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Full Lined Ceramic Ball Valves for Smelting of Copper Industry

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Copper that is mined from copper ore, after beneficiation, becomes high quality copper concentrate. Then, after being smelted, refined copper and copper products are yielded.

There are two main methods of smelting copper, one is pyrometallurgy, and the other is hydrometallurgical. Nowadays, the main smelting method is pyrometallurgy, which accounts for 85% in the world.

The details are as follows:

  1. Pyrometallurgy

Pyrometallurgy usually adopts original ore, in which its content can reach 20%-30% after mineral processing. Copper concentrate is put into an airtight blast furnace, reverberatory, electric furnace, or flash furnace for matte smelting. The output of molten matte is then put into the converter for converting into a blister copper, and next into another kind of reverberatory. Following oxidation refining complex or casting anodes for the purpose of electrolysis, electrolytic copper with grade of up to 99.9% is finally produced. The process is short and with strong adaptability, and copper recovery rates can reach 95%. However, because sulfur escapes as waste gas, and is not easy to recycle, pollution can easily result. In recent years, more and more pyrometallurgy methods have been developed,such as the silver method, Noranda process, Japan’s mitsubishi process etc.

Source: Metals: Scarce: Base – Copper Production: Ore Processing: Sulfide Ore- Smelting

    2. Hydrometallurgy

Hydrometallurgy is usually suitable for low grade copper oxide, and the product of refined copper is called electrolytic copper. Modern hydrometallurgy methods usually can be separated as: the sulfating roasting- leaching- electrodeposition method; leaching- extraction- electrodeposition method; and bacterial leaching method. These methods are suitable for leaching of low grade complex ore, copper oxide ore, dump leaching contained waste copper ore, selection of tank leaching or in situ leaching. This smelting technology is gradually advancing, and is predicted to reach 20% of total output at the end of this century. Adopting hydrometallurgy will greatly reduce smelting costs.

Characteristics and comparisons of the above two methods

(1) Equipment for the latter method is simpler, but the impurity content is greater.

(2) The latter method is subject to limitations in the grade of ore and types.

(3) The cost of the former process is higher than the latter.

According to the above, the hydrometallurgical method is relatively advantageous, but the scope of its applications is more limited, so not all the smelting of copper ore can adopt this technique. As technology has improved over recent years, more and more countries have applied the technique in copper ore smelting, including the US, Chile, Canada, Australia, Mexico and Peru.

Some other metals, just like gold, nickel,etc. may have the same method as copper.

Copper concentrate powder is very abrasive, common metal pipes and valves are easy to be worn. Foyo full lined ceramic ball valves have proven and successful performance in copper concentrate transportation pipe lines.

In January, 2016, Foyo delivered two 4″-CL150 lever operated ceramic ball valves to a copper smelting plant, and after more than two years, the valves are still be in service in the copper concentrate pipe lines.

Thanks to the excellent performance of Foyo full lined ceramic ball valves, the end user re-ordered two ceramic ball valves for thier copper concentrate line. It is certain that our products save a lot of maintenance costs for our customers.

I manage the editorial affairs for MONETA Tanıtım, which produces specific publishing, specially for the sphere, Turkey industry. We work for content development through digital and print media, with a new generation, dynamic publishing intellection.

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Valves

Bürkert UK stock-holding for standard everyday process products

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Aiming to minimise the complexity of process control projects in a number of industries; from water to food & beverage and pharma, Bürkert UK has massively increased its product range and its UK stock-holding for standard everyday process products.

Bürkert now holds a wide variety of the more common valve designs including ball valves, butterfly valves and quarter-turn valves in standard sizes on the shelf. This increase in the product line represents a considerable investment in stock-holding, with over £1 million worth of stock now held in the UK, to compliment industry recognised angle seat, globe and control valve packages.

Neil Saunders Bürkert UK General Manager explains the move, “Quite simply we are adding convenience for our customers by offering more of what our systems customers and distribution partners want on a same day / next day availability basis.

“Bürkert offers over 100,000 catalogue items from commodity solenoid valves to high-precision food and pharmaceutical grade products, however while lots of the clever, problem solving items we are famous for are made to order, there are also standard valves required for almost any project. They don’t have exotic specifications and tend to be sourced when they are needed. If customers can have a Bürkert model, available straight away, then the quality and the brand reputation that goes with that is an added bonus for them.”

Cost effective solutions

Cost pressures are everywhere, so conformity of fit and compatibility can make a big difference in ensuring a process automation project is commercially successful. Hence, all our new products complement the existing range of more specialist valves and are designed to work in harmony with Bürkert’s numerous pneumatic and electric actuators and control heads. Every product is quality audited and built to the highest standards with full traceability of materials and certifications provided on request.

This improved product offering enables Bürkert to deliver a more comprehensive solution, especially for larger scale projects where consolidation of supply is a significant factor. Now, Bürkert can provide a cost-effective package that is supported by expert design and specialist application knowledge, as well as on-demand supply of more general-purpose process valves for water, steam and air.

This reduces costs for project teams and greatly simplifies the purchasing process by involving much fewer vendors and cutting the number of purchase orders that need to be raised. Other savings can also be made thanks to Bürkert’s knowledge and expertise being applied to a much greater part of the installation

Real-world savings example

The principle is neatly illustrated by a recent project for a biotech company that previously had only used Bürkert to supply its specialist products. The original quote was for several ball valves with actuators, integral pilot valves and feedback switches for use in Zone 1 (potentially explosive atmospheres), all from stock.

Having submitted the quote, the electrical department from the same customer subsequently contacted Bürkert looking for a number of ATEX pneumatic control panels. Further discussions about where the panels would be used revealed that they were for the same project as the ball valves.

Due to the nature of the working environment, the electricians did not want to run two armoured cables to the valve, one for the pilot valve on the side of the actuator and another for the switch box. The aim was to use the additional control panels to reduce the amount of cabling going to the valves.

The Bürkert engineers then explained that the ball valves that had been already quoted for the project included an integral switch box with the pilot valve inside it, so only one multi-core cable would be required. As a result, the additional control panels would not be required, saving the customer approximately £80,000.

One-stop shop

By increasing the range of products available, Bürkert UK is better placed as a project partner, offering high quality products, vast design expertise and customised logistics for improved project efficiency.

With larger scale projects involving hundreds of valves, potentially from numerous suppliers, maintaining an effective logistics process can be difficult. As an integral supply partner to a project, Bürkert can implement a customised logistics process that packages together all the components for a specific area of the installation. Deliveries are timed with the build process and  tagged to ensure they are delivered to exactly the right location, saving time and money on the installation.

As a one-stop shop for process control components, Bürkert aims to help customers with the design, procurement and installation of new and replacement equipment, as well as support its distribution partners with better access to a wider range of product.  Now, with a massive UK stock-holding, it can provide immediate delivery on a wide range of common products as well as sourcing more complex, application specific components within a short timeframe.

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Valves

Rotork is CMA range expands for improved control valve automation

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Rotork has extended its CMA range of compact modulating actuators with new sizes specifically designed for reliable automation of larger linear control valves.

The new actuator is capable of a maximum 4,500 lbf (20 kN) seating thrust. The new sizes increase the CMA range modulating thrust performance to 3,000 lbf (13 kN) with a 114.3 mm (4.5”) stroke length for the automation of larger valves with higher pressure ratings. The combined performance of the CMA and the larger CVA ranges enables Rotork is innovative electrical control valve actuation technologies to be applied to process control applications of virtually any size and description.

CMAs are robust enough to handle extreme temperature swings, corrosive environments and are also available for explosionproof areas. The CML-1500 and CML-3000 models, including those with hazardous area approvals, are watertight to IP68 for temporary submersion (7 metres, 72 hours). The optional Reserve Power Pack (RPP) uses supercapacitors to provide the actuator with enough stored energy to perform predetermined action on mains power failure, such as moving to the fully closed position, fully open position or anywhere in between. Manual operation is available as standard.

The cost-effective electric solution is suitable for a wide variety of applications found in sectors such as power generation, chemicals, petrochemicals and the majority of other process industries. The new sizes are ideal for linear valve control with modulating duty, generally in remote locations, such as oil pipelines and remote gas extraction stations where power supplies are limited. Single-phase or DC electrical power is all that is required for control valve actuation, saving the installation and on-going costs associated with instrument air supplies. Simple cabling replaces cumbersome lines and hoses, eliminating freezing and leaking problems.

The CMA is a low power consumption solution (less than 1 Watt at standby) for automation in established or remote installations such as oil installations and offshore facilities where there are pneumatic limitations. The design allows for solar powered and battery back-up supplies in remote locations where electric energy consumption is a concern and power is often provided through solar collection for the operation of remote automated critical systems such as wellheads. The new sizes retain all the features and benefits of the established CMA range of compact modulating actuators, providing continuous modulation with 0.1% accuracy for the most demanding process control applications.

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Valves

New Alfa Laval Mixproof 3-body valve designed for hygienic processes

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Looking for optimal process flow, outstanding hygiene, maximum uptime and low total cost of ownership?

The Alfa Laval Unique Mixproof 3-body valve with its modular, three-valve-body design provides reliable fluid handling and safety, making it perfect to use as a changeover valve for hygienic industries such as food, dairy, beverage and home-personal care. This translates into substantial savings and efficiency gains.

Cost-effective mixproof valve

Get exceptional results and save money by replacing two or more valves of other types with a single Alfa Laval Unique Mixproof 3-body valve. Two independent plugs and the fully balanced design enable two different fluids to pass through the same valve without risk of cross-contamination even in the event of pressure shock.

Exceptional spillage-free operation

Ensuring safe and hygienic operation, the double-seat design avoids cross-contamination while the double lip seals provide added protection for you to enjoy long-lasting, spillage-free operation.

Easy maintenance & optimal cleanability

Maintenance and cleaning are quick and easy due to a top-loaded design, no adjustable components, maintenance-friendly actuator and built-in leakage detection on all seals.

The Alfa Laval Unique Mixproof 3-body valve is always equipped with seat lift and seat push function hence meets stringent hygienic standards.

Easy to configure and upgrade

Optimize your hygienic process by customizing the Alfa Laval Unique Mixproof 3-body to suit your needs. Its modular design also makes it easy to apply the double seat valve whenever your process needs change while ensuring efficient, hygienic and continuous production.

You get the full benefit of using Alfa Laval Unique Mixproof valves by combining them with Alfa Laval ThinkTop and ThinkTop Basic valve sensing and control units.

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