References
Innovative Dust Handling Solutions for Pasar's Smelting Operations
Kopar engineered a redesign and modernisation of the dust handling system for Philippine Associated Smelting and Refining Corporation (Pasar), focusing on the area beneath and following the Waste Heat Boiler (WHB). This project showcases Kopar's technical prowess in upgrading existing systems to enhance efficiency and reliability.
About Pasar
Philippine Associated Smelting and Refining Corporation (Pasar) is the only copper smelting and refining company in the Philippines. For over three decades, Pasar has been a critical player in the country's production of high-quality copper from various global sources, contributing significantly to the local economy.
Key Technological Highlights
- Dust management: Tight structures including the sliding flange connection were designed to prevent dust spillage, crucial for maintaining a clean and safe working environment.
- Conveyor Support System: Modification of conveyor supporting from legs to suspension from the boiler, integrating it tightly with the WHB to maintain continuous and efficient operations.
- Thermal Insulation: The design considered the need for insulation to keep material temperatures above the acid dew point, thus preventing corrosion and ensuring the system's integrity over time.
- Material Selection: The performance of the equipment is greatly enhanced by selecting the right manufacturing materials. Boron steel conveyor chains ensure uninterrupted operation and extend the equipment's lifespan, which significantly enhances system availability.
Project Phases
The project began with Kopar's specialists performing an onsite assessment to understand the current setup's condition and challenges. Following this, Kopar outlined a plan including detailed recommendations for upgrading the systems.
The enhancements included optimising the number of conveyors to balance efficiency with wear reduction and integrating a new crusher to decrease the size of WHB dust and slag particles. This adjustment aimed to minimise subsequent conveyor wear.
During the initial visit, Kopar conducted precise measurements and a 3D scan of the area, enabling the design of equipment that was perfectly tailored to the site's specifications. This meticulous planning ensured seamless installation and integration to Pasar plant. Kopar's technical supervisor ensured functionality during the commissioning phase.
”As we strive to enhance our operations, Kopar's expertise in dust handling has been very valuable. Their tailored solutions and proactive service approach have improved our smelting process' efficiency."
Scope of Delivery
- Optimised Conveyor Count: The redesign included optimising the number of conveyors to balance efficiency and wearing.
- Additional Crusher: A new crusher was introduced to reduce the size of WHB dust and slag particles, thereby minimising the wear on subsequent conveyors and improving downstream pneumatic conveying efficiency.
- Tailored Equipment Design: On the initial visit, Kopar's team took precise measurements and performed a 3D scan of the area, which allowed them to design equipment that perfectly fits the site's specific requirements.
Results:
The redesign successfully eliminated the need for manual handling of hot dusts and ensured that all structures were adequately sealed to prevent dust leakages. These changes have markedly increased the system's safety and reliability, with significant reductions in downtime and maintenance requirements.
Conclusion: This project enhanced the operational aspects of Pasar's facility and established improved standards for handling high-temperature industrial dust.
"We were impressed by Kopar's customised solutions and thorough attention to our needs."
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