Outotec Flash Smelting technology

Outotec Flash Smelting technology is the cleanest smelting method available and the most feasible way of producing copper and nickel. Outotec's state-ofthe-art technology enables the producer to meet the environmental requirements of today and tomorrow. Half of the world's sulde-based copper and nickel is produced with Outotec Flash Smelting technology.

Benefits
Offers new business options for metal production Reliable and proven process and equipment Low investment and operating costs Capability to treat different qualities of raw materials with variable feed rates High recovery of valuable metals Meets the strictest environmental requirements Safe and hygienic working conditions Long life cycle between major maintenance periods

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Outotec Flash Smelting in brief

Concentrate burner Heat recovery boiler

Electrostatic precipitator

Loss-in-weight feeding system

Flash Smelting furnace

Outotec Flash Smelting technology has the leading position in the copper smelting business by virtue of its exibility, low energy consumption, high sulfur capture and economy of scale. It has become the benchmark for pyrometallurgical processing in both the copper and nickel industry. Today, approximately 50% of the worlds primary copper and nickel are produced with Outotec Flash Smelting technology. The Flash Smelting process has been in development for more than half a century since it was rst applied by Outokumpu in Harjavalta, Finland in 1949. Outotec Flash Smelting technology is energy efcient since it makes use of the reaction heat of concentrate, and therefore external fuel is not needed. Outotec's technology allows a total of 99.9% of sulfur capture, due to the low volume process gas and compact and sealed equipment. Flash Smelting has been awarded the ASM historical Landmark Status and rated as BAT (Best Available Technology) production method by the European Union due to its energy efciency and environmental performance.

The Flash Smelting process is continuously developed in collaboration with our customers and Outotec's R&D division. Therefore it has preserved and will preserve its position as the state-of-the-art technology for pyrometallurgical processing of copper and nickel. With improved efciency and higher oxygen enrichment, the modernization of an old smelter can result in a 3-fold increase in capacity with a relatively small investment cost.

Superior environmental performance

Energy efficiency High sulfur dioxide capture 99.9% Low green house gas emissions Low off-gas volumes Sealed equipment-good working conditions Process heat recovery and utilization European Union BAT National Ten Key Environment Friendly Project award for Xiangguang Copper Smelter

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Yanggu Xiangguang copper ash smelting and ash converting plant, China.

Production Network a new business option The Production Network concept enables producing blister copper from mattes that are produced in different geographic locations. Solid matte produced in multiple ash smelters or in other type of smelters can be collected and used as a raw material for a single ash furnace, which converts the matte to blister copper. In fact, it is preferable to integrate matte smelting with operations at one of the concentrate supplying mine sites, which will reduce transportation costs and optimize the production chain from mine to smelter. The Production Network concept will increase capacity utilization of the matte delivering smelters in the mine sites.

Outotec Flash Smelting technology transfer For a new or existing operation, an Outotec Flash Smelting technology transfer package offers environmentally sustainable methods for copper and nickel production with low total investment and unit operating costs. The package involves all aspects of smelter design and project management: nn Feasibility studies and R&D services nn Basic and detail engineering and supply of proprietary and key equipment nn Project implementation with Outotec experts on-site nn Supervision of detail engineering, installation and commissioning nn Training of operating personnel nn Guarantees for plant capacity and product quality nn Long-term commitment and extensive customer support and services

Production Network concept

CONCENTRATE SMELTING IN SMELTER A

CONCENTRATE

SMELTING IN SMELTER B

ADDITIONAL MATTE

HIGH GRADE CONCENTRATE FLASH CONVERTING

BLISTER COPPER

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Outotec Flash Smelting technology for the copper and nickel industries
Copper Flash Smelting and Kennecott-Outotec Flash Converting Outotec Flash Smelting combined with KennecottOutotec Flash Converting is an integrated solution for

Flash Smelting is a natural choice for higher grade copper concentrates. The process is currently used on a commercial scale in Poland, in Australia and most recently in Zambia. Outotec Direct Nickel Flash Smelting In the Outotec Direct Nickel Flash Smelting process high-grade nickel matte is produced directly in a ash smelting furnace. Slag is cleaned in an electric furnace producing low-sulfur matte and waste slag. The technology enables lower investment, operating and maintenance costs. This unique Outotec technology ensures higher recovery of nickel, cobalt and precious metals as material re-circulation is minimized. The process also improves working conditions in the smelter as ladle transfer of molten material is eliminated and as a result, emissions are minimized. The rst Outotec Direct Nickel Flash Smelting processes were introduced in Harjavalta, Finland in 1995 and in For taleza, Brazil in 1997. Outotec Slag Cleaning Electric furnaces are commonly used for slag cleaning in copper and nickel smelters. Based on our wide experience in smelter projects, Outotec provides solutions for the whole slag cleaning process unit, including secondary material handling, granulation and off-gas treatment.

high-capacity smelters using the minimum number of smelting units and effective emission control. High capacity combined with small unit size ensures low investment and operating costs. The Outotec technology improves the productivity of existing installations, such as sulfuric acid plants, further cutting down unit operating costs. The working conditions for operations staff will improve and environmental emissions will decrease due to the compact process. High sulfur recovery will be achieved thanks to the constant ow of high-strength SO 2 process gas from the furnaces. Additionally, the Production Network concept provides economic exibility as smelting and converting can be operated independently. Therefore, a customer will realize lower transportation costs as well as advantages in plant design and operation. Outotec Direct Blister Copper Flash Smelting The Outotec Direct Blister Copper Process is one of the most advanced applications of Flash Smelting technology. In Direct-to- Blister Flash Smelting blister copper is produced within a single furnace. The process offers new options for using different raw materials, while minimizing investment costs. Direct Blister

Electric furnace designed by Outotec.

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OUTOTEC FLASH SMELTING AROUND THE WORLD More than 55 licences

Copper Flash Smelting Flash Converting Direct to blister Nickel Flash Smelting Direct Nickel Flash Smelting Not in operation

Outotec your technology transfer partner

Outotec Flash Smelting for both technology greeneld offers projects new and opportunities modernization and expansion of existing copper and nickel plants. When the complete process line is designed and delivered by Outotec the installation fulls all process, operation, maintenance and environmental requirements. The Outotec Flash Smelting process and the smelter equipment are under continuous development. Intensive research and development work in the laboratory, bench-scale and pilot-scale tests enable nding innovative solutions for protability improvements and environmental efciency. Outotec creates and maintains long-term partnerships ensuring that the latest technology developments are continuously available to customers. Outotec organizes regular licensee congresses for the Flash Smelting Family to exchange information of improvements and technical developments , and to build relationships between Flash Smelting Family members.

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Outotec services improve process performance

Outotec aims to maintain long-term working partnerships with its customers to ensure the full value of their operations and equipment is realized. Outotecs global network of service centers are dedicated to providing ongoing specialist technical and maintenance support. This support maximizes productivity and optimizes customer plants and processes. Through these local service centers, customers have unparalleled access to Outotecs broad expertise base and extensive operational experience. Additionally, customers can tap into the latest technological developments from Outotecs extensive research and development programs. Outotec delivers solutions from spare parts procurement and support, preventive maintenance programs, plant audits, through to optimization and upgrades, project management and training. Equipment services As the original equipment manufacturer (OEM) you are assured that Outotecs spare parts and consumables are of the highest quality and specifically designed for the application. Through Outotecs specialized manufacturing, procurement and logistics channels you will have the peace of mind for timely access to genuine spare parts whenever required. Outotecs team of specialists understand the pressures of production. Our specialists will work with you to develop preventive maintenance programs and with regular involvement, help to optimize plant availability and reliability, while minimizing downtime.

Plant and process support services Outotec's advanced plant and process assessment indentifies areas with the most potential for improvements, e.g. equipment, automation systems, metallurgical processes and complete plants. Our intimate knowledge of the process demands and equipment requirements ensures that any modifications or upgrades are seamlessly integrated into your existing operations.

Total service package from Outotec:

Process support services nn Troubleshooting nn Optimization nn Simulation nn Integration nn Design nn Technology transfer nn Commissioning nn Process control analysis nn Training Equipment services nn Spare parts and spare parts management nn Equipment inspections and maintenance nn Training Plant services nn Plant assessments nn Operation and maintenance support services nn Upgrades and modernizations nn Shutdown maintenance services

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Total furnace rebuild solution

Outotec Solution Offerings
PHASE 1:
Planning & Engineering Furnace Rebuild Scope Development Rebuild & Shutdown Planning Basic Engineering Detail Engineering

Customer Benets

PHASE 2:
Supply

New Equipment Steel Structures Refractory & Cooling Elements Mechanical & Piping Components Instrumentation & Control Equipment

PHASE 3:
Construction

Construction/Shutdown Management Furnace Demolition Mechanical Installation Refractory Installation Instrumentation & Control Installation

PHASE 4:
Commissioning & Start-up

Furnace Heat-up Mechanical Commissioning E&I and Controls commissioning Process Commissioning Start-up Process Support

PHASE 5:
Furnace Follow-Up Audits

Equipment Inspection & Audit Furnace Condition Audit Campaign Life Assessment Remote process monitoring Process Audit

Improved furnace availability Increased production Life- cycle service

Based on Outotecs deep understanding of the processes, equipment and project management Outotec is uniquely positioned to deliver Flash Furnace Smelting clients service solutions. For furnace upgrade complete, full

Benefits of Outotec services

Critical original spare parts in stock Comprehensive process and equipment expertise Minimize downtime and unscheduled stoppages Maximum operating performance

projects, the solution can range from concept engineering to supply, installation, commissioning and start-up of their furnace. Outotecs strength in design and delivery of flash furnace technology, coupled with the former Auburns experience and track-record for executing furnace rebuild and shutdown projects provides clients with a single source, high value and full service solution for furnace upgrade/rebuild projects.

From individual supply and services to complete furnace rebuild solution contracts

Safe working environment Proven furnace technology Integrated project solution Enhanced furnace productivity Improved campaign life Mechanical and process performance guarantees Best implementation and safety practices Reduced downtime Process expertise Smooth and fast ramp-up to production Enhanced ROI

Outotec develops and provides technology solutions for the sustainable use of Earths natural resources. As the global leader in minerals and metals processing technology, Outotec has developed over decades several breakthrough technologies. The company also offers innovative solutions for the chemical industry, industrial water treatment and the utilization of alternative energy sources. Outotec shares are listed on the NASDAQ OMX Helsinki.

pyro@outotec.com www.outotec.com Copyright 2011 Outotec Oyj. All rights reserved.

Finland, September 2011.