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SAFETY AND EQUIPMENT SAFEGUARDING TO ADDRESS A FURNACE RUN-OUT
Anglo PlatinumPolokwane Smelter
byJonathan Mochabane
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2009
Agenda
• Furnace background information– Smelting process overview– Design
• Furnace run-out– Background information– Polokwane Smelter run-outs– Case study
• Improvement plan– Scope of work– Project benefit
• Questions
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2009
Flash dryers
Matte casting and Crushing Plant
Slag granulationand dewatering
Off-gasPlant
Furnace background informationSmelting process overview
To Rustenburg A C P
Off-gasDry concentrate
Furnace
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2009
Furnace background informationSmelting process overview
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2009
Furnace background informationDesign
• 6 in-line rectangular furnace (Hatch design)• Capacity: 650,000 t/a (87 tph)• Power: 80 MW (3 X 54MVA transformers)
68 MW max• Products : Matte @ 1500 deg
Slag @ 1650 degOff-gas @ 600 deg
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2009
Furnace background informationDesign
Refractory system; Magnesia chrome
bricksBinding system;
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2009
• Furnace cooling system – Water cooling
• copper coolers– Air cooling
• furnace hearth and the sidewalls
• Control and Monitoring system – PLC controlled– System Control And Data Acquisition (SCADA)
Furnace background informationDesign
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2009
Agenda
• Furnace background information– Smelting process overview– Design
• Furnace run-out– Background information– Polokwane Smelter run-outs– Case study
• Improvement plan – Scope of work– Project benefits
• Questions
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2009
Furnace run-outBackground information
• Definition – A run-out is an uncontrolled flow of molten material from the
furnace• Possible causes
– matte penetration between the copper coolers or the refractory walls of the furnace (binding/refractory failure)
– Matte/slag levels exceeding maximum limits (operational error)– Water leaking inside the furnace (copper corrosion resulting in
an explosion)– Loss of cooling water
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2009
Furnace run-outPolokwane run-outs
• Run-out impact – Health and safety hazards – Equipment damage
• Inadequate equipment protection
– Production loss• Prolonged Mean time to
repairs (MTTR)• Prolonged ramp up period
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2009
Furnace run-outPolokwane run-outs
Electrical And Instrumentation
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2009
Copper cooler
Conveyor belt and structure
Molten material
Furnace run-outPolokwane run-outs
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2009
Furnace run-outCase Study
• Objective:– To identify areas susceptible to heat – Outline ventilation requirements to dissipate heat – Assess possible insulation options (refractory, etc)– Identify unsafe areas– Identify safe exit routes during an emergency
• Tool/Method – Computational Fluid Dynamics (CFD)
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2009
Furnace run-outCase Study
Slag side (south end wall)
Matte side (north end wall)
Run-out pitCasting pits
Furnace
Matte caster
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2009
Furnace run-outCase Study: CFD M1
MCC room
Electric cables
Furnace transformers
Hearth cooling fans
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2009
Furnace run-outCase Study: CFD M8
MCC room
Cable rack
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2009
Agenda
• Furnace background information– Smelting process overview– Design
• Furnace run-out– Background information– Polokwane Smelter run-outs– Case study
• Improvement plan – Scope of work– Project benefits
• Questions
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2009
Improvement plan Scope of work:
• Extension of the bund wall around the ground floor level• Erection of fire resistant floor on the copper cooler level• Sealing gaps/openings• Fire proofing of exposed steel structures• Improvement of Emergency escape routes
– Horizontal rather than vertical escape
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2009
Improvement plan Scope of work:
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2009
Improvement plan Project benefits:
• Health and safety– Improved emergency escape ( horizontal vs. vertical escape)– Minimised exposure to fumes– Reduced number of contractors on site for repairs
• Equipment – Shielded/ protected from thermal energies
• Production – Reduced downtime
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2009
Run-out Maintenance Downtime
Average hearth temperature prior start-up
Ramp up duration to 30MW
Feb 2008 29 days 200 deg 26 days
Nov 2008 17 days 230 deg 24 days
Future 10 days 350 deg 15 days
Improvement plan Project benefits:
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2009
• Future downtime improvement
Number of days = Feb 2008 – Future= 30
Matte saving = tons/day X %matte fall x days saved= 2000 X 0.15 X 30= 9000 tons
Platinum ounces = oz/ton matte X Matte tons=13.3 X 9000 = 120 000 oz
Improvement plan Project benefits:
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Questions