Injection of Dry Copper Concentrates in the Ausmelt Top-Submerged Lance (TSL) Furnace

This chapter delves into the innovative approach of injecting dry copper concentrates into the Ausmelt Top-Submerged Lance (TSL) furnace, a method aimed at enhancing energy efficiency and reducing CO2 emissions in copper smelting. The study, conducted as part of BHP’s Olympic Dam operations expansion, explores the potential benefits of dry feed injection, particularly for concentrates with higher Cu to S ratios. The chapter details the pilot plant testwork, which successfully demonstrated stable operation and lower feed carryover rates compared to conventional roof feeding. It also discusses the commercial scale outcomes, highlighting the potential for a 50% reduction in offgas volume and a 90% reduction in fuel consumption and associated CO2 emissions. The chapter concludes that dry feed injection is a viable process option that can be combined with traditional roof feeding, tailored to specific copper concentrate compositions, and offers potential for debottlenecking and expansion pathways for new builds.