Smelter roaster and refinery
Audit and Diagnosis
When a process stops responding as it should, the answer lies in the data.
In a smelter or refinery, symptoms rarely point to the cause of an issue.
A drop in white metal grade, high copper in slag, or visible emissions at the converter mouth can each have very different origins: concentrate composition, oxygen balance, refractory wear, or insufficient gas capture.
Intervening without a diagnosis means committing budget and downtime to a hypothesis.
What we do
We integrate with the plant’s technical team as a specialist counterpart. We carry out process audits focused on the gas cleaning train, the downstream sulfuric acid plant, and fugitive emissions, identifying root cause, not the visible symptom.
Our protocol includes
- Review of historical data: SO2 concentration, mass and energy balance, white metal grade, and slag grade
- Technical inspection of the gas cleaning train: electrostatic precipitators, scrubbers, and cooling towers
- Inventory and quantification of fugitive emissions at furnace and converter mouths
- Performance evaluation of wet electrostatic precipitators
- Non-destructive testing where equipment integrity is in question
- Technical report with root cause, risk ranking, and prioritised recommendations
The result: technical clarity before committing budget or downtime.
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Start technical inquiry TopAdvisory and Consulting
Knowing what to do is just as important as understanding what is happening.
Making intervention decisions in a plant requires specific process expertise.
Identifying the problem is not enough. You need to understand the operational consequences of each option before committing to one.
What we do
We act as a specialist technical counterpart throughout the decision-making process.
We translate available information into concrete recommendations, prioritised by operational impact and implementation feasibility.
Our scope includes
- Technical interpretation of audit results and non-destructive testing
- Evaluation of intervention alternatives with associated risk analysis
- Technical criteria for equipment and technology selection for the gas cleaning train
- Support in defining the scope of planned shutdowns
- Coordination with technology suppliers where the solution requires specialised equipment
The result: a clear, unambiguous technical roadmap your team can execute with confidence.
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Systems and Process Engineering
Every intervention is an opportunity to improve the system.
Gas capture and cleaning systems are as critical as the furnace or converter.
A poorly specified or undersized gas cleaning train compromises the downstream sulfuric acid plant, regulatory compliance, and the operational continuity of the entire facility.
What we do
We develop engineering solutions for the gas cleaning train and the sulfuric acid plant, with the rigour required by a continuous, high-criticality process.
Every decision is backed by calculation and process experience.
Our scope includes
- Detail engineering for replacement or modification of wet electrostatic precipitators and gas scrubbers
- Technical specification of fugitive emission capture systems at furnace and converter mouths
- SO₂ fugitive emission inventory and benchmarking studies
- Review of thermal and mass balances for the gas cleaning train
- Basic and detail engineering for sulfuric acid plants
- Technical coordination with technology manufacturers and suppliers
- Verification of regulatory compliance for SO₂ and SO₃ emissions
The result: an executable, documented engineering solution aligned with the operational and regulatory requirements of the smelter.
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Start technical inquiry TopTechnologies and Equipment
Technology selection is not a purchasing decision. It is an engineering decision.
The gas cleaning train determines the quality of gas reaching the sulfuric acid plant, regulatory compliance, and operational safety.
An undersized precipitator, a poorly specified scrubber, or an insufficient monitoring system compromises everything downstream.
What we do
We integrate world-class technology into the specific context of each smelter, specifying every solution based on process and engineering requirements, not a catalogue.
Available technologies and equipment
- Daltec: high-efficiency process blowers for metallurgical gases
- Durr Megtec: wet electrostatic precipitators for acid mist and fine particulate capture
- Ecosystems Europe: gas scrubbers and emissions control systems
- Ohio Lumex: dew point sensors for corrosion control in the gas cleaning train
- Sensia: SO₂, hydrocarbon, and VOC fugitive emission monitoring at furnace and converter mouths
The result: precisely specified equipment, backed by process engineering and post-installation technical support.
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Consumables and Spare Parts
Managing critical consumables and spare parts is not a procurement function, it is a reliability function.
In smelters, we cover the gas cleaning train and the downstream sulfuric acid plant.
For equipment specific to the furnace and converter, refractories, tuyeres, and flux, we work with each client’s specialised suppliers.
What we do
We advise on the identification, specification, and procurement of critical consumables for the gas cleaning train and the associated sulfuric acid plant.
Available consumables and spare parts
- Internal elements and spare parts for wet electrostatic precipitators
- Filter elements for gas scrubbers and emissions control systems
- SO2, hydrocarbon, and VOC fugitive emission sensors
- Dew point sensors for corrosion control in the gas cleaning train
- Catalyst, ceramic packing, and tower internals for the sulfuric acid plant
- Spare parts for acid piping and distribution systems
The result: correctly specified consumables for the gas cleaning train, procured on time, without compromising operational continuity.
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