Success stories
Superheated steam injection in copper processing
Project Description
Need to inject steam at a temperature above 180°C in a furnace where it is mixed with hydrogen to adjust its reduction potential during the extraction of iron silicate in copper processing
Original situation:
Challenges posed by the client:
The customer, a European leader in copper processing, needed to inject steam at a temperature above 180°C into a furnace where it is mixed with hydrogen. Here are additional details of the application
- Reduction potential setting: In the copper processing process, especially in the refining stage, a furnace is used to melt the copper and remove impurities such as iron silicate. Reduction potential refers to the ability of the furnace to remove these impurities and produce high purity copper. The introduction of steam together with hydrogen facilitates the adjustment of the reduction potential of the furnace.
- Minimum temperature of the mixture to avoid condensation: it is crucial to maintain a minimum temperature of 143°C in the mixture of steam and hydrogen to avoid condensation of water
- Steam temperature required: It is recommended that the steam be at least 250°C, to ensure that the mixture maintains an adequate temperature throughout the reduction process. This ensures efficient iron silicate extraction and high quality copper production.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
- 24 kW steam generator: a steam generator with a capacity of 24 kW designed to produce approximately 30 kg/hour of steam. This generator provides the initial source of steam required for the hydrogen mixing process in the electric furnace.
- Steam superheater (afterheater): a steam superheater capable of raising the steam temperature from 180°C to 250°C. This stage is crucial to ensure that the steam reaches the required temperature for mixing with hydrogen without condensing during the process.
- Pressure reduction system: a system designed to modulate the steam pressure before it enters the electric furnace, prior to passing through the afterheater. This ensures that the steam is adjusted to the specific conditions required for the reduction process in the furnace.
- Condensate recovery tank: a tank designed to recover and reuse the hot water condensed during the process. This not only optimizes water consumption, but also helps maintain the efficiency of the steam generator by making maximum use of the resources available in the system.
Technology used:
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FAQs
We understand that many questions arise. Here are some of the most common ones.
There are no pollutant emissions beyond those produced in the electricity production process, therefore, they can become neutral depending on the electricity mix.
Electric steam boilers are the present and the future.
Perfectly.
It is even recommended for maximum efficiency.
There is no problem in remote control as long as the current regulations are respected.
A steam generator is a pressurized equipment that, together with the piping network it affects, is subject to regulatory control and complementary technical instructions, according to Regulation published in Royal Decree 809/2021, of September 21.
Its maintenance is divided into a part of simple compliance by the owner:
- Know and apply the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Not to put the installation into service or prevent the operation of pressure equipment if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use the pressure equipment within its intended operating limits as specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Perform maintenance on the installations, pressure equipment, safety accessories, and control devices in accordance with the operating conditions and manufacturer’s instructions, and examine them at least once a year.
- Arranging for the necessary periodic inspections as required by Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying a heat source to water, it is transformed into steam from the boiling point and at atmospheric pressure.
From this point on, depending on the required degree of saturation of the steam for its correct application, we will have to increase the pressure in order to obtain a higher temperature.
To change the temperature and degree of saturation of the steam, we must always modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
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