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Outotec® Ausmelt TSL ProcessThe Outotec® Ausmelt TSL Process is an efficient, We have the world’s leading smelting technology environmentally flexible portfolio which includes the Outotec® Ausmelt TSL pyrometallurgical process for treating a wide range of Process, the Outotec® Flash Smelting Process, the feed materials: Outotec® Kaldo Process and other complementary nn copper, nickel, lead, tin and polymetallic offerings. This extensive array of technologies and concentrates expertise ensures you receive not only the best possible nn copper and lead secondaries solution, but one that is tailored to match your specific nn zinc bearing residues requirements. friendly and highly nn various waste materials and ferrous feedstocks Feed Port reaction and primary combustion. (optional) such as feed material dissolution.002 Outotec Ausmelt TSL Process Outotec® Ausmelt TSL Process in brief Based on Top Submerged Lance (TSL) technology. the Ausmelt TSL Process has become a leading smelting technology due to its versatility.ideally suited to retrofit into constrained plant area „„ Rapid ramp up to full production Furnace Taphole . Benefits of the Patented Lance Furnace Shell Outotec Ausmelt TSL Process „„ Low investment and operating costs „„ Environmentally friendly „„ Flexibility to process a wide range of Forced Cooling feed materials (optional) „„ Compact furnace system . Critical process phenomena. take place in the intensely agitated slag layer. Outotec’s commitment to the continuous Protective Slag Coating development of the Ausmelt TSL Process . As a result. the Ausmelt TSL Process is extremely efficient with high specific smelting rates. oxygen and fuel directly into the molten slag bath via a Lance Sealing Device vertically suspended lance.ensures you receive a best practice solution. Air & Oxygen is based on injecting air. Standby Burner The Ausmelt TSL Process Fuel.in close collaboration with our customers . energy transfer. It is equally suitable for new Gas Offtake/Boiler installations and for modernization of existing smelting plants. cost effectiveness and environmental benefits. can dramatically improve a site’s environmental performance.) . the Ausmelt The addition of post combustion air with the Ausmelt TSL Process provides significant improvements in Lance Shroud System is used to maximize the recovery of occupational health and safety. residues and waste materials. Kerney. As a result. sulphides. Unlike other and heavy metal emissions from the site. International Science and Technology Conference: Lead Metallurgy – Achievements and Problems Conference. The slag does not require any downstream processing and is simply Environmental benefits of the Outotec Ausmelt TSL Process „„ Reduced offgas and SO2 emissions SO2 Emissions (t/y) before discarding.g. The Weser-Metall GmbH Nordenham lead smelter This further reduces the plant’s energy requirements is a prime example of how the Ausmelt TSL Process and minimises green house gas emissions. This modernization project. smelting technologies the Ausmelt TSL Process produces a benign slag that meets Toxicity Characteristic 12000 Leaching Procedure (TCLP) requirements. This energy may be used in other sections of the plant or for electricity generation. significantly reduced SO2 slags. is required. Dust Emissions (kg/y) granulated to vitrify and lock in metallic components 10000 8000 6000 4000 2000 „„ High strength SO2 offgas „„ Reduced energy consumption „„ Ability to treat waste materials and heavy metal residues „„ Ability to process secondary materials 0 SO2 Emissions Sinter Machine/Blast Furnce (1995) Dust Emissions Ausmelt TSL Process (2008) Emissions at Weser-Metall before and after the installation of the Ausmelt TSL Process (U. 2010 (preprint). plastics) reduces significant savings. Legnica. as a smaller offgas handling system the fuel requirements compared to alternative processes.Outotec Ausmelt TSL Process 003 Superior environmental performance The Ausmelt TSL Process is one of the most energy Outotec® Ausmelt TSL Furnaces are fully sealed and efficient smelting technologies available. In the Ausmelt operate under a slightly negative pressure to eliminate TSL Process the direct injection of fuel into the slag fugitive emissions to the environment. “The Nordenham Pb Smelter and its Challenges”. energy available in the system. the bath and ability to utilise the energy released during the lower offgas volumes and higher strength SO2 also offers oxidation of the feed (e.. which involved The Ausmelt TSL Process offers a range of process replacing an existing sinter plant/blast furnace process solutions for the treatment of various metallurgical with the Ausmelt TSL Process. In addition to these benefits. are becoming increasingly important feed sources. of feed materials including low grade concentrates. e-waste.5 millions tonnes of concentrate per year. Copper smelting and converting The Ausmelt TSL Process offers an integrated solution for copper smelting and converting or it can be coupled with existing site processes. Outotec has a strong track record of projects achieving rapid ramp-up to design capacity or even exceeding design production capacity.004 Outotec Ausmelt TSL Process Versatility of the Ausmelt TSL Process The flexibility of the Ausmelt TSL Process allows us Secondary copper to tailor a processing solution to suit your specific requirements. to materials complex polymetallic ores. These materials. materials with high impurity with high impurity and organic contents such as contents and secondary and industrial waste materials. producers are looking for technologies to process secondary copper materials. through to high grade metallic scrap. The Ausmelt TSL Process has been widely adopted in commercial operations and successfully implemented worldwide. For copper smelting the Ausmelt TSL Process has been installed in relatively small operations through to large scale operations processing in excess of 1. ranging from low grade slags and residues. concentrates and pressure for sustainable development. The Ausmelt TSL Furnace can process copper concentrates with a wide range of copper contents and high impurities contents. This versatility. combined with Outotec’s With increasing competition for high grade primary extensive metallurgical knowledge and experience. which are often problematic for conventional smelting technologies. enables us to deliver an optimized plant design. . The Ausmelt TSL Process The Ausmelt TSL Process can handle a wide range is suitable for a wide range of secondary copper feeds. (Jinchang City) KCM SA (Plovdiv) Hindustan Zinc Ltd. metallic scrap. zinc bearing residues. can also be needs of this competitive market. approximately a third of the world’s tin is The Ausmelt TSL Process has been rated the BAT (Best produced with the Ausmelt TSL Process. electric arc furnace (EAF) dust and various residues. Nickel converting is also available achievable with the Ausmelt TSL Process. especially recovery can be targeted specifically using the Ausmelt lead acid batteries. Ausmelt Other TSL Furnaces can process up to 100% secondary lead materials such as lead acid batteries. PGM consistency of secondary lead materials. (Sukpo) Wuxin Copper (Urumqi) Empresa Metalurgica Vinto (Oruro) Lead MAPO Project (Seoul) Zhong Tiao Shan (Houma City) Minsur (Pisco) Votorantim Metais (Juiz de Fora) Anglo American (Bindura) Namibia Custom Smelters (Tsumeb) Rio Tinto Zimbabwe (Eiffel Flats) PGMs Anhui Tongdu Copper (Tongling City) Daye Non-ferrous (Daye) Portland Aluminium/Alcoa (Portland) Anglo Platinum (Rustenburg) Tin Ausmelt (Whyalla) Waste Treatment Not in Operation Ausmelt TSL Furnaces around the world Nickel smelting and converting Ausmelt TSL Furnaces have been designed. (Akita) Korea Zinc (Onsan) Young Poong Corp. has allowed Outotec to offer ‘off the TSL Process. for environmentally friendly technologies to process low grade concentrates and secondary materials. municipal waste incinerator ash (MWIA). treated using the Ausmelt TSL Process. The Ausmelt Available Technology) for the production of lead. to successfully process polymetallic concentrates. The Ausmelt TSL Process has also been adapted low grade slags and residues. built and Small-scale lead producers can now also benefit from operated to handle nickel concentrates with nickel the flexibility and superior environmental performance content as low as 5%. unsuitable for other processes. . Similarly. The TSL Process can be used to smelt tin concentrates or emergence of the Ausmelt TSL Process as the preferred as a fuming operation to recover tin from low grade lead smelting technology has been driven by the search concentrates or slags. (Chanderiya) Global Resource and Materials (South Korea) China Tin (Laibin) Nickel Aluminum Yunnan Tin Corporation (Gejiu City) Birla Copper (Dahej) Copper Zinc Huludao Copper Group (Huludao) Jilin Nickel Group (Panshi) Mitsui (Hachinohe) Dowa Mining Co. ferrous materials and various industrial waste materials including spent pot linings (SPL).Outotec Ausmelt TSL Process 005 HCHM (Hulunbeier) Russian Copper Company (Chelyabinsk) Weser Metall (Nordenham) Intertrust (Kurdjali) Carat-TSM (Sorsk) Chifeng Jinjian Copper Group (Chifeng) Jinchuan Nonferrous Metals Corp. The to upgrade low grade mattes before refining. concentrates with high MgO shelf’ small scale secondary lead plants to meet the levels. Tin Lead Today. Ltd. 006 Outotec Ausmelt TSL Process Complementary Outotec technologies Outotec’s technology portfolio covers the entire production chain from mine to metal. combined with our comprehensive understanding of equipment and process requirements. energy consumption and emissions. energy and water industries. processes and equipment. optimization and maintenance of existing plants. In addition to building new capacity. From conceptual studies and process development through to project implementation. Outotec can help. Outotec „„ Sulphuric acid plants „„ Automation and process control delivers technology and services for the expansion. Outotec’s technology portfolio modernization. . „„ In addition. This broad range of technology offerings and industry experience. hydrometallurgical. metal recovery. „„ Electro-refining „„ Precious metal recovery This unique ability to supply comprehensive plant „„ Slag cleaning solutions allows us to provide plant and process „„ Offgas handling guarantees for key performance measures including throughput. Outotec is dedicated to supporting you at every stage of a project lifecycle. also extends into the mineral processing. chemical. ensures you Complementary Outotec technologies „„ Smelting technologies „„ Refining receive fully integrated process solutions customized to „„ Casting your specific needs. training or ongoing technical and maintenance support. Outotec delivers solutions from spare parts procurement and support. procurement and logistics channels you will have the peace of mind of timely access to genuine parts whenever required. Total service package from Outotec: Process support services nn Troubleshooting nn Optimization nn Simulation nn Integration nn Design nn Technology transfer nn Commissioning nn Process control analysis nn Training Equipment services nn Spare parts and spare parts management nn Equipment inspections and maintenance nn Training Plant services nn Plant assessments nn Operation and maintenance support services nn Upgrades and modernizations nn Shutdown maintenance services . through to „„ Comprehensive process and equipment expertise optimization and upgrades. metallurgical processes and complete plants. Our customer plants and processes. e. customers have are seamlessly integrated into your existing operations. Outotec’s team of specialists understand the pressures of production. equipment. automation This support maximizes productivity and optimizes systems. potential for improvements. Through Outotec’s specialized manufacturing.Outotec Ausmelt TSL Process 007 Outotec services improve process performance Outotec aims to maintain long-term working partnerships Plant and process support services with its customers to ensure the full value of their operations and equipment is realized. Additionally. preventative maintenance programs. indentifies areas with the most ongoing specialist technical and maintenance support. customers can tap into the latest technological Benefits of Outotec services developments from Outotec’s extensive research and „„ Critical original spare parts in stock development programs. plant audits. project management and „„ Minimize downtime and unscheduled training. Our specialists will work with you to develop preventative maintenance programs and with regular involvement. stoppages „„ Maximum operating performance Equipment services As the original equipment manufacturer (OEM) you are assured that Outotec’s spare parts and consumables are of the highest quality and specifically designed for the application. Outotec’s global Outotec's advanced plant and process assessment tool. unparalleled access to Outotec’s broad expertise base and extensive operational experience. offer optimal availability and reliability minimizing downtime. intimate knowledge of the process demands and equipment requirements ensures that any modifications or upgrades Through these local service centres.g. network of service centres are dedicated to providing ef-X® Efficiency Explorer. Outotec has developed over decades several breakthrough technologies. Outotec develops and provides technology solutions for the sustainable use of Earth’s natural resources.outotec. . All rights reserved.com www. The company also offers innovative solutions for the chemical industry. industrial water treatment and the utilization of alternative energy sources. www. October 2011.Finland.com Copyright © 2011 Outotec Oyj. Outotec shares are listed on the NASDAQ OMX Helsinki.outotec.com info@outotec. As the global leader in minerals and metals processing technology.