Selected NonFerrous Operations Case Histories. Metallurgical Process Specialists

Transcription

1 Selected NonFerrous Operations Case Histories Metallurgical Process Specialists

2 Anode Converter SO 2 Emissions Client: ASARCO Location: Hayden, Arizona Landmark EPA legislation created new ground level NAAQS. This standard imposes limitations for smelter operations to be enforced in GCT has developed a project from Concept through to Detailed Engineering to improve SO 2 emissions from Converter operations that will provide confidence to achieve the new ground level concentration limit of 75 ppb on a 1-hour average. Key project elements: Replace 5 converter operation with 3 larger converters, complete with controls, feed systems, ladles and tuyere punchers. Improve hooding and off gas collection system to minimize potential fugitives to achieve > 99% SO 2 fixation. Install new ESP, fans, water cooled hoods, secondary hoods and damper controls. Retrofit 1911 era building to accommodate new larger converters, ancillary equipment and install a roof canopy system for tertiary ventilation. Upgrade plant infrastructure to include; blast air blowers, compressed air, cooling towers, electrical substation. Existing Converter Aisle Total estimated project cost: ~ $110 Million Conceptual Engineering 2010 Basic Engineering Detailed Engineering Construction Phases Project approach and role Overall EPCM

3 Anode Furnace Off-Gas system Client: ASARCO Location: Hayden, Arizona Engineering, Design and Construction Management of a new Anode furnace off-gas system.. Design Includes: Installation of exhaust port on furnace shell. Pneumatic operated mouth cover. Refractory lined primary off gas hood. Retrofit existing building to accept refractory ductwork Spray cooling system 115,000 scfm baghouse with 700 HP fan and motor Arc flash resistant starter, PLC controls and instrumentation. Before project Conceptual Engineering 2010 Detail Engineering 2011 Construction and start up CAPEX: $9.3 M After Commissioing

4 Anode Furnace Off-Gas system Client: ASARCO Location: Hayden, Arizona Engineering, Design and Construction Management of a new Anode furnace off-gas system.. Benefits realized: Control of visible emissions from Anode furnace. Reduction of heat released to Anode furnace building Improved control and decreased reduction cycle time. Estimated 25-30% reduction in Natural Gas usage. Improved housekeeping and work environment Project Outcome Project completed in 10 months after receipt of order. (ARO) Actual Cost controlled within 10% of preliminary budget. 0 Reported accidents or incidents. Project installed with no interruption to operations. Commissioning and start up period of 2 weeks. Anode Furnace New Off-Gas System

5 Anode Furnace Off-Gas system Client: Mexicana de Cobre Location: La Caridad, Mexico Conceptual and Basic Engineering of a new anode furnace off-gas system Design Includes: Installation of exhaust port on furnace shell. Pneumatic operated mouth cover. Refractory lined primary off gas hood. Spray cooling system 345,000 m3/hr baghouse with ID fan and motor Arc flash resistant starter, PLC controls and instrumentation. Conceptual Engineering 2012 Basic Engineering 2014 Basic Engineering Layout

6 Electric Smelting Furnace Off-Gas System Design Client: PT-Inco Location: Indonesia Preliminary and Detail Design and Commissioning of a New Off-Gas System for 4 Electric Smelting Furnaces. Primary and Secondary Fume Collection Design New 375,000 ACFM Baghouse for EF1, EF2, and EF3 ESP to 250,000 ACFM Baghouse Conversion for EF4 Detail Engineering - Process, mechanical, civil/structural and electrical/instrumentation Equipment Sizing, Specification Preparation, and Bid Evaluation Total Drawings: Over 300 Commissioning and Performance Testing EF3 Commissioning April 2005 EF4 Commissioning February 2007 EF1 & 2 Commissioning Summer 2007 New EF3 Baghouse System

7 Rotary Kilns 1-3 Upgrade Study Client: PT Vale Location: Indonesia Scoping Study to Upgrade Kiln 1-3 off-gas systems. System capacity increase evaluation Evaluate options for providing increased capacity and improved dust removal performance: Scrubber vs. ESP vs Baghouse Dedicated or common gas cleaning equipment Size units for additional or total capacity Scoping Study March 2006 New Rotary Kiln ESP System

8 Smelter ESP Audit Client: PT Vale Location: Indonesia Inspection and audit of all existing ESPs at smelter Physical internal inspection of each ESP Mechanical Structural Electrical Review of original design and current operating conditions Recommendations to improve ESP condition and performance ESP Audit February 2008 ESP

9 Rotary Kiln 4 Off-Gas Upgrade Study and Basic Design Client: PT Vale Location: Indonesia Conceptual Study and Basic Engineering to Upgrade Kiln 4 ESP system to meet 50 mg/nm 3. System capacity increase evaluation Evaluate impact of multiple fuel and reductant options Evaluate options for providing increased capacity and improved dust removal performance: Modify or replace existing multiclone Modify or replace existing ESP Build in current location or adjacent Scoping Study September 2013 Basic Design December 2013 New Rotary Kiln ESP System

10 Rotary Kiln 1 Off-Gas 2 nd Scrubber Addition Client: BHP Billiton Cerro Matoso Location: Colombia Conceptual Study, Basic and Detailed Engineering to Upgrade Kiln 1 off-gas system capacity by adding a 2 nd wet scrubber. System capacity increase evaluation Evaluate options for providing increased capacity and improved dust removal performance: Modify or replace existing scrubber Addition of 2 nd scrubber Conceptual Study April 1998 Basic/Detailed Engineering February 2000 New Rotary Kiln 2 nd Scrubber System

11 Electric Smelting Furnace Off-Gas System Design Client: BHP Billiton - Cerro Matoso Location: Colombia Preliminary and Basic Engineering of a New Off-Gas System for Electric Smelting Furnace #1 and #2. Primary and Secondary Fume Collection Design Double capacity of existing secondary baghouse Primary and secondary gases to expanded secondary baghouse Basic Engineering - Process, mechanical, and civil/structural Equipment Sizing, Specification Preparation, and Bid Evaluation Commissioning and Performance Testing Preliminary Engineering EF#2 March 2006 Gas Analysis Testing EF#2 June 2006 Basic Engineering EF#2 June 2007 Commissioning EF#2 Aug 2008 Basic Engineering EF#1 Aug 2009 Detail Engineering EF#1 Dec 2010 New Spray Chamber and Air-to-Gas Heat Exchanger

12 Electric Smelting Furnace Off-Gas System Design Client: Xstrata Nickel Location: Dominican Republic Preliminary and Detail Design and Commissioning of a New Off-Gas System for 2 Electric Smelting Furnaces. Primary and Secondary Fume Collection Design Two 124,000 ACFM Pulse Jet Baghouse 1 Relocated Baghouse and 1 New Baghouse Detail Engineering - Process, mechanical, and civil/structural Equipment Sizing, Specification Preparation, and Bid Evaluation Total Drawings: 50 Commissioning and Performance Testing Relocated Baghouse in Operation Basic Engineering May 1998 Detail Engineering May 2002 Startup July 2005 Hot Commissioning July 2005 New Baghouse During Construction

13 Process Gas Handling System and Evaluation Client: Mexicana de Cobre La Caridad Location: Sonora, Mexico Preliminary Engineering: Evaluation of Teniente and CPS converter gas handling system CFD analysis to develop recommendations to improve gas mixing prior to acid plant and reduce the pressure drop Pressure loss modeling of the existing off-gas system Develop recommendations for the following: Improve Teniente and CPS primary hood performance Reduce system infiltration Improve acid plants performance Preliminary Study 2012 Primary Off-Gas System Pressure Loss Model

14 Smelter Air Emissions Reduction Scoping Study Client: Vale Inco Copper Cliff Location: Copper Cliff, Ontario Canada Scoping Study for Reducing Overall Smelter SO 2, Particulate, and Metals Emissions Project Work Includes: Define existing emissions rates from each process Evaluate capabilities of existing off-gas systems Evaluate alternative converting technologies Evaluate various SO 2 removal technologies Scrubbing Acid Plant Liquid SO 2 Plant Develop options to improve emissions capture from: Flash furnaces Bulk converters Roasters MK Melter MPV s Anode Furnaces Order-of-Magnitude capital cost estimates for each option Benchmarking of gas cleaning and converting technologies at multiple smelters around the world Conceptual Study August 2007 Benchmarking Study October 2007

15 New Converter Secondary Hood Design Client: Vale-Inco Copper Cliff Location: Ontario, Canada Preliminary and Detail Design and Commissioning of a New Primary and Secondary Hood for a Bulk Converter. Primary Water-Cooled Hood Design Secondary Off-Gas Hood Design 150,000 ACFM exhaust rate Retractable door used for access to charging mouth Detail Engineering - Process, mechanical, civil/structural and electrical/instrumentation Computational Fluid Dynamic (CFD) Modeling Determination of required flow rate Optimize hood configuration for best capture Evaluate performance of hood design and predict percent capture Commissioning and Performance Testing Basic Engineering 2005 Detail Engineering 2006 Startup 2007 Converter Secondary Hood Configuration During Charging Operation

16 Existing Smelter Primary Off-Gas System Study Client: Lonmin Platinum Location: South Africa Study of Existing Smelter Primary Off-Gas System Project Work Includes: Evaluation of existing system design and performance Develop options to: Improve emission capture Improve system capacity Improve performance of particulate and SO 2 scrubbing Recommendations include: Install draft control on individual furnaces and converters Remove cyclone and mixing box from system Modify fan impeller design to reduce buildup Install ESP on converter off-gas Increase venturi scrubber pressure drop Improve ph control and liquid-to-gas ratio on SO 2 scrubber System Optimization Study May 2007

17 Concentrate Spray Dryer Emissions Control Client: BHP Billiton Kalgoorlie Nickel Location: Kambalda, Australia Study to Improve Particulate Collection and Odor Control from Existing Concentrate Spray Dryer Off-Gas Systems Project Work Includes: Evaluation of existing system design and performance and establish existing particulate emissions rates and odorous constituents Develop options to: Improve emission capture Improve scrubbing performance for SO 2,H 2 S and VOCs Provided conceptual drawings and cost estimate Recommendations include: New higher efficiency cyclones/multiclones I.D. fan improvements Existing gas scrubber upgrades Increase venturi scrubber pressure drop Improve ph control and liquid-to-gas ratio on SO 2 scrubber Scoping Study Aug 2007 Basic Engineering Asst. Nov 2007

18 Existing Smelter Secondary Emissions Reduction Study Client: Lonmin Platinum Location: South Africa Conceptual Study to Provide Capture and Cleaning of Secondary Emissions Sources Project Work Includes: CFD modeling of Converter secondary hood conceptual design Furnace taphole hood conceptual design Define exhaust rate requirements for each activity at each source Define system capacity and gas cleaning requirements Recommendations include installation of: Converter secondary hoods Furnace taphole hoods and ladle hood Baghouse for particulate removal SO 2 scrubber for SO 2 removal Conceptual Study May 2007

19 Atlantic Copper Smelter Fugitive Emissions Reduction Study Client: Atlantic Copper Location: Spain Engineering Study: Conduct smelter roofline SO2 emissions testing Collect and process operating data and emissions data Identify and analyze high priority SO2 emissions sources from the smelter Identify the available options and evaluate the most suitable solution to address SO2 emissions from the sources identified Provide recommendations and develop implementation plan to effectively reduce SO2 fugitive emissions from the smelter Engineering Study Present Roofline Emissions Testing

20 FF and Converter Primary Off-Gas Handling System Review Client: Atlantic Copper Location: Huelva, Spain Evaluation and Optimization of Flash Furnace and Converter Primary Off-Gas System. Review Off-Gas System Design and Performance Identify Weak Points and Potential Improvements System Air Infiltration Flow Distribution Improve Hot ESP Efficiency Improve Wet ESP Efficiency Develop an Order-of-Magnitude Capital Cost Estimate, Operating Cost Estimate, and Implementation Plan for the Most Practical Modification Options Optimization Study Completed November 2005

21 Smelter Fugitive Emission Reduction Evaluation Client: Atlantic Copper Location: Huelva, Spain Preliminary Engineering for Converter Secondary Off-Gas System. Converter Secondary Hood Design Retractable Secondary Hood Retractable Secondary Hood with Canopy Hood (Recommended) Secondary Off-Gas System 400,000 ACFM Baghouse SO 2 Scrubbing System Preliminary Engineering March 2001 Retractable Secondary Hood Option Retractable Secondary Hood with Canopy Option

22 New 4LTPA Smelter Expansion Client: Sterlite Copper Location: India Basic and Detailed Engineering for new 400,000 TPA Smelter Expansion Including Peirce Smith Converter and Anode Vessel Design, Converter Primary and Secondary Hood Design, and Anode Matte Tap Hood Design New P.S. Converter and Anode Vessel Design Converter Primary and Secondary Hood Design Detail Engineering Process, mechanical, civil/structural and electrical/instrumentation Equipment Sizing, Specification Preparation, and Bid Evaluation Total Drawings: 110 Basic Engineering July 2010 Detail Engineering December 2010

23 Smelter Secondary Off-Gas System Design Client: Sterlite Copper Location: Tuticorin, India Basic Engineering with Detail Design and Commissioning Assistance of a New Primary and Secondary Converter Hoods and Off-Gas System. Secondary Off-Gas System Retractable Secondary Hoods for three converters 150,000 ACFM Secondary Hood exhaust rate per Converter Lime Scrubber (By others) Detail Engineering - Process, mechanical, civil/structural and electrical/instrumentation Computational Fluid Dynamic (CFD) Modeling Determination of required flow rate Optimize hood configuration for best capture Evaluate performance of hood design and predict percent capture Predicted capture efficiency of 94% at design exhaust rate Converter Secondary Hood Configuration During Pouring Operation Basic Engineering January-April 2001 Startup & Commissioning December 2001 Converter Secondary Hood Configuration During Charging Operation

24 FSF and FCF Secondary Gas Collection System Study Client: Kennecott Utah Copper (KUCC) Location: Salt Lake City, Utah Conceptual Study for FSF and FCF Secondary Gas Collection Project Work Includes: Field measurements and evaluation of existing system Develop options to: Improve emission capture Provide dust as well as SO 2 control Reduce worker exposure to pollutants Order-of-Magnitude (±30%) capital cost estimate and operating cost estimates Recommendations include: Increase system capacity with installation of new baghouse and SO 2 scrubber Provide damper control to optimize system performance Re-design local hoods to improve fume capture Conceptual Study February 2008 Basic Engineering May 2009

25 Granulation System Off-Gas System Design Client: Kennecott Utah Copper (KUCC) Location: Salt Lake City, Utah Feasibility Study for New Granulator Off-Gas System Project Work Includes: Field measurements and evaluation of existing system Develop options to: Improve emission capture Provide dust as well as SO 2 and H 2 S control Reduce maintenance requirements Budgetary (±15%) capital cost estimate along with operating cost estimates Recommendations include Dedicated system for each granulator Close coupled scrubbing system to minimize dirty side ductwork 2 stage system with venturi for particulate removal and packed bed tower for gas scrubbing Feasibility Study July 2006

26 Flash Furnace Fume Control System Client: Kennecott Utah Copper Location: Magna, Utah Conceptual Engineering Over Four Areas of the Copper Smelting Operation: FCF Fume Control System 8,000 ACFM Tapping Hoods Install New Blister and Slag Tapping Hoods FSF Slag Pot Tunnel Ventilation Improvements Recommended Installation of Rubberized Roll-up Door Recommended Slag Pot Hood Exhaust Rate of 60,000 ACFM Secondary Gas Collection System Baghouse Matte and Slag Granulation Off-Gas Cleaning Conceptual Engineering May 2001 Proposed Tapping Hood

27 Kiln Off-Gas System Preliminary Engineering Client: Lynas Location: Malaysia Define off-gas system capacity and technology requirements for new kiln and acid mixer off-gas systems. Review preliminary system design provided by vendor Quantify expected system performance and emission rates Identify Improvements in technology selection and equipment design Gas cleaning requirements include: Wet particulate scrubbing SO 2 scrubbing Wet ESP for acid mist removal Emergency vent scrubbing Develop an order-of-magnitude capital cost estimate for recommended system design Preliminary Engineering February 2008

28 Xstrata Nickel Converter Fugitive Emissions Reduction Conceptual Engineering Client: Xstrata Nickel Location: Sudbury, Canada Conceptual engineering of new converter aisle fugitive emissions collection system. Project Work Includes: Ventilation Survey and Plume Analysis Relate Emissions to Converter Aisle Activities Converter Secondary Hood Design Combined primary + secondary hood for slag cleaning converter Separate secondary hoods for other vessels CFD modeling of converter secondary hoods Collection of other fugitive emissions Endwall slag tapping launder Slag pot fill area Recommendations 163,000 Nm3/hr Charging Exhaust Rate 131,000 Nm3/hr Tapping Exhaust Rate 620,000 Nm3/hr Baghouse Capacity (4 operating vessels) Capital Cost Estimate: $36 million CFD Modeling of Hood Concept Conceptual Engineering January Monovent Temperatures Along Length Of Aisle

29 Xstrata Copper Anode Furnace Arsenic Emissions Reduction Client: Xstrata Copper Location: Rouyn, Canada Anode Furnace Secondary Hooding Basic Engineering Project Work Includes: Smelter Ventilation Survey and Plume Analysis Relate Arsenic Emissions to Anode Furnace and Converter Operations Secondary Hooding for vessels: Anode Furnaces #5 and #7 Anode Furnace #6 Converter #7 CFD Modeling of Anode Furnace Secondary Hoods To Determine Required Flow Rate To Optimize Hood Design For Best Capture Recommendations In Progress Basic Engineering June 2007

30 Lead & Copper Client: Xstrata Copper ; Xstrata Zinc Location: Mt. Isa, Australia Scoping Study for Reduction of Stack Emissions of SO 2 and Lead. Goal is to Achieve >95% SO 2 Capture and Treatment. Design Includes: Measure and Define Emissions Rates from Each Process Evaluate Capabilities of Existing Off-Gas Systems Benchmarking of Emissions Standards for Various Worldwide Emissions Agencies and Rates for Similar Smelting Operations Evaluate Various Dust Capture and Gas Cleaning Options to Reduce Lead Emissions: Existing Baghouse Modifications Scrubbers ESPs Evaluate Various SO 2 Removal Options and Technologies: Acid Plant Tail Gas Treatment Scrubbing Acid Plant Liquid SO 2 Plant Order-of-Magnitude Capital Cost Estimate for Each Option Scoping Study July 2007 Pre-Feasibility Study August 2008

31 Copper Study Client: Mexicana de Cobre Location: La Caridad, Nacozari, Mexico Scoping Study for Reduction of Roofline and Stack Emissions of SO 2 and particulate. Study Included: Measure and Define Roofline and Stack Emissions Rates from Each Process Identify high-priority areas to address emissions Develop conceptual options for reducing emissions from high-priority areas improved hood design ductwork modifications system capacity upgrades optimize control strategy and flow distribution install new dry or wet SO 2 scrubbing technologies install new baghouse Benchmarking of Emissions Rates for Similar Smelting Operations Order-of-Magnitude Capital Cost Estimate for Each Option 5-year plan development for staged implementation Testing and Study August 2014

32 Smelter Secondary Off-Gas System Design Client: Aurubis Pirdop Location: Bulgaria Preliminary and Detail Design of a New Secondary Off-Gas System for Copper Smelter. Existing Copper Converter Secondary Hood Evaluation Retractable hood to collect skimming and pouring Predicted efficiency: 90% During skimming and pouring 30% During charging New Converter Secondary Off-Gas System Design New 400,000 ACFM Baghouse Lime Scrubber Detail Engineering - Process, mechanical, civil/structural and electrical/instrumentation Converter Secondary Hood CFD Modeling Determine optimal canopy hood location and geometry Determine exhaust rate required to capture the converter charging fumes Predicted efficiency over 90% for charging operation with 200,000 ACFM exhaust rate Basic Engineering January-March 2006 Overall Off-Gas System Layout

33 Electric Smelting Furnace Off-Gas System Debottlenecking and Capacity Study Client: BHP Billiton - Olympic Dam Location: Roxby Downs, Australia Scoping Study to Evaluate the Existing ESF Off-Gas System Performance and Limitations to Accommodate a Potential Production Increase Established ESF Off-Gas Collection Requirements. Identified Existing System Limitations. Review the Existing System Performance. Furnace Ingress Air Requirements for Post Combustion Gas/Particulate Cooling Method Ductwork Buildup Off-Gas Fan and Scrubber Performance Recommendations Included: Alternate Gas/Particulate Cooling Methods Ductwork Modifications to Increase Gas Velocities New Higher Capacity Off-Gas Fan Provide Additional Recommendations Required for Capacity Increase Preliminary Engineering February 2008 ESF Particulate Cooler Modifications

34 Fume Collection System Evaluation Client: BHP Billiton - Olympic Dam Location: Roxby Downs, Australia Fume Collection System Evaluation. Review the Existing System Performance. Existing Tapping Hood Exhaust Rates are Too Low. Existing Slag Pot Hoods are Too Far Away from Fume Source. Identify the Existing System Limitations. Discuss the Potential Modifications to Improve System Performance. Evaluated the Possibility of Using Natural Ventilation for the Slag Pot Hoods. Determined Required Flow for All Hoods. Provide an Action Plan to Reduce Dust Levels. Provide Conceptual Hood Arrangements for Tapping Hoods and Slag Pot Hoods. Existing Flash Furnace/Tapping Hoods Preliminary Engineering December 2004 Recommended Modifications

35 Refinery Ventilation System Evaluation Client: Teck Trail Operations Location: Trail, BC Evaluate Performance of the Silver Refinery Fume Collection System to Minimize Fugitive Emissions and Optimize Flow Distribution. Evaluate Draft Requirements for Existing Hoods on Refinery Slag Fuming Furnace, Converters, and Pots Evaluate New Hood Design for Slimes Conveyor and SFF Tapping Emissions Fathom Ductwork Modeling to Optimize Damper Control Logic and Flow Distribution Evaluate Impact of Modifications on Gas Cleaning Equipment (Scrubber, Baghouse, and Fans) Implementation Plan and Order-of-Magnitude Cost Estimate for Recommendations Slag Fuming Furnace Enclosure with Tapping Hoods Prefeasibility Study April 2003 Bottom Blown Oxygen Converter (BBOC) Hood Tapping Operations

36 Smelter Fugitive Emission Reduction Study Client: Freeport MacMoRan Location: Miami, Arizona Conceptual Study to Review Options to Meet New Ambient SO 2 Standards Study Includes: Evaluate alternative solutions to ensure compliance with new ambient SO2 standards Evaluated Options Include: Process changes Aisle layout modifications Converter secondary and/or tertiary hooding Anode furnace off-gas system options Process gas system handling improvements Acid plant improvements ISASMELT and electric furnace secondary gas system improvements Building enclosure and ventilation Study Complete August 2012

37 Process Gas Handling System Upgrade Detail Design Client: Freeport MacMoRan Location: Miami, Arizona Engineering and Design of Upgrades to the Converter Off- Gas System and Acid Plant Gas Cleaning Section Design Includes: Replacing Air-to-Gas Coolers with Evaporative Cooling (30,000 SCFM per converter) Replacing Venturi Scrubbers with Used Radial Flow Scrubbers (140,000 SCFM) Replacing Star Coolers with Packed Gas Cooling Tower (140,000 SCFM) Installing new 9,500 gpm water cooling tower Installing new electrical substations and MCCs Detail Engineering 2006 CAPEX: $9M

38 Converter Mouth Cover Design Client: Freeport MacMoRan Location: Miami, Arizona Detail Engineering of New Hoboken Converter Mouth Cover and a Performance Evaluation of an Air-to-Gas Heat Exchanger. Developed new mouth cover for Hoboken Converter to: Decrease off-gas flow rate Increase SO 2 Strength Increase off-gas temperature Allow for additional converter capacity Evaluated performance of air-to-gas off-gas cooler Detail Engineering 2005

39 Tenby10 Project Feasibility Studies Sinter Plant and Slag Fuming Plant Client: Nyrstar Port Pirie Smelter (NPPS) Location: Port Pirie, South Australia Feasibility Study for Sinter Plant Venturi Scrubber System Feasibility Study for Proportioning Plant Ventilation System Feasibility Study for Slag Fuming Plant Major Capacity Increase Project Work Includes: Field measurements and evaluation of existing systems in Sinter Plant and Slag Fuming Plant Develop options to: Reduce lead dust emissions from Sinter Plant conveyors, transfer points and mixing tables Reduce lead dust emissions from Proportioning Plant conveyors, shuttles and transfer points Increase Slag Fuming gas train capacity including reduction of fume emissions and H 2 S control. Capital cost estimates (±50% & ±30% as requested) along with operating cost estimates Recommendations include Installation of cartridge filters on Proportioning Plant bins Upgrade of Sinter Plant venturi scrubber system including new collection points, conveyor covers and venturi scrubbers Strategy for gas train capacity increase including various ductwork modifications, replacement of stack fan and stack Sinter Plant Feasibility Study July 2007 Proportioning Plant Feasibility Study August 2007 Slag Fuming Plant Feasibility Study July 2007

40 Measurement of Smelter Roofline SO 2 and Particulate Emissions Client: Freeport MacMoRan Location: Miami, Arizona Conducted a Field Survey at the Phelps Dodge Smelter in Miami, Arizona. WPGCT Coordinated Air Testing at Several Locations in the Smelter. The Objectives of the Study were as Follows: Verify the Building Ventilation Rates. Quantify the Fugitive Emissions. Relate the Fugitive Emission Rates to the Operating Activities Study Complete August 2000 Smelter Roofline Testing SO 2 Concentration

41 Chagres Smelter Development Prefeasibility Study Client: Anglo American Chagres Location: Chile Prefeasibility Study for Upgrade of Smelter Flash Furnace Primary Gas System Upgrades Flash Furnace Fugitive System Upgrades Converter Primary Gas System Upgrades New water-cooled primary hood design and CFD New Converter Secondary Gas System Design Converter and Process Gas Heat Recovery Study New Anode Furnace Off-Gas System Design Conceptual Study 2009 Prefeasibility Study 2011 New Converter Primary Hood Design CFD Modeling

42 Converter 3 and 5 Upgrades Study Client: Vale Inco Copper Cliff Location: Ontario, Canada Study for Upgrade of Primary Hoods for Bulk Converters CFD Modeling of existing hoods Preliminary Design for new water-cooled hoods Upgrades to process gas handling system Flue Improvements Study 2006 Converter 3 and 5 Study 2008 New Converter Primary Hood Design CFD Modeling

43 REVIEW OF PRIMARY OFF-GAS HANDLING SYSTEM DESIGN Client: CODELCO - EL TENIENTE Location: Chile Review and evaluate the primary gas collection system design for the Teniente converters and Peirce Smith converters including. Review of primary off-gas collection system design Review of gas handling system pressure losses and flow distribution Benchmarking of other smelters gas handling systems and control strategies Study December 2001 Recommended Hood Design

44 Hood Design and Supply Client: Codelco Caletones Location: Chile Design and Supply of a New Water-Cooled Primary Hood System for a Peirce-Smith Converter: Design new water-cooled hood for a CPS converter Optimize hood design using CFD Modeling Design of new closed loop cooling water circuit Equipment Supply includes: Water-cooled primary hood Movable Hood Door and Winch Pneumatic Back Flap Circulation pumps Heat exchanger Basic and Detail Engineering April 2013 Anticipated Start-Up November 2014 Peirce-Smith Primary Hood

45 Boiler Off-Gas System Design Review Client: Vale Inco Goro Location: New Caledonia Design Review of Boiler Off-Gas System Project Work Includes: Evaluation of existing system design Review and Comment on Key Design Features: SCR/SNCR design and configuration Duct velocities and fan design Materials of construction Particulate scrubbing requirements and design SO 2 scrubbing requirements and design Efficiency (%) % 95.00% 90.00% 85.00% 80.00% 30% at μm ΔP = 4.2 kpag 15% at μm 15% at 0.5 μm ΔP = 5.1 kpag 15% at 0.5 μm 15% at 0.25 μm ΔP = 8.1 kpag 75.00% 70.00% 65.00% Design Review October % Pressure Drop (kpag)

46 CONVERTER PRIMARY OFF-GAS MODIFICATIONS Client: BHP Copper Location: San Manuel, Arizona Improvements to four Pierce Smith converter flue dust collection to meet state guidelines for handling of hazardous waste. Re-design of #6 converter primary water-cooled hood to minimize build-up and improve dust handling. Evaluation of improvements to primary gas handling system. Preliminary engineering for flue dust handling including: Converter hood modeling and re-design Mechanical dust gather and crushing Dense phase pneumatic transfer system Concept drawings and capital cost estimate Detail Design of: #6 converter water-cooled hood Jacket thermal analysis Piping system modification Sloped hood design Study of converter off-gas handling system: CFD modeling of dust dropout Evaluation of various gas handling systems Converter Hood CFD Model. Start: August 1996 Completion: December 1997

47 Tankhouse Emissions Reduction Tankhouse Acid Mist Control Conceptual Engineering Client: BHP Billiton - Minera Escondida Location: Chile Conceptual engineering of improvements to cell house ventilation to reduce acid mist. Project Work Includes: Evaluate and Optimize Existing Process Operating Parameters and Controls Benchmark Operations with International Standards Ventilation Survey, Smoke Testing and Plume Analysis Assess Existing Cell House Ventilation and Limitations Evaluate Existing Cell Hood Design and Extraction Systems Develop CFD Evaluate existing ventilation systems Evaluate various practical alternatives to reduce acid mist concentrations Evaluate existing cell hood design Evaluate alternate hood designs Establish Ventilation Gas Cleaning/Scrubbing Requirements Recommend Staged Implementation Plant to Meet Emissions Targets Tankhouse Model Domain Predicted Tankhouse Acid Mist Concentrations Conceptual Engineering March 2011

48 Fugitive Emissions Reduction Cannington Product Stewardship Client: BHP Billiton Cannington Mines Location: Queensland, Australia Conceptual and Feasibility Engineering to Achieve Zero Fugitive Concentrate Emissions from Multiple Sources and Locations Throughout the Supply Chain from Mine to Port. Project Work Includes: Evaluation of sources including conveying systems, truck and rail loading stations, truck and rail unloading stations, ship loading systems, and storage facilities. Develop options to: Alternate modes of transportation Improvements to existing conveyors and transfer point ventilation systems New ventilation systems at rail transfer and ship loading locations Capital cost estimates (±40% & ±25% as requested) along with operating cost estimates Recommendations include Improvements to dust handling at conveyors and transfer points at mine and intermediate loading facilities Double seal concentrate in bulker bags, then containers for shipment by rail/truck New ship unloading facilities at port New ship loading system Conceptual Study May 2009 Feasibility Engineering Nov 2009

49 Fugitive Emissions Reduction Karara Iron Ore Project Client: Karara Mining Ltd Location: Western Australia Conceptual and Basic Engineering for Material Handling System Dust Control Systems for Greenfield Iron Ore Mine Project Work Includes: Development of dust control systems for crushers, screens, conveyors, transfer points, and storage facilities. Develop options to: Minimize dust emissions Minimize worker exposure to emissions in enclosed spaces Work Included: Capital cost and operating cost estimates PFDs / PIDs Major equipment specifications and data sheets Coordination of layout drawings in 3D PLANT AIR SCREEN FEED CONVEYOR 1303-CV-002 CONT CV CH-018 CV-002 HEAD CHUTE TO ATMOSPHERE 1303-DA-017 DRAFT CONTROL DAMPER 1303-DA-022 DRAFT CONTROL DAMPER 280-AE-0301-CS 400-AE-0303-CS 660-AE-0307-CS 850-AE-0311-CS VENDOR PACKAGE SUPPLY BY OTHERS SUPPLY BY OTHERS 280-AE-0302-CS 530-AE-0306-CS 530-AE-0310-CS 1050-AE-0318-CS 1350-AE-0319-CS VENDOR PACKAGE 1303-DA-018 DRAFT CONTROL DAMPER 380-AE-0304-CS 380-AE-0305-CS 1303-DA-023 DRAFT CONTROL DAMPER 1303-DC-004 SECONDARY SCREENS DUST COLLECTOR 1510-AE-0020-CS 1303-FA-004 SECONDARY SCREENS DUST COLLECTOR FAN 1630-AE-0021-CS 1303-ST-004 SECONDARY SCREENS DUST COLLECTOR STACK 1303-FE-002 SN-005 FEEDER SUPPLY BY OTHERS 1303-FE-003 SN-006 FEEDER SUPPLY BY OTHERS 1303-CH-130 SN-005 FEED CHUTE 380-AE-0308-CS 1303-DA-019 DRAFT CONTROL DAMPER 1303-CH-131 SN-006 FEED CHUTE 380-AE-0309-CS 1303-DA-024 DRAFT CONTROL DAMPER 1303-RV-004 SECONDARY SCREENS DUST COLLECTOR ROTARY VALVE SUPPLY BY OTHERS SUPPLY BY OTHERS 1303-SN-005 SIZING SCREEN 740-AE-0314-CS 1303-SN-006 SIZING SCREEN 740-AE-0317-CS Conceptual Study May 2010 Feasibility Engineering Oct CH-054 SN-005 UNDERSIZE CHUTE 1303-DA-020 DRAFT CONTROL DAMPER 560-AE-0312-CS SUPPLY BY OTHERS 490-AE-0313-CS 1303-CH-055 SN-006 UNDERSIZE CHUTE 1303-CV DA-025 DRAFT CONTROL DAMPER 560-AE-0315-CS SUPPLY BY OTHERS 490-AE-0316-CS SCREEN UNDERSIZE CONVEYOR 1303-CV-005 CONT. SECONDARY CRUSHER FEED CONVEYOR 1303-CV-003 CONT CH-043 SN-005/CV-003 TRANSFER CHUTE 1303-DA-021 DRAFT CONTROL DAMPER SUPPLY BY OTHERS 1303-CV CH-042 SN-006/CV-003 TRANSFER CHUTE 1303-DA-026 DRAFT CONTROL DAMPER SUPPLY BY OTHERS SECONDARY CRUSHER FEED CONVEYOR 1303-CV-003 CONT.

50 Fugitive Emission Capture Reduction Building Transfer Point Dust Control Client: Xstrata Nickel Location: Dominican Republic Design of dust control system for multiple conveyor and equipment pick-up points of a 12 unit shaft furnace plant. Cyclone and baghouse system for dust capture and control.

51 Fugitive Emission Capture Furnace Feed Dust Collection System Upgrade Evaluation Client: Xstrata Nickel Location: Sudbury Evaluation of a new system to collect dust from the transfer points on 11 belt conveyors and 12 bins and route the ductwork through a central dust collector. A new central baghouse, fan, ductwork, and vents replaces the 2 existing shaker type dust collectors and 8 existing bin vents. Modifications were designed to improve the dust collection efficiency at all material handling transfer points and to upgrade the baghouse system to accommodate the increased flow and reduce equipment maintenance

52 Non-Ferrous Process Technology New Electrolytic Lead Refinery Pre-Feasibility Client: Met-Mex Penoles, S.A. de. C.V. Location: Mexico Pre-Feasibility Engineering of a New Greenfield Electrolytic Lead Refinery to Treat Impure Lead and Produce a 99.99% Pure Lead Product. Project Work Includes: Develop Process Design Basis Prepare Mass and Energy Balance Determine Metal Inventories Benchmark Electrolytic Lead Refineries with Similar Operation Develop Environmental Control Philosophy Define Utility and Infrastructure Requirements Establish Major Equipment Components, Sizing and Layouts Develop General Arrangement Drawings Establish Project Implementation Plan Determine CAPEX and OPEX at ± 30% Pre-Feasibility Engineering January 2012 Electrolytic Refinery Layout

53 Non-Ferrous Process Technology Primary Lead Smelter Technology Evaluation Client: Met-Mex Penoles, S.A. de. C.V. Location: Mexico Preliminary Engineering Study and Technology Evaluation of New Direct Lead Smelting Technologies. Project Work Includes: Benchmark Lead Smelters with Operations of New Direct Lead Smelting Technologies Develop Process Description and Design Basis for Each Technology Prepare Mass and Energy Balance Determine Type and Amount of Energy Requirements Determine Type and Amount of Reagent Requirements Calculate Metal Recoveries Determine Manpower Requirements Develop Process Block Diagrams Establish Major Equipment Components, Sizing and Layouts Define Environmental Impact Establish Project Implementation Plan Determine CAPEX and OPEX at ± 40% Preliminary Engineering March 2012 MMP Existing Lead Smelter

54 Non-Ferrous Process Technology New Lead Smelter Conceptual Engineering Client: Met-Mex Penoles, S.A. de. C.V. Location: Mexico Conceptual Engineering Study for a New Greenfield Lead Smelter to Produce 140,000 tpa Lead Bullion. Project Work Includes: Evaluate and Integrate Direct Smelting Technologies into Overall New Lead Plant Develop Balance of Plant including Pyrometallurgical and Electrometallurgical Refinery, Acid Plant, Effluent Treatment Plant, Material Handling, Co-Gen Plant, Process and Hygiene Ventilation Systems Prepare Mass and Energy Balances Develop Process Block Diagrams and Process Flow Diagrams Develop Process Description and Control Philosophy Develop Preliminary General Arrangements and Key Elevation Drawings Develop Overall Site Master Plan for Each Smelting Technology Establish Major Equipment Components, Sizing and Layouts Define Environmental Impact Establish Project Implementation Plan Determine CAPEX and OPEX at ± 25% Total Estimated Project Costs: > $750 MUSD Project Approach and Role Project Lead and Technology Integrator Conceptual Engineering 2013 MMP Existing Lead Smelter

55 Metallurgical Process Specialists SMELTER REBUILD Client: BHP Copper Location: San Manuel, Arizona Preliminary engineering and detail design of the flash furnace primary off-gas and the fugitive gas collection system upgrade. Evaluation of improvements to flash furnace emergency venting system. Detail engineering for waste heat boiler gate valve relocation. Flash Furnace Off-Gas System: Field measurements to assess the performance of the existing gas handling system Assess the limitations of the existing system to handle increase in the off-gas volume CFD modeling to predict dust dropout and pressure loss between the waste heat boiler and the ESP outlet Provide recommendations and detail design to handle extra gas volume Flash Furnace Fugitive Gas Collection System: Field measurements to quantify the existing flow conditions Assess the exhaust flow rate requirement for each emission source Provide recommendations to handle extra gas volume while minimizing capital expenditure and changes to existing system Flash Furnace Emergency Venting System: CFD modeling to review existing stack conditions and to make recommendations to improve furnace draft. WHB Emergency Gate Valve Relocation Start: August 1996 Completion: December 1997