Mettop Process Control and Regulation System

The Peirce Smith converter is the key metallurgical vessel in the majority of copper smelters. During the two step process, oxygen enriched air is injected through a row of tuyeres into the matte received from a primary smelting unit. Additionally, in the first step the iron content is oxidized into a fayalite slag by the addition of silica. During the second step, the remaining copper sulphide is converted into blister copper with a final sulphur content of approximately 200 ppm. The overall efficiency of this process is determined by the total reaction time, the slag quality and quantity, and the chemistry of the final blister copper. To increase the reaction kinetics during both stages, the METTOP Process Control and Regulation (MPCR) system was developed, which consists of four elements: OPC - Optical product control ACR - Automatic computer regulation GCU - Gas control unit GIS - Gas injection system The OPC system from SEMTECH records the optical spectrum emitted by the off gas flame providing immediate, detailed process information. Using this online data, additional gas can be automatically injected into the converter through a gas injection system opposite the tuyere zone. An improved oxygen distribution in the melt and the accurate determination of the process end point results in a significant reduction in the process cycle time. Furthermore, by maintaining the reaction closer to the equilibrium the final sulphur and oxygen content can be reduced compared to the conventional process. In particular, the final sulphur content can be lower than 70 ppm, eliminating the need for an oxidation step in the anode furnace.