Direct-to-Blister to Flash Converting and Transition of Slag Systems: Proposed Future for Olympic Dam Smelter

The chapter delves into the current operations of the Olympic Dam smelter, which utilizes a direct-to-blister flash smelting furnace (DBF) to produce blister copper and high-grade slag. As the smelter considers expanding to process increased volumes of concentrate, the article explores the viability of transitioning to a conventional matte smelting and converting furnace flowsheet. This transition is necessitated by the expected changes in feed composition, which will challenge the economic viability of the current flowsheet. The proposed future flowsheet involves adding new facilities for concentrate handling and a primary smelting furnace to produce copper matte, which will then be processed by the existing DBF operating as a converting furnace. The article discusses the challenges of converting the existing DBF to a double flash process, including modifications required for the furnace and the addition of new anode furnaces. It also explores the potential for continued operation of the electric slag furnace (ESF) and the economic implications of this decision. The chapter provides a detailed analysis of the slag systems, including the phase diagram for the FeO x –CaO–SiO 2 –Cu 2 O system and the effects of SiO 2 content on calcium ferrite liquidus temperature. It presents three potential routes for transitioning from silicate slag to calcium ferrite slag, each with its own advantages and challenges. The article concludes with recommendations for future study work and the potential benefits of delaying the transition until a subsequent major outage to minimize risks and operational inefficiencies.