EXTRACT FROM NEWSLETTER 2/2017 PRODUCTION OF NON-FERROUS METALS SMS group is the reliable partner to all plant operators when it comes to producing copper and other non-ferrous metals and to innovative and sustainable developments, optimizations and modernizations.
RETROSPECT OUTLOOK Non-ferrous metals or NF metals are changing the world. There is no modern industrial sector that can do without these valuable metals. Innovative solutions for the production of such metals are offered by PolyMet Solutions, a joint venture of SMS group and Mettop. The joint venture PolyMet Solutions unites two partners with innovative knowledge in the field of non-ferrous metals to the advantage and benefit of the customers. Dr. Rolf Degel, Vice President Non-ferrous Metals, SMS group Non-ferrous metals find their applications in smartphones, tablets and computers. These materials with their particular properties are the basis of our modern life. The importance of the non-ferrous metals market is reflected by two figures. In 2016, the production of non-ferrous metals was worth more than 300 billion Euros. This corresponds to 40 percent of the value of raw steel production in the same year. Hence, the NF metal industry is almost as important as the iron and steel industry. SMS group is well prepared for this huge market and for growing future challenges. A large contribution here is the new joint venture PolyMet Solutions that was founded by SMS group and Mettop, an Austrian engineering company, with the objective to develop new technical solutions and to enhance customer value. The prices of nearly all metals have come under pressure during the past few years. Therefore, competitive technologies are regarded a crucial factor to achieve success in this critical market situation respectively to stabilize the market position. PYRO- AND HYDROMETALLURGICAL SOLUTIONS FROM POLYMET SOLUTIONS The competencies of both companies converge at PolyMet Solutions (see below). The joint venture supplements the wide range of solutions of SMS group in the field of NF metals mainly through solutions concerning primary pyrometallurgical process routes that produce metals from ore concentrates. The secondary process route chiefly serves to process metals from secondary metal sources. This recycling route is eco-friendly and saves resources. Polymetallic ore is a mineral containing more than two metals. The production of copper is accompanied by extracting large volumes of precious byproducts such as gold, silver, platinum and palladium. This makes the copper industry the second largest producer of gold and silver worldwide. As a general rule, non-ferrous metals are extracted in pyrometallurgical or in hydrometallurgical processes. However, these two procedures can be combined. The joint venture enables Mettop and SMS group to offer holistic plant solutions for these process lines. PROCESS COMPETENCY The profound and detailed understanding of process sequences is a basic condition to build reliable and efficient new metallurgical plants and to optimize existing ones. The target is to provide the customers profitable, flexible, high-quality and permanently available plant solutions. PolyMet Solutions has both the know-how and the required experience. SUPPLIER OF KNOW-HOW Expert for solutions in pyrometallurgical process routes which produce metals from ore concentrates especially in the field of cooling systems to control and minimize refractory wear. PLANT AND EQUIPMENT SUPPLIER Reliable partner and success guarantor for the implementation of challenging projects for the production and processing of NF metals and ferroalloys particularly in the field of reduction furnaces and electric smelters. SUPPLIER OF COMPONENTS Development of innovative and intelligent components and technologies to find new solutions in the NF metals sector for example safe cooling systems, electrolytic processes, and concepts for furnace lining and cooling. 2 SMS group extract newsletter 02 2017
High intensity CFM cooler for metallurgical furnaces. INTELLIGENT FURNACE COOLING SYSTEMS The innovative cooling solutions of PolyMet Solutions come into play where furnaces have to stand the highest loads and stresses, for instance in areas of very high temperatures or temperature fluctuations, aggressive exhaust gases and slags, or at critical spots such as taphole areas. Custom-tailored cooling systems for furnace vessels make sure varying loads are compensated in a targeted and effective manner. The solutions offered by the joint venture include air cooling, spray cooling, cooling technologies with integrated copper elements such as CFM (Composite Furnace Modular) cooling systems, plate and finger coolers. ILTEC TECHNOLOGY We are very pleased with the joint venture, a win-win situation especially for our customers. Dr. Iris and Dr. Andreas Filzwieser, founders and managers of Mettop GmbH cooling circuit hardware for the IL-B2001 medium, cooling element layout or the required cooling performance, all is perfectly tailored to the respective application and the needs of each individual customer. The major innovation in the field of furnace cooling is the ILTEC (Ionic Liquid Cooling) Technology which paves the way for increased plant safety. This revolutionary, patented cooling technology is jointly marketed by Mettop and SMS group. It permits water-free cooling to be implemented and thus makes operation safe wherever it is applied. SAFE FURNACE COOLING The latest brochure of PolyMet Solutions is available under www.polymet-solutions.com The special ionic liquid IL-B2001 with its superior characteristics in terms of operating temperature (50 C 250 C), physical properties and, in particular, the total lack of reaction when getting in contact with liquid metal or slag, opens up a completely new way of optimizing cooling processes in metallurgical plants. However, the main idea behind ILTEC is not to replace all water-cooled areas, even if this would be possible, but to use this technology in zones where water cooling is dangerous and involves the risk of refractory material hydration or of corrosion effects due to cooling. Also with respect to heat recovery, the higher operating temperature of up to 200 C offers great benefit over previous cooling concepts using water as cooling medium. Be it engineering, closed Example of an ILTEC system. 02 2017 SMS group extract newsletter 3
RETROSPECT OUTLOOK copper scrap copper concentrates copper matte black copper smelting furnace Converter anode ca. 20-30% ca. 20-75% ca. 98-99% furnace ca. 98,5-99,5% electrolysis dross ca. 1-10% copper matte ca. 63-75% copper-slag purification furnace residuals ca. 10-15% dross ca. 5-20% dross (for road construction) ca. 0,6-0,8% copper scrap Simplified flow diagram for primary copper production (in percent Cu). PRIMARY COPPER PRODUCTION EQUIPMENT FROM ONE SOURCE The joint venture PolyMet Solutions supplies to its customers all plants for primary copper production from one source from a partner with comprehensive process know-how. The portfolio ranges from equipment for primary smelting to electrolysis with the METTOP- BRX Technology. SMELTING COPPER CONCENTRATE There are several procedures available for smelting copper concentrate. PolyMet Solutions specialized in optimizing the commonly used methods with respect to lifetime and process management. In addition, an own primary smelting method is being developed at present that will speed up reaction times inside the furnace by means of high-speed burners. whole furnace vessel. In addition there are further positive effects in the smelting process which ensure that the copper content in the cleaned slag is minimized to under 0.7 percent. SMS group also offers its customers cooling and lining concepts that increase the furnace lifetime to a multiple of conventional designs. Moreover, SMS group is working on further concepts to boost recycling rates. CONVERTING PolyConvert is a system developed by PolyMet Solutions that increases the efficiency of the conversion process and ensures significantly longer lifetimes of the furnace vessel. The key element of PolyConvert is under-bath tuyère cooling by means of a non-explosive cooling liquid (ILTEC Technology) as introduced above. This innovative solution can be used in conventional Peirce Smith converters and multiply the service life. The system can be integrated in new plants as well as existing ones. The service portfolio of SMS group also includes the revamp and maintenance of such a system. Slag cleaning furnace from SMS group. SLAG CLEANING FURNACES Ranking among the leading suppliers of slag cleaning furnaces, SMS group has developed a new generation of furnaces. In continuous operation, the novel, rectangular furnace design offers considerable advantages compared to conventional round furnaces. The electrodes are arranged side by side to ensure uniform power distribution and cover the PolyConvert with under-bath tuyère cooling. 4 SMS group extract newsletter 02 2017
RETROSPECT OUTLOOK Anode casting control system from SMS group in operation. REFINING AND CASTING Exact refining of blister copper paired with a precisely operating casting wheel increases the efficiency of plants. SMS group supplies both units as integrated solution. In the field of anode furnaces, PolyRefine is the latest development which helped implement a number of future-oriented technologies and bring them to market maturity. These technologies include new charging and deslagging systems as well as the furnace design. The result is shorter tap-to-tap times, better quality and reduced fuel consumption. Plant users will furthermore enjoy the advantage of a high degree of automation and of low emission levels. Casting wheels for copper anodes from SMS group impress with their high availability, their reliability and low operating costs. Major factors contributing to their high efficiency are automated operation and maintenance friendliness. Hence, casting wheels make anode production cost-effective and, at the same time, satisfy the market s growing demands on quality. Depending on the desired product quality, different materials may be used such as copper cathodes and copper scrap of grades 1 to 3 (for example birch/cliff). The so-called PolyRefine furnace has an extended burning zone and attains a higher smelting performance and efficiency. The stable temperature profile prevents the furnace roof from overheating. REDUCING ENERGY CONSUMPTION WITH PROX BURNER The plants are equipped with an extremely variable PROX burner. Compared to conventional fire refining furnaces, the specific energy consumption is substantially reduced. The flame length is adjustable and optimizes furnace heating. The refined liquid copper is either directly cast in the CONTIROD * line or mixed with liquid ETP copper from the shaft furnace. These plants have a capacity of up to 60 tons per hour. HIGHLY EFFICIENT INJECTORS (SIS) A further means to increase the sustainability of plants in the field of non-ferrous metals is the SIS system which was developed and patented by SMS group. It combines innovative burner and oxygen injector technologies and stands out due to high productivity and low production costs. In the SIS system, refining nozzles do not get in contact with the bath and need extremely little maintenance. They make sure the smelt is thoroughly mixed and reduce gas consumption. PolyRefine furnace of a CONTIROD * line. POLYREFINE CONTIROD * For its CONTIROD * lines, SMS group developed a new generation of fire refining furnaces. They open up the possibility of producing FRHC copper and ETP copper from copper scrap. Variable PROX burner. 02 2017 SMS group extract newsletter 5
RETROSPECT OUTLOOK Remelting Shaft furnace Induction furnace Holding furnace Drum furnace Combined processes Contirod * directube Forming and finishing Slabs/billets preheating Hot and cold rolling Milling, extrusion Cold pilgering Planetary rolling Tubes and profiles drawing Annealing Cutting/straightening/coiling Product range. ones, for continuous and semi-continuous applications, and for special alloys. INTEGRATED SOLUTION SETS BENCHMARKS METTOP-BRX Technology in operation at Brixlegg AG. ELECTROLYSIS SMS group and Mettop are currently experiencing a rising demand for innovative copper electrolysis technologies. Together with Montanwerke Brixlegg AG, Mettop developed the patented METTOP-BRX Technology. This solution provides for the fresh electrolyte to be introduced directly between each pair of electrodes. Due to this parallel flow method, the fresh electrolyte is guided in upward flow direction to the surface of the respective cathode, thus enhancing the existing flow from natural convection. Using the METTOP-BRX Technology does not impact the settlement of anode slime. The design of the parallel flow devices or of integrated cells that have already been installed will be tailored to the specific needs of each customer. Vertical continuous casters offer a maximum degree of economic efficiency and operational safety in the production of slabs or extrusion billets, for instance. Horizontal continuous casters are used to produce high-quality, cold rollable strip, extrusion billets, wire rod, tubes/pipes and bars, mainly from copper alloys. CONTIROD * lines unite melting, casting and rolling facilities to form an integrated solution. Using this perfectly harmonized configuration, customers of SMS group are setting benchmarks around the globe in the production of wire rod. In the field of tube/pipe production, too, SMS group covers the complete value chain. To produce mother tubes on a highly efficient basis, customers rely on both, directube system and extrusion. Further processing is accomplished by drawing machines. Finishing section and handling equipment complete the whole package. UNIQUE METTOP-BRX TECHNOLOGY Thanks to the improved flow behavior, the METTOP-BRX Technology permits a high current efficiency to be achieved despite a rise in current density by up to 50 percent, while cathode quality is maintained at a constantly high level or even improved. Thus, current densities of up to 420 amperes per square meter are feasible. PRODUCT RANGE FOR SMELTING, ROLLING, EXTRUDING AND DRAWING Customers engaged in the production of extrusion billets, cold rollable strip, tubes/pipes, wires, bars, rods, hollow ingots, sections, anodes as well as hot and cold rolled products benefit from the vast product range of SMS group. In the field of copper plants, SMS group is the only supplier worldwide who can cover the entire metallurgical process chain from copper smelting to the finished product. The portfolio includes different continuous casters, horizontal and vertical CONTIROD * line. The directube system of SMS group is an innovative technology that provides cost efficiency even when small or medium-size volumes are produced. The special feature characterizing directube is that the process step extruding can be completely omitted. The cathodes are cast from copper cathodes on a horizontal caster and immediately processed to mother tubes on a planetary rolling mill. Finally, the shells are processed to sellable products on further SMS group machines. *CONTIROD is a registered trademark of Aurubis Belgium 6 SMS group extract newsletter 02 2017
RECYCLING OF ELECTRONIC WASTE WITH URBANGOLD TECHNOLOGY Every year, more than 40 million tons of electronic wastes are collected. Therefore, it is no surprise that the material is a valuable source of metals. Professional recycling is not only an ecological advantage, but offers economical incentives. Domiciled in Austria, UrbanGold GmbH offers solutions for the metallurgical treatment of non-ferrous grades gained from WEEE (Waste of Electrical and Electronic Equipment) materials. In October 2016, SMS group and UrbanGold, an affiliate and spin-off company of Mettop, signed a cooperation agreement. The common objective is to market UrbanGold s technology that serves the efficient recycling of precious materials such as gold, silver, platinum, nickel and copper. More than 98 percent of these metals can completely be recovered and converted to pure metal products. Recent studies demonstrate that the payback period to the users may be less than two years. SMELTING OF LOW-GRADE MATERIALS POSSIBLE ECOPLANTS The technology for electronic waste recycling is a further contribution to the ecoplants range of SMS group. The key component of UrbanGold s technology is HENRI (High Energy Noble Reactor). It permits the smelting and recycling of so-called low-grade materials with a share of organic material of up to 50 percent. Cooling the furnace vessel with the ILTEC Technology from Mettop is a basic condition for safe process with minimized refractory wear by HENRI. Due to the low-grade materials to be smelted, gas treatment is an important aspect in UrbanGold s technology. Advanced gas cleaning solutions make sure the exhaust air will not contain any environmentally harmful substances like mercury, bromine, fluorine or chlorine. In addition to the integrated solution, UrbanGold offers a compact plant for the recycling of printed circuit boards. The smelting and refining steps are accomplished in a TBRC (Top Blown Rotary Converter) which has been standard for decades for the recycling and refining of copper scrap. The latest generation is equipped with an integrated tapping system in the side wall. This ensures slag-free metal tapping and considerably enhances process flexibility. The modular system UrbanGold Compact requires lower investment costs and may be expanded to a complete UrbanGold plant by an upgrade later on. The market for electronic waste recycling is growing fast. From a technological and, in particular, an ecological point of view, UrbanGold is the perfect answer to the growing electronic waste recycling market. Dr. Rolf Degel, Vice President Non-Ferrous Metals, SMS group 02 2017 SMS group extract newsletter 7
RETROSPECT OUTLOOK RUSSIA FIRST PLANT OF ITS KIND WORLDWIDE Aurus places order with SMS group to supply UrbanGold Compact plant for electronic waste recycling. Aurus, a company based in Moscow, Russia, has placed an order with SMS group for the supply of an UrbanGold Compact plant. The plant will be established near Moscow and process about 6,000 tons of printed circuit boards per year. It will be used to produce LME grade metals such as copper, nickel, gold, silver, and platinum. The required process was developed within the scope of a cooperation between SMS group GmbH, UrbanGold GmbH, PolyMet Solutions and Mettop. The package of SMS group comprises the supply of all components, i.e. facility for mechanical preparation of the raw materials, TBRC converter (Top Blown Rotary Converter), refining furnace (PolyRefine), casting wheel, electrolysis, gas cleaning and automation systems. SMS group will prepare the engineering, supervise erection and commissioning, and train the customer s personnel. UrbanGold, a spin-off of SMS group s joint venture partner Mettop in Austria, is responsible for the equipment design and for the metallurgical process. Mettop will supply all components needed for electrorefining. Commissioning of the plant is scheduled for 2018. With this order, SMS group has succeeded in entering a growing market with an innovative product from its portfolio. With the first plant of its kind worldwide, SMS group and UrbanGold are demonstrating their expertise in electronic waste recycling technology. For smaller volumes of electronic waste, too, both companies together offer a profitable integrated concept which allows valuable precious metals to be recovered cost-efficiently. Aurus was founded by Pik Group, a construction company, and IC VAP, a producer of ferrous and non-ferrous products. Contract signing in Moscow: Dr. Rolf Degel (left), Vice President Non-ferrous Metals, Dr. Guido Kleinschmidt (3rd from right), Member of the Managing Board, both SMS group GmbH; Vladislav Sviblov (center), Vice President Development, Pik Group, Russia; Alexander Sharuda (4th from right), General Director; Vladimir Zotov (2nd from right), Development Director, IC VAP, Russia. Flow diagram: UrbanGold Compact plant. 8 SMS group extract newsletter 02 2017
The SMS group refractory service for non-ferrous metals Using suitable refractory linings and lining concepts, plant users may reduce their operating costs and increase profitability. The appropriate lining concept considers the individual requirements of production process and furnace vessel to attain the best possible solution. In addition, plant users may resort to the fully integrated service management system of SMS group ensuring high added value over the entire operating period. The Technical Service of SMS group will of course work at the customer s site and render professional assistance for refractory linings. A copper producer in Zambia is already using the new service offer and confirms its high benefit as the company is now able to focus on its core competencies. Refractory material optimization knowledge about the efficiency of similar furnace linings worldwide refractory lining monitoring system available highly competent and experienced refractory department Refractory design process-oriented refractory design 3D engineering Refractory material supply material supply by selected approved refractory producers independent material selection material specification quality control Service on site refractory maintenance on site performance checks and reports refractory condition monitoring and reports maintenance schedules SERVICE Refractory materials warehouse contract on refractory consignment stock available warehouse management through refractory service staff on site material handling and storage building global warehouse management Refractory installation turnkey refractory change or installation effective removal of hot and cold materials dismantling and installation refractory recycling and material reuse 02 2017 SMS group extract newsletter 9
RETROSPECT OUTLOOK MOPANI COPPER MINES PLC IN ZAMBIA CONTRACTS SMS GROUP TO RENDER FULL SERVICE FOR REFRACTORY LININGS THROUGHOUT THE COMPLETE COPPER LINE SMS group and PolyMet Solutions have been awarded an order by the Zambian company Mopani Copper Lines PLC to supply the refractory lining for the consignment stock agreement for refractory on ISA Smelt, MSEF, PSC and Anode furnaces.. The customer ranks among the leading copper producers in Africa. As in addition to supply and installation, this type of maintenance contract is also aimed at optimizing the lining and cooling concepts, it opens a new chapter for the customers. Dr. Rolf Degel rolf.degel@sms-group.com Lining of an anode furnace. A CONVINCING FULL SOLUTION Mr. Sharuda, what was the main reason for you to contract SMS group for the supply of an UrbanGold Compact plant? Sharuda: We have been watching the electronic waste market in Russia for years. It is developing extremely positive, and we see good opportunities for growth. What are the crucial factors of your purchasing decision in favor of UrbanGold? Sharuda: There are several reasons that influenced our decision. The technology offers a high output and comprises tried and tested components. SMS group, together with UrbanGold, prepared a convincing full solution for us. And SMS group is enjoying high reputation in the Russian market. Alexander Sharuda, General Director, Aurus 10 SMS group extract newsletter 02 2017
Dr. Degel: SMS group and Mettop are surprised by the positive feedback from our customers in the NF metals industry. Competition among complete systems suppliers is much smaller than in the iron and steel industry. Our customers further appreciate that we are now transferring our high degree of innovation also to NF projects. From left to right: Dr. Rolf Degel, Dr. Guido Kleinschmidt (both SMS group), and Dr. Andreas Filzwieser, Mettop GmbH. INTERVIEW COOPERATION OPENS UP NEW OPPORTUNITIES TALKING WITH DR. ROLF DEGEL, DR. GUIDO KLEINSCHMIDT AND DR. ANDREAS FILZWIESER Dr. Kleinschmidt, what gave the impetus for the joint venture PolyMet Solutions? Dr. Kleinschmidt: SMS group is the leading supplier of metallurgical plants. We were looking for a suitable partner with detailed and profound knowledge in the field of non-ferrous metals to be able to offer full solutions in particular to the copper industry. We found the ideal partner in Mettop. Dr. Filzwieser, how does Mettop assess the cooperation with SMS group? Dr. Filzwieser: Right from the start, we were positive about the chances of such cooperation. SMS group perfectly harmonizes with us as we are now able to master larger projects. Our company is too small to bear the sole responsibility, and it cannot provide the required human and financial resources. What products are you focusing on? Dr. Kleinschmidt: Our customers show a rising demand for service solutions that include refractory materials and cooling concepts. The service contract with Mopani Copper Mines in Zambia is a step in the right direction. Also, the market for electronic waste recycling is growing fast, and we believe that UrbanGold s technology with its highly profitable processing of electronic waste is the right answer. An important milestone here is the Aurus project. Personally, I welcome the opportunities coming along with ILTEC Technology. It will completely redefine plant safety at SMS group for several units. Dr. Filzwieser: Moreover, we see opportunities to change metallurgical processes. The option to implement cooling underneath the smelter bath is revolutionary. We already have good ideas of how to use this system in converters, blast furnaces, coolers and tapping areas. Thanks to the wide temperature range of the ionic liquid, it makes perfect sense to install the ILTEC cooling system with energy recovery. Dr. Degel: After several years of low investments, the market for electrolytic plants to produce highest-purity copper is speeding up again. In this sector, too, SMS group is working hand in hand with Mettop to supply adequate components or turnkey plants. The advantages of the patented METTOP- BRX Technology are apparent to our customers: 50 percent production increase with the same plant size. I have not heard of a similar innovative leap in this industrial sector. What are your visions of the future? Dr. Kleinschmidt: We laid down the goal in our vision: We want to be the leading partner to the metal industry. To this end, we have to find the best solutions jointly with our customers. Our metallurgical expertise in the non-ferrous and ferroalloys sector is unique. Paired with our strengths in the design, manufacture and supply of high-quality equipment, we are convinced we can even further expand our competitiveness in this sector within short time. Dr. Filzwieser: We fully agree with these statements, and we are very confident that our company will continue to grow within the joint venture together with our strong partner SMS group. 02 2017 SMS group extract newsletter 11
HAVE A SOUND SLEEP WITH ILTEC ILTEC- Ionic Liquid Technology Some conventional water-cooled areas in metallurgical vessels are prone to explosion with dramatic consequences for the equipment as well as for the safety and health of the personnel. This for sure gives you sleepless nights. To boost the safety of your plant. To provide a safer workplace for your personnel. To help you sleep better. We listen. We learn. We deliver. Our new, revolutionary, non-explosive cooling media IL-B2001 eliminates the risks associated with furnace cooling. It prolongs the vessel lifetime and allows a complete new view on the principles of metallurgical processes. What s more, the technology is fully proven and already applied in references for the metals and non-ferrous industry. Let s add value along the entire value chain, together. SMS group GmbH Eduard-Schloemann-Strasse 4 40237 Düsseldorf, Germany Phone: +49 151 145 33688 iltec@sms-group.com Leading partner in the world of metals www.sms-group.com