanding Main event returns to Santiago Shanghai hosts fifth copper week 2013 Santiago, Chile use of electric vehicles. The present The 16th CRU World Copper More than 2,000 people from The future of China and its vision 2016 Kobe, Japan number of passenger cars in use Conference is being held during more than 20 countries around the is key to the forming of strategy in 2019 Vancouver, Canada worldwide approximates 1,000 CESCO Week in Santiago, Chile world, representing more than 100 the coming decades. (planned) million vehicles, with about 100 from 3 - 5 April 2017 (see also page leading companies, met from 15 - 17 The Chilean delegation was million to be added every year 19). CESCO Week is a key date November 2016 at the fifth annual headed by the Minister of Mining, over the next decade. Within two in the copper calendar and the CESCO WEEK SHANGHAI, Aurora Williams; Nelson Pizarro, Conference makeup decades or so, electric vehicles are World Copper Conference is firmly the main copper event in Asia, CEO of Codelco; Iván Arriagada, The Press Area at the 2016 World Copper Conference The schedule included 10 plenary 4 Illustration of the copper requirements in electricity generating systems. Source: Copper 2016 expected to represent about one- established as a flagship event during organised by the Center for Copper Executive President of Antofagasta lectures, short courses on Arsenic third of new cars sold. Presently the week. Around 475 delegates from Copper and Diamonds, Rio Tinto and Mining Studies (CESCO). The Minerals; Diego Hernández, and Recycling, and a workshop an internal combustion engine 35 countries are expected. Several • Jorge Gomez, Executive President, 12th Asia Copper Conference (Metal President of the National Mining on Bottom Blowing Technology requires about 20 kg of Cu/vehicle, 2017 CEO and Governmental Mineral Collahuasi Bulletin Events), the V CEO’s Society (SONAMI); Mauro Valdés, presented by delegates from China. while a plug-in hybrid requires Speakers have been announced, • Mikael Staffas, President, Summit and the V Asian Copper President of the High Law Program, The event included a successful about 55 kg of Cu/vehicle, and a namely: Boliden Mines Dinner took place. Alejandra Wood, and representatives of CESCO. The Trade Show with 35 exhibitors. fully electric car requires around • Oscar Landerrectche, Chairman of • Daniel Meilan, Secretary of Executive Director of CESCO, 2017 dates are still to be announced. Post conference tours were well 80 kg of Cu/vehicle, so there will the Board, Codelco Mining, Ministry of Energy believes Chile must set the standard www.asiacopperweek.com attended and included: Saganoseki be increasing copper demand for • Aurora Williams, Minister of & Mines, Argentine Federal as world leaders in the sector. www.cesco.cl (PPC), Naoshima (Mitsubishi) passenger cars in future. With an Mines, Government of Chile Government and Toyo (Sumitomo). average of 0.12 cars per capita in • Nelson Pizarro, Chief Executive Starting with a site visit to The successful event reflected the China, there is some way to go to Officer, Codelco Chuquicamata and Ministro Sulphur 2017 SIPS 2017 remarkable growth in the copper reach the higher level of about • Jiangqiang Wu, President, Hales Mines on 3 April, the three- This event was in London in The SIPS 2016 Conference on industry in the region. By 2015, 0.85 cars per capita in the USA. Chinalco China Copper day programme also includes the 2016 and included a useful Session Hainan Island Province in November Asia accounted for 12 million Finally it was announced by the • P. Ramnath, Chief Executive International Exploration Forum, on Metallurgical Sulphuric Acid saw more than 520 scientific works tonnes of refined copper, or 52% 2019 Chairman, Dr. Joel Kapusta Officer, Sterlite Copper, Vedanta Metallurgical Sulphuric Acid and a significant exhibition area. from over 80 countries around the of world production (Figure 2). of BBA, Montreal, Quebec, Canada, • Daniel Malchuk, President Seminar, Innovation Showcase, The CRU Sulphur 2017 world. Corporate Sponsors were The same year, copper smelter that Copper 2019 would be held Americas, Mineral Operations, Technical Case Studies, and International Conference & Flogen Technologies, Domel and production in Asia approximated in Vancouver, B.C., Canada in BHP Billiton ICA Workshop - Copper Demand Exhibition takes place in Atlanta, TOMS group. SIPS 2017 takes

11 Mt of copper (60% world 5 Left is Yoshihiro Nishiyama, Copper 2016 Conference Chairman, and President and CFO, Pan Pacific August 2019. • Ivan Arriagada, CEO, Antofagasta and Substitution. GA from 6 - 9 November 2017. place 23 - 27 October in Mexico. output). Some of the key findings Copper Co. Ltd., and right is Dr. Joel Kapusta of BBA Inc., the Copper 2019 Conference Chairman www.metsoc.org/copper-2019 • Arnaud Soirat, Chief Executive, www.worldcopperconference.com www.crugroup.com/events www.flogen.org/sips2017

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 24 | SAFETY AND MAINTENANCE www.copperworldwide.com www.copperworldwide.com EXTRUSION TECHNOLOGY | 25 BHP Billiton continues Banyard LFi Seminar on extrusion Inductotherm Group colleagues from Europe, Samarco remediation Russia, USA, Taiwan, Japan and China, India and Korea, joined a two day technology One year after the Samarco tragedy, BHP Billiton is creating a new global tailings masterclass at Inductotherm Heating & Billiton CEO Andrew Mackenzie has paid his dam standard for its operations. Welding Ltd in Basingstoke, England in respects to the people affected by the dam failure December. Inductotherm is home of the and provided an overview of the remediation Maintenance roles Banyard brand for the Non Ferrous and Steel work. Mr Mackenzie said “The Samarco dam The new BHP Billiton website launched sectors, in particular Banyard induction failure was a terrible tragedy and our thoughts in December makes company news and solutions for the Extrusion Industry. Banyard remain with those affected. The emphasis has information easier to find and promotes job approaches 50 years in these market sectors. shifted to the Renova Foundation which will opportunities on the homepage. The company This important learning event took place implement the long term programs to restore has already been recruiting globally-focused to focus on the markets development for the environment and rebuild the communities.” roles in its Maintenance Centre of Excellence the singularly exceptional LFi products. More than 3,000 people have been mobilised to (MCOE) hubs based in its Adelaide, Brisbane Inductotherm has a dedicated centre of rebuild infrastructure, provide community and and Perth offices. Each MCOE has been created excellence in the UK that supports its Banyard social services and prepare for the wet season. to remotely yet collaboratively support sites global reach in engineering, process calculation, The findings from the external investigation into to deliver safe, sustainable improvement layout design, sales and after sales. The goal the causes of the dam failure were published in focussing on equipment performance. is to maintain a position as a leader in the Andrew Mackenzie is Director of BHP Billiton Limited and CEO of BHP Billiton LFi Seminar group visiting the 6” billet heater test installation August 2016 and shared with the industry. BHP www.bhpbilliton.com Plc. Photo: BHP Billiton Aluminium and Steel extrusion markets and to have Group companies manufacturing to • Multi-turn and multi-layer coil detailed overview of the lesson learnt compete locally. design benefits and where working closer with the Occupational Acid topics are Shredder housing The Group colleagues were given the • Digital connectivity and its operation integrators of press manufacturers can opportunity to gain insight into the design in maintenance and planned service. present the most efficient, cost competitive safety awards up for discussion design expedites criteria, topology, characteristics and benefits as With 2016 installations in India and Korea, solution, whilst still achieving all customer’s well as the features of the LFi power supply and the hosts shared the experiences of the needs. Access was provided to the Inductotherm for Metso The 2017 Sulfuric Acid Roundtable will take maintenance its many application uses, learning about: projects, proving the equipment, responding Heating & Welding Test bay to view, control place from 3-6 April 2017 in The Woodlands • Multiple zone heating, igbt technology, taper to queries and providing results that have and present an LFi 750 kW Unit with Metso has been recognised with two awards (Houston), Texas. The 2015 Workshop attracted Metso has developed a new housing design that gradients, phase locking, inverter power provided a repeat order through the community dedicated heating exercises. This application for its proactive and dedicated efforts in more than 180 participants from around the world. cuts service downtime, facilitates the maintenance • Control, digital connectivity, of Inductotherm Group companies. based on a 6” Aluminium Billet Heater, occupational safety. One of the awards Presentations will be given by event co-sponsors of recycling equipment and makes it easier to communication, diagnostics Recently Banyard Sales and Engineering is available to view until the end of was presented to Metso for its outstanding on a variety of topics relevant to the industry, keep the machinery in top shape. Available for • Temperature control, pyrometers, staff undertook an Extrusion Technology February 2017. management in preventive security by the including: almost every Metso LindemannTM shredder and thermocouples training course and the event provided a www.inductothermhw.com National Safety Council of Chile, and the other model, the new solution enables multiple one to Manuel Guzman, Manager, Health Maximizing Energy Recovery in maintenance operations to be performed and Safety at Metso Chile, who received the Metallurgical Acid Operations conveniently, swiftly and at one time. The most Management Award for Prevention presented Speaker: Hannes Storch, Outotec significant improvement in Metso’s new housing by the Institute of Occupational Safety. Metso model is the detachable front wall. The removable is continuously looking for new innovative ways Selecting the Correct Converter Design unit provides easier access to wear parts and to enhance occupational safety and well-being Speaker: Guy Cooper, speeds up the replacement of worn components. at work. One of the most important initiatives NORAM Engineering & Constructors The new housing design also enables several implemented by Metso’s Pacific Rim market area maintenance tasks to be carried out at the same in 2016 was the immersed virtual reality training HAZOP - Hazard & Operability Review, time. With the detachable front wall lifted out system, where risk situations can be trained for Are We Safe? of position with a crane, the rotor adjustment in a 3D factory environment. Speaker: Len Friedman, and the replacement of wear plates can be www.metso.com Acid Engineering & Consulting conveniently handled simultaneously. www.acidroundtable.com www.metso.com

Innovative Technologies for the Copper Industry Küttner GmbH & Co. KG Team Non Ferrous [email protected] Essen, Germany www.kuettner.com

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 26 | THE BUYERS GUIDE www.copperworldwide.com www.copperworldwide.com THE BUYERS GUIDE | 27

PROCESSING LINES REFRACTORIES AND INSULATION MINO S.p.A. SMELTING – PRIMARY 2017 BUYERS GUIDE DANIELI FRÖHLING RHI AG Küttner GmbH & Co. KG

ACID LINING ELECTROLYTIC REFINING FURNACES, HEAT TREATMENT MATERIALS HANDLING Via Torino 1 Alfredstr. 28 ACCS Ltd METTOP GmbH EBNER Industrieofenbau GmbH Combilift Ltd 15122 - San Michele (AL) D-45130 Essen P.O. Box 362 – 15121 Germany Wienerbergstraße 9 Italy Tel: 0049 201 7293 0 Josef Fröhling GmbH & Co. KG Tel: 0039 0131 363636 A-1100 Vienna Fax: 0049 201 7293 134 Scherl 12 Fax: 0039 0131 361611 D- 58540 Meinerzhagen Austria Email: [email protected] Scott Lidgett Road Ebner-Platz 1 E-mail: [email protected] Gallinagh Germany Web: www.kuettner.com Stoke-on-Trent, ST6 4NQ Peter-Tunner-Strasse 4 A-4060 Leonding Tel: 0043 (0) 50 213 – 6322 Web: www.mino.it Tel: 0049 (0)2354 7082 0 Contact: Dr. Farzad Salehi United Kingdom Austria Monaghan Town Contact: Geminiano Chiesa A-8700 Leoben Fax: 0049 (0) 2354 7082 200 Fax: 0043 (0) 50 213 – 6391 Tel: 0044 1782 817107 Tel.: 0043 (0)732 6868 Co. Monaghan Austria Email: [email protected] SMELTING – SECONDARY Email: [email protected] Tel: 0043 (0)3842 81787 Fax: 0043 (0)732 6868 1000 Ireland E-mail: [email protected] Web: www.accsltd.co.uk Web: www.danieli-froehling.de Primetals Technologies USA LLC Fax: 0043 (0)3842 82023 E-mail: [email protected] Tel: 00353 (0)47 80500 Contact: Dr Thomas Skidmore Contact: Detlef Neumann Web: www.rhi-ag.com Kumera Corporation E-mail: [email protected] Web: www.ebner.cc Fax: 00353 (0)47 80501 Contact: [email protected] Web: www.mettop.com Contact: Mr. Dieter Brandstätter (Sales E Mail: [email protected] Contact: Dr. Andreas Filzwieser Executive Manager) hpl-Neugnadenfelder COOLING SOLUTIONS Web: www.combilift.com Maschinenfabrik GmbH Saint-Gobain Industrial METTOP GmbH ELECTROWINNING Contact: Sales Office FURNACE LEVEL MEASUREMENT Ceramics Limited 50 Prescott Street Worcester, Massachusetts, USA Metalex Kumera Corporation Agellis Group AB 01605 Kumerankatu 2 Tel: 001 508 755 6111 FI-11100 Riihimäki Fax: 001 508 849 6573 Finland E-mail: [email protected] Tel: 00358 (0)20 755 4200 Peter-Tunner-Strasse 4 Web: www.primetals.com Fax: 00358 (0)20 755 4320 A-8700 Leoben Tellusgatan 15 Contact: David Gow E-mail: [email protected] Hernando de Aguirre 162 Of. 806 Mill Lane, Rainford Austria SE-22457 Lund Web: www.kumera.com Santiago St Helens, Merseyside Tel: 0043 (0)3842 81787 Sweden Spangenbergstr. 20 Contact: Hannu Mansikkaviita Chile Kumerankatu 2 Fax: 0043 (0)3842 82023 Tel: 0046 46 101360 D-49824 Ringe/Neugnadenfeld WA11 8LP, UK SAMPLING AND ANALYSIS E-mail: [email protected] Tel: 0056 2335 2217 FI-11100 Riihimäki Fax: 0046 46 101361 Germany Tel: 0044 (0)1744 887939 Web: www.mettop.com Fax: 0056 2321 8280 Finland Alex Stewart (International) E-mail: [email protected] Tel: 0049 5944 9301 0 E-mail: Küttner GmbH & Co. KG Contact: Dr. Andreas Filzwieser E-mail: [email protected] Tel: 00358 (0)20 755 4200 Web: www.agellis.com Fax: 0049 5944 9301 44 [email protected] Corporation Web: www.metalex.cl Fax: 00358 (0)20 755 4320 Contact: Magnus Persson E-mail: [email protected] Web: Contact: Alejandro (Alex) R. Lillo Web: www.hpl-group.de COPPER RECYCLING TECHNOLOGY E-mail: [email protected] www.ceramicmaterials.saint-gobain.com Contact: Mr. Thomas Pieper Alfredstr. 28 FURNACES Web: www.kumera.com Contact: Craig Brennan ANDRITZ MeWa GmbH HEAT RECOVERY Contact: Hannu Mansikkaviita D-45130 Essen Kumera Corporation REFRACTORIES ENGINEERING Germany Küttner GmbH & Co. KG 2b Sefton Business Park, Netherton Tel: 0049 201 7293 0 Liverpool, Merseyside MINERAL PROCESSING METTOP GmbH Fax: 0049 201 7293 134 Alfredstr. 28 L30 1RD Herdweg 4 Email: [email protected] D-45130 Essen UK D-75391 Gechingen Weir Minerals Europe Limited Web: www.kuettner.com Germany Tel: 0044 (0)151 525 1499 Germany Alfredstr. 28 Contact: Dr. Farzad Salehi Tel: 0049 201 7293 0 Fax: 0044 (0) 151 523 3760 Tel.: 0049 7056 925 0 D-45130 Essen Fax: 0049 201 7293 134 Fax: 0049 7056 925 169 Kumerankatu 2 E-mail: Germany Email: [email protected] SOLVENT EXTRACTION Email: [email protected] FI-11100 Riihimäki [email protected] Tel: 0049 201 7293 0 Web: www.kuettner.com Web: www.andritz.com/mewa Finland Web: www.alexstewartinternational.com Fax: 0049 201 7293 134 Contact: Dr. Farzad Salehi Metalex Contact: International Sales Team Contact: Stephen Russell Tel: 00358 (0)20 755 4200 Email: [email protected] Peter-Tunner-Strasse 4 Fax: 00358 (0)20 755 4320 Web: www.kuettner.com Halifax Road PROJECT ENGINEERING A-8700 Leoben ELECTROLYTE PURIFICATION E-mail: [email protected] Contact: Dr. Farzad Salehi SCREENING Web: www.kumera.com Todmorden Austria Metalex Contact: Hannu Mansikkaviita Küttner GmbH & Co. KG Tel: 0043 (0)3842 81787 Oschatz GmbH Lancashire OL14 5RT Schenck Process United Kingdom Fax: 0043 (0)3842 82023 E-mail: [email protected] Küttner GmbH & Co. KG Tel: 0044 1706 814251 Hernando de Aguirre 162 Of. 806 Web: www.mettop.com Fax: 0044 1706 815350 Alfredstr. 28 Santiago D-45130 Essen Contact: Dr. Andreas Filzwieser Chile Email: [email protected] Germany Pallaswiesenstraße 100 Tel: 0056 2335 2217 Westendhof 10-12 Web: www.minerals.weir Alfredstr. 28 Tel: 0049 201 7293 0 Fax: 0056 2321 8280 Hernando de Aguirre 162 Of. 806 64293 Darmstadt D-45130 Essen D-45143 Essen Contact: Sales Fax: 0049 201 7293 134 ROLLING MILL TECHNOLOGY Santiago Germany E-mail: [email protected] Germany Germany Email: [email protected] Chile Tel: 0049 61 51 15 31 0 Web: www.metalex.cl Tel: 0049 201 7293 0 Tel: +49 201 1802-0 PNEUMATIC CONVEYING/ INJECTION Web: www.kuettner.com DANIELI FRÖHLING Tel: 0056 2335 2217 Fax: 0049 61 51 15 31 66 Contact: Alejandro (Alex) R. Lillo Fax: 0049 201 7293 134 Fax: +49 201 1802-165 Contact: Dr. Farzad Salehi Fax: 0056 2321 8280 Schenck Process E-mail: [email protected] E-mail: [email protected] Email: [email protected] E-mail: [email protected] Web: www.schenckprocess.com WEIGHING AND FEEDING Web: www.metalex.cl Web: www.kuettner.com Web: www.oschatz.com METTOP GmbH Contact: Alejandro (Alex) R. Lillo Contact: Dr. Farzad Salehi Contact: Sales Team Contact: Ingo Fjelsten Schenck Process

ONE ENTRY WITH LOGO Unit 3, Alpha Court TO ADVERTISE Capitol Park, Thorne Josef Fröhling GmbH & Co. KG Pallaswiesenstraße 100 Doncaster DN8 5TZ Peter-Tunner-Strasse 4 Scherl 12 HERE PHONE 64293 Darmstadt UK A-8700 Leoben FOR FOUR ISSUES (2017) D- 58540 Meinerzhagen, Germany Germany Tel: 0044 (0) 1302 321313 Austria Tel: 0049 (0)2354 7082 0 Tel: 0043 (0)3842 81787 CHRIS HOLDING Tel: 0049 61 51 15 31 0 Fax: 0044 (0) 1302 554400 Fax: 0049 (0) 2354 7082 200 Fax: 0043 (0)3842 82023 Fax: 0049 61 51 15 31 66 e E-mail: [email protected] E-mail: [email protected] Email: [email protected] +44 (0) 7731 784798 E-mail: [email protected] £185 / EUR 265 / USA $320 Web: www.schenckprocess.com Web: www.mettop.com Web: www.danieli-froehling.de Web: www.schenckprocess.com Contact: Richard Sims Contact: Dr. Andreas Filzwieser Contact: Detlef Neumann Contact: Martin Brauer

Copper Worldwide Vol 7 No 1 Copper Worldwide Vol 7 No 1 28 | DAILY LIVES www.copperworldwide.com Daily lives…Detlef Neumann, Director Sales, Danieli Fröhling Renowned for its planning, design, manufacturing and supply of strip processing lines and cold rolling mills, worldwide customers speak highly of their long lasting “Fröhling” machines

It is before 6 in the morning by that specific customer and when my alarm clock rings. how the layout might look best It’s time to get up and start the for that case. Another daily task day with a fresh coffee. Lotta, for me is to check and confirm our dachshund, fawns still cost calculations and commercial tired but decides that at least offers. Lucky me to have such for her it’s too early for a walk. a good team and experienced I usually like to have the first colleagues that I can very much cup of coffee standing on our rely on their diligence, so that I patio and have a look into the rarely need to change something. garden. Gardening is one of my Nevertheless, we as a team like hobbies and I enjoy especially to discuss both technical and that time of the year when I commercial matters to make can spend spare time outdoors sure of finding the optimum planting something, pruning solution. Every colleague has the roses or just sitting on the his dedicated experience and lawn chair with a cold beer sharing is essential in order and watching birds and bees. to learn from each other and I snatch up my tablet and improve our own knowledge. check the daily news as well Later, the Managing Director as the weather forecast before to whom I report is asking me to I get to the car and drive to our explain the monthly sales report company. It takes me about 30 and outlook. We need to prepare minutes to drive from my home the planning for the next months to the office. I like to hear radio and discuss latest trends in the during the ride, normally news market and how to adapt best. and background reports about The high workload and need for politics and business rather additional, qualified personnel than music. is a topic as well. I can receive Danieli Fröhling is located some positive comments about in Meinerzhagen, a small town the latest results of “my” Spares not far from Cologne. Josef & Services Department - a Fröhling, a German engineer, plaudit that I will pass on to the founded the company right team because they deserve it. after WWII when industry Of course, travelling belongs Detlef Neumann is Director of Sales at Danieli Fröhling in Germany was down and to my professional life as well. reconstruction of the country acting mainly in the steel sector. In 2004, I always enjoy business trips, was getting off the ground. Everything at this I was appointed the Sales Director of Danieli meeting customers and colleagues from other company started with a small workshop in Fröhling, and since then I have been leading divisions of the Danieli family. Unfortunately a private house, but soon grew to a mid-size the sales teams for complete lines as well as for within a standard business trip there is little company providing equipment and services for revamping projects, spares and services. time to see more than airports, taxis, plants and the metals industry. Fröhling, shortly after its First thing in the office is to check and answer hotels, but if a free weekend day or evening can foundation, became specialised in cold rolling my emails. We have business partners and be found, I try to absorb as much as possible of mills and cutting lines. Our equipment may offices around the world and naturally emails the local flair, discover the regional cuisine be found on 4 continents, and is used in steel, also arrive overnight from China, the Americas and try to see some of the sights. copper and aluminium plants. We design and or wherever. Some of my colleagues are on a The day spins away and the to-do-list for supply cold mills in various configurations from sales trip and may need support from home. the next one is already set. One more email to 2-hi up to 20-hi mills which are providing best Our Chinese colleague reports about a new write or a last call made before I go home to see final product quality of the rolled strip. Our potential project and wants to have advice how the family. On the way back, thoughts are still slitting and trimming lines have set standards to follow it up. Then there are the latest reports with some open problems or ideas - how to do regarding processing speeds and cutting from our building sites that need to be studied this and that maybe better. Back at home, my accuracy. These facts and the long lifetime of as well. Over the working day, there are many wife and I clarify who will take the dog out and our lines are reasons why worldwide customers different tasks that may occur and that is what who will prepare the dinner - both of us like speak highly of their “Fröhling” machines and I like in my current job: diversity in work, cooking so either way will work well. Later, at often return to us when it comes meeting and exchanging with different people, the dinner table after a good meal and having a to new investments or enhancement projects. and having the possibility to work with persons glass of wine, we agree that our work makes life I have been working with Danieli Fröhling from various cultures and countries. exciting - but life is more than work and the since 2001. I studied mechanical engineering The day continues with discussions amongst right balance is important to remain in shape until end of the 1980’s and then was employed our colleagues about a new technical offer, how for things to come. in various positions in an engineering company to deal with some special requirements made www.danieli-froehling.com

Copper Worldwide Vol 7 No 1 COPPER IS THE ELEMENT, PROPERZI IS THE ROD LINE

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HEADQUARTERS FRANCE DIVISION USA BRANCH Continuus-Properzi S.p.A. Properzi France Properzi International, Inc. Sordio (LO), Italy Saint Ouen l’Aumône, France Sparks, Maryland 21152, USA Phone: +39. 02. 988 49 21 Phone: +33. 1. 34 32 34 80 Phone: +1. 443. 212. 4320 [email protected] [email protected] [email protected]