Kansanshi Copper Smelter ISACONVERT™ Furnace Tapping System Design, Operation, and Improvements

In 2019, the construction and commissioning of what was to be the world’s first commercially operated ISACONVERT™ furnace was completed at the Kansanshi Copper Smelter. Between 2019 and 2021, the ISACONVERT™ furnace was operated in four campaigns in which the matte treated steadily increased from an average of 35 tonnes per day to an average of 245 tonnes per day. Manual blister and slag tapping were among the areas that had challenges and initially had a significant impact on the plant availability. Frequent failures to close the tap-holes occurred and hot metal spills were experienced as a result, giving rise to safety concerns. Several changes were implemented that resulted in a significant improvement in safety for the tappers, as well as a reduction in plant down time. This paper describes the design and operation of the ISACONVERT™ blister and slag tapping systems, and the improvements that led to successful operation of the furnace.