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Copper

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COPPER

Waste heat boilers for copper smelters.

Smelting copper concentrate releases a gas at over 1,200 °C that carries dust, molten particles and the sulphur that becomes the plant's acid. Cooling it is the first job in the gas line, and it is ours.

Where the heat is

Copper is made by smelting concentrate in a flash or bath furnace. Smelting and converting both produce SO2-rich off-gas at high temperature; it is cooled in a waste heat boiler, cleaned, and sent to the sulphuric acid plant where it is recovered as a by-product. Two heat recovery stages follow each other: the smelter boiler and the acid plant’s own boiler and heat exchangers.

What the boiler has to do

  • Survive accretion, fouling and corrosion in a gas that carries molten sticky dust and sulphuric acid at the cold end
  • Keep the radiant section open
  • Drop the gas below the sticking temperature before the convective banks
  • Dislodge deposits with online cleaning systems

What we supply

  • Smelter boilers on smelter and converter off-gas: upstream converter boilers and downstream off-gas boilers
  • Multi-pass radiation-convection layout with water-cooled ducts
  • The waste heat boiler, air preheaters and gas-gas heat exchangers of the sulphuric acid plant
  • Experience on ISA smelt, flash smelting furnaces and more

Our Industrial Products

Modern Boiler Plant Under Blue Skies

Smelter Boilers

Smelter and converter boilers in water-tube construction.

Industrial Heat-Exchange Plant Under Blue Skies

Sulphuric Acid Plant WHB

The waste heat boiler of the acid plant that follows.

Industrial Heat Exchanger Structure

Air Preheaters

Steam and gas air preheaters for the acid plant and the smelter.

Waste Heat Boilers

The kiln exhaust boiler, water-tube, dust-tolerant.

AFBC Boilers

Burns plant dolochar and coal fines; hopper-bottom design.

CFBC Boilers

For larger power blocks and harder fuels.

Captive Power Plant

Kiln boiler plus AFBC into one turbine, delivered on EPC.

Thermal Systems provides efficient Converter Boilers for smelter plant in Copper Industry

  • Experience on ISA Smelt, Flash Smelting Furnace and more

  • 3 Pass Uptake – Downtake – Convection Section Design

  • Water cooled horizontal duct design

  • Upstream Converter Boilers & Downstream Offgas Boilers

  • Online hammering / rapping mechanism for high dust removal

  • Gas – Gas Heat Exchangers – Shop / Site Assembled

India’s only Boiler Manufacturer with successful installations on various types of copper smelters.

DOWNLOAD BROCHURE

Copper Smelters

Smelted metals can be used in a variety of applications, depending on their properties and the desired end product. For example

Copper smelted from copper ore is used in electrical wiring, plumbing, and other applications that require a high-conductivity metal.

Heat Exchanger | Pre Heating Units

For copper smelters, Thermal Systems supplies waste heat recovery boilers (WHRB) on smelter and converter off-gases — 3 Pass Uptake–Downtake–Convection design with water-cooled ducts and online rapping.

For the acid plant section, Thermal Systems supplies gas–gas heat exchangers and pre-heating units, shop- or site-assembled.

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