Operational Excellence in PS Converting at Saganoseki Smelter & Refinery

Saganoseki Smelter & Refinery is one of the largest copper producers in Japan to produce 450,000 tons of new copper annually. Saganoseki used to operate six PS converters with "4 Hot-2 Blow" scheme, but managed to change its operation to "3 Hot-2 Blow" scheme with four PS converters, while maintaining the same production capacity. To achieve the operational change, the following improvements have been carried out; 1) Extending service life from 220 to 350 batches, 2) Shortening cycle time by increasing the blowing rate and the matte grade, 3) Reducing environmental impact by applying sophisticated fugitive gas collection system and 4) Saving energy by waste heat boiler’s modifications. The operational change has been successfully executed, and results in drastic productivity increase and cost reduction. Currently, Saganoseki is maintaining the efficient and consistent operation with 4 PS converters. This paper describes the above-mentioned improvements for increasing productivity and the recent operational conditions of the PS converters.