copper & ferro-nickel smelter SERVICES

TURNKEY FURNACE REBUILD PROJECT SERVICE - PROJECT AND CONSTRUCTION MANAGEMENT

  • Industrial Vacuum & Silo Cleaning Services
  • Drilling and installation of thermocouples
  • Hot and cold furnace repairs
  • Manufacture of customised precast refractory shapes
  • Demolition of furnaces, removal of refractory linings, and waste management
  • Refractory materials and Industrial Plant Spares management, including selection, procurement, and testing
  • Salamander tapping and controlled furnace decommissioning and cool down
  • Mechanical, structural, steel and piping dismantling, fabrication and erection
  • Quality assurance and control systems
  • Design, manufacture and installation of anchor systems
  • Installation of refractory materials
  • Hot sealing and insulation
  • Drying and curing of refractory linings
  • Furnace start-ups and commissioning

PRIMARY & SECONDARY VESSELS SERVICES

Dickinson Group offers the complete range of services on the following Copper & Ferro-Nickel smelter vessels:

  • PS Converters / Teniente Converters
  • Flash Furnaces & Slag Cleaning Furnaces
  • Anode Furnaces
  • Isasmelt , Ausmelt & Smelting Furnaces
  • Matte Settling Electric Furnaces
  • Six-in-Line / Three-in-line / Two Electrode Furnaces
  • Mould Twin Casting Wheel

ISASMELT & AUSMELT FURNACES

  • Cleaning Copper & Ferro-Nickel spills
  • Stack cleaning and maintenance
  • Cleaning service on the boiler and transition piece
  • Shell repairs or replacements
  • Partial, major or full refractory installation
  • Partial, major or full demolition of refractories
  • Refractory materials supply & coordination
  • Tap hole repairs or replacements
  • Launder replacements
  • Platform repairs or replacements
  • Precast launder tiles

ISASMELT

ANODE FURNACES

  • Cleaning copper spills
  • Slag settling chamber cleaning
  • Diesel ,water, air and nitrogen line repairs or replacements
  • Tuyere maintenance
  • Lip maintenance
  • Lip repairs or replacements
  • Shell plate repairs or replacements
  • Maintain spare charge door units
  • Charge door repair or replacements
  • Gooseneck repairs or replacements
  • Partial ,major or full Refractory installation
  • Partial, major or full Demolition on refractory
  • Material supply and coordination
  • Maintain spare gooseneck units
  • Charge door platform repairs
  • Tuyere plate repairs or replacements
  • Tap hole shell repair
  • Copper cooler replacements
  • Lip cleaning with the Brokk
  • Porous plug maintenance
  • Slag settling chamber repairs and maintenance
  • Growth monitoring
  • Full reline Brick Removal 3.5 days
  • Partial repair Brick Removal 2.5 days
  • Full reline Refractory brick installation 13 days
  • Partial reline Refractory Brick Installation 8 days
  • Full reline on Anode Furnace 16.5 days

MATTE SETTLING FURNACES

  • Demolition of furnace side and end walls up to the base of furnace
  • Installation of new members and alignment
  • De-bricking of MSEF furnace roof
  • Growth monitoring
  • Slag launder head maintenance
  • Feeding chutes repairs/maintenance
  • Matte Launder blocks installation
  • Matte launder repairs or replacements
  • Structural repairs or replacements
  • Material supply and coordination
  • Partial, major or full Demolition on refractory
  • Partial ,major or full Refractory installation
  • Shell repairs or replacements
  • Tap hole repairs/maintenance
  • Supply of precast launder blocks
  • Matte Launder maintenance
  • Electrode repairs/maintenance
  • Roof cleaning and maintenance
  • Cleaning copper spills
  • Removal of roof brick suspension members
  • Installation of new roof bricks where necessary
  • Bricking of new side walls and the repair of the DR System where necessary
Last reline completed in 33 days including demolition mechanical & refractory installation. Removed working Hearth and sidewalls from Skew back up of the permanent lining.

MATTE SETTLING FURNACES PRECAST LAUNDERS

  • Less skill require as installation & removal is rigging activity
  • Reduces need to constantly repair Launder refractories
  • Reduce Labour required for launder maintenance
  • Ease of Installation and removal
  • Pre-dried up to 650 oC
  • Ready to use with no drying out required
  • Reduce time required to replace the blocks
  • Increases refractory lining life cycle
  • Modular design with capability to remove only damaged sections
  • Ability to keep pre-cast launders in stock

FLASH & SLAG CLEANING FURNACES

  • Growth monitoring
  • Slag launder head maintenance
  • Feed chutes repairs & maintenance
  • Matte launder block installation
  • Matte launder repairs or replacements
  • Shell repairs or replacements
  • Partial, major or full refractory installation
  • Partial, major or full demolition of refractories
  • Refractory materials supply & coordination
  • Tap hole repairs or replacements
  • Supply of precast launder blocks
  • Matte launder maintenance
  • Electrode repairs & maintenance
  • Roof cleaning & maintenance
  • Cleaning copper spills

SIX & THREE-IN-LINE & SMELTING FURNACES

  • Growth monitoring
  • Slag launder head maintenance
  • Feed chutes repairs & maintenance
  • Matte launder block installation
  • Matte launder repairs or replacements
  • Shell repairs or replacements
  • Partial, major or full refractory installation
  • Six & Three-InPartial, major or full demolition of refractories
  • Refractory materials supply & coordination
  • Tap hole repairs or replacements
  • Supply of precast launder blocks
  • Matte tap hole deep repairs
  • Electrode repairs & maintenance
  • Roof cleaning & maintenance
  • Cleaning copper spills

CONVERTERS

  • Full reline hot to hot rebuilds 15 days
  • Cleaning copper spills
  • Off gas maintenance and repairs
  • Swivel and bustle repairs and maintenance.
  • Repairs on tuyer mounting plates
  • Distribution pipe installation
  • Tuyer line base plate repairs
  • Shell repairs or replacements
  • Pouring lip ,gable and invert arch liners supply and replacements.
  • Protection plate repairs or replacements
  • Hood inspection and repairs (Hood door, hood rails and water leaks)
  • Partial ,major or full Refractory installation
  • Partial, major or full Demolition on refractory
  • Material supply and coordination
  • Cleaning of hang ups
  • Apron repairs or replacements
  • Retaining plate and mounting plate repairs or replacements on the mouth area
  • Burner hole repair or replacement
  • Tuyer boxes maintenance
  • Supply of tuyer pipes and installation
  • Discharge chute’s repairs
  • Auxiliary maintenance (handrails, walkways)
  • Growth monitoring
  • Pouring lip cleaning with the Brokk
  • Partial repair hot to hot repairs 12 days-Line & Smelting Furnaces

MOULD TWIN CASTING WHEEL

  • Material supply
  • Curing facility
  • Maintain the refractory on the following units:
  • Pouring spout
  • Spoons
  • Launder tip
  • Long lasting launder
  • Receiving launder
  • Y-Piece
  • Intermediate ladle
  • Spare units
  • Supply of precast shapes on the spoon tips
  • Mechanical repairs on units (Anchors, Base plates etc.)

Our company currently carry out maintenance on spoons, launders and intermediate launders utilizing recycled brick lining grog to reduce refractory consumption up to 50%

COPPER RECOVERY – VACUUM SERVICES

GALLERY



                



CORPORATE HEAD OFFICE
Tel: +27 (0) 16 421-3720
Fax: +27 (0) 16 422-1038
Email: sales@dgrp.co.za



10 Smuts Avenue
P.O. Box 63, Vereeniging
1930. South Africa