Modeling and control of copper loss in smelting slag

A series of technical improvements have been implemented to address the issue of high copper losses in rotary holding furnace (RHF) slag, which were experienced at the Xstrata Copper Smelter at Mount Isa in 2007 and 2008. The copper losses in smelting slag in the RHF were more than 3% in 2006 and 2007. Thermodynamic models and viscosity models have been applied in the operation of Xstrata Copper Smelter in Australia. The theory of RHF key performance indicators has also been developed to reduce the copper losses in RHF slag. The RHF KPIs Theory has been applied in Mount Isa Copper Smelter. The copper losses in RHF slag dropped from 3.1% in 2007 to 0.76% in April 2009. The average copper loss in RHF slag in 2009 and 2010 was about 0.9%.