Non-ferrous Metallurgy

Cooling of hot and sticky

dust-loaded process gases
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Transport of a pre-fabricated waste heat boiler
downstream flash smelting furnace in South Australia
At home in the world
Oschatz best technology
backed by experience
Oschatz is a globally operating plant
constructor with over 160 years experience,
more than 1,400 employees as well as subsidia-
ries, representative offices and branches around
the world. Our plants for cooling waste gases
and converting recovered heat into industrially
utilizable steam are used throughout the world
in the following industries:
Iron and Steel Metallurgy
Non-ferrous Metallurgy
Chemical Industry
Power Plant Technology
Solutions for the non-ferrous industry
For decades, Oschatz waste heat boilers have
been used worldwide for all production processes
of non-ferrous metals such as copper, zinc, lead,
nickel or tin. We develop tailor-made solutions
for our customers based on the specific process
demands and needs for every plant and process,
fully in line with the overall objective of maximiz-
ing productivity and profitability.
The hot and sticky dust-loaded process gases
and the various processes in the non-ferrous
metallurgy present a challenge for our gas cool-
ing and heat recovery technology. But thanks to
most advanced production practices for waste
heat boilers combined with innovative cleaning
systems for effective heat transfer, safe and reli-
able process waste heat boilers are produced.
Due to future-oriented solutions for the differ-
ent processes, our customers have the opportu-
nity even after decades of operation to in-
crease the process capacity after simple and
quick modifications at the boiler. All Oschatz
plants are produced with most advanced technol-
ogy so that they run optimally and very reliably
even after thousands of operation hours.
Depending on their destination, systems and
components are fabricated in our two modern
production facilities in Kocaeli, Turkey, and
Nanjing, China. Needless to say, we comply with
all quality standards, such as ISO 9001, the ASME
standard, the Pressure Equipment Directive, AD,
EU standards, etc.
Our Market is the World
Processes and solutions
Waste heat boilers for the non-ferrous metallurgical industry
Waste heat boilers in the non-ferrous
industry are usually designed as evaporation
systems based on the wide range of technical
standards valid on a worldwide scale.
Oschatz designs waste heat boilers with
two types of water-circulation systems:
combined natural and forced circulation
(e.g. two-pass vertical boiler with
convection pass),
forced circulation only (e.g. horizontal boiler).
The choice of the waste heat boiler type and
water circulation system depends on geometry
and location of the process furnace outlet.
On the basis of many years of develop-
ment and experience Oschatz designs
and manufactures:
membrane wall elements,
evaporator/super-heater screens,
evaporator/super-heater bundles/systems,
wall, screen and bundle hammering systems,
soot blowers for special cases.
The wide range of products available from
Oschatz meets process requirements of the
non-ferrous industry all over the world. Oschatz
can ensure gas cooling parameters to meet the
customers' demands, based on given gas inlet
conditions.
Transport of two evaporator
bundles for horizontal waste
heat boiler section
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Our Market is the World

Waste heat boiler downstream

flash smelting furnace in Waste heat boiler assembly
Olympic Dam, Australia in the workshop

Waste heat boilers downstream flash smelting
Clean solutions for flash smelting of copper and nickel
Flash smelting of copper and nickel con-
centrates takes place in a furnace with reaction
shaft (Outokumpu flash smelting process). The
process gases are cooled in a special waste heat
boiler. The products are traditionally processed
further on in a converter. Another flash smelting
process is the Kivcet process for lead smelting.
Here the process gases are cooled with two
waste heat boilers. One boiler is installed down-
stream the smelting furnace, the other boiler is
installed downstream the electric furnace.
The waste heat boilers are equipped with
membrane walls, screens and bundles. To avoid
corrosion in the waste heat boilers the water/
steam-side operating pressure is typically chosen
between 40 and 70 bar. Depending on the SO2/
SO3 concentration in the process gas it is then
assured that the temperature of the boilers'
surfaces lies significantly above the sulphuric
acid dew point. It is imperative for the boiler The successful handling of the thermal expansion
surfaces to be kept as clean as possible in order of the boilers in smelter conditions is an essential
not to exceed the maximum allowable gas tem- factor for maximum availability and avoidance
perature for the filter unit. Exactly for this pur- of leakages. This is achieved by flexible pendulum
pose Oschatz has developed and patented a supports that keep the boilers in position. An
highly efficient hammering system for the clean- additional advantage of the pendulum supports
ing of the boiler surfaces (see p. 10). is that the boiler screens and bundles are essen-
The horizontal waste heat boiler downstream tially better accessible for maintenance works.
Outokumpu flash smelting process consists of
a radiation chamber in which the gas is cooled
down to 600 C 800 C and an adjacent con-
vection part in which convection heating sur-
faces are installed. For the Kivcet process each
radiation chamber of both boilers consits of two
vertical shafts. Just like in the waste heat boiler
downstream Outokumpu flash smelting process
the convection part is horizontal, too. The typical
gas outlet temperature is approximately 350 C.

Kivcet furnace with

Flash smelting furnace waste heat boilers
with waste heat boiler

Design range Design range

Offgas rate 15,000 - 140,000 m3(STP)/h Reaction shaft Electric furnace

Offgas temperature at boiler inlet 1,250 - 1,400 C Offgas rate 20,000 - 25,000 m3(STP)/h Offgas rate 5,000 - 10,000 m3(STP)/h
Offgas temperature at radiation chamber end 600 - 800 C Offgas temperature at boiler inlet 1,200 - 1,300 C Offgas temperature at boiler inlet 1,300 - 1,350 C
Sulphation air 2,300 - 21,000 m3(STP)/h Offgas temperature at radiation chamber end 550 - 700 C Offgas temperature at radiation chamber end 550 - 700 C
Offgas temperature at convection section end 350 - 400 C Offgas temperature at convection section end 350 - 400 C Offgas temperature at convection section end 350 - 550 C
Feed water temperature 105 - 140 C Feed water temperature 105 - 140 C Feed water temperature 105 - 140 C
Steam pressure 40 - 70 bar Steam pressure 40 - 70 bar Steam pressure 40 - 70 bar
Steam temperature 250 - 285 C Steam temperature 250 - 285 C Steam temperature 250 - 285 C
Steam rate 10 - 90 t/h Steam rate 20 - 40 t/h Steam rate 2 - 10 t/h
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Our Market is the World

Waste heat boiler downstream

ISASMELT furnace in Mount Isa,
Australia

Waste heat boilers Two-pass vertical waste heat boiler

ISASMELT furnace with waste heat boiler
downstream Ausmelt process
Design range
Leach residue smelting and fuming of zinc
Offgas rate 15,000 - 140,000 m3(STP)/h
Offgas temperature at boiler inlet 1,200 - 1,550 C
Offgas temperature at radiation chamber end 600 - 900 C Originally, in the top submerged (TSL) The engineering concept developed by Oschatz
Offgas temperature at convection section end 350 - 400 C lance smelting technology, the brick-lined leads to significantly less shutdown intervals
Feed water temperature 105 - 140 C furnaces and hoods are surrounded by a water resulting in significantly increased production
Steam pressure 40 - 70 bar
cooled jacket. Oschatz supplies a furnace shell capacity and therefore assures a better economic
Steam temperature 250 - 285 C
Steam rate 10 - 90 t/h and hood cooling that is integrated into the efficiency of the whole plant.
evaporation system of the waste heat boiler.
These components are designed as gastight
welded membrane walls. In order to protect the
membrane walls from excessive heat load, they
Waste heat boilers downstream ISASMELT process are equipped with studs on which a thin castable
layer is applied. The lifetime of these components
Lance smelting and converting of copper, nickel, lead, zinc and tin complies with the usual average lifetime of boiler
pressure components. Compared to this, the
brickwork of an originally water cooled construc-
In the top submerged (TSL) lance smelting saturated steam is not used, it is tion needs to be relined at least once a year.
technology for the recovery of copper, nickel, condensed in an air cooled conden-
lead, zinc and tin, the process gas has a temper- sator which is installed above the
ature range of 1,200 C to 1,550 C. The gas is steam drum. While using recycling
directed into a waste heat boiler to be cooled. material, the acid dew point is
During the cooling process dust properties lower. Therefore a lower steam tem- Design range
change from the molten to the dry phase. De- perature can be chosen, too.
Smelting furnace
pending on the concept of the whole plant, the The first part of the waste heat boiler uptake
Offgas rate 15,000 - 120,000 m3(STP)/h
process gas is cooled down to between 600 C is made even and smooth to prevent built-ups.
Offgas temperature at boiler inlet 1,250 - 1,800 C
and 900 C in a two-pass vertical boiler or down This part can also be removed for access to the Offgas temperature at boiler outlet 350 - 900 C
to approx. 350 C in a three-pass vertical/hori- furnace and boiler. An evaporation cooled furnace Steam pressure 30 - 70 bar
zontal boiler. The dust is partly separated in the roof operating above the acid dew point has a Steam rate 11 - 90 t/h
Ausmelt furnace with waste heat boiler
waste heat boiler. longer lifetime than water cooled roofs. A relief Fuming furnace
door is arranged at the top of the furnace. It can Offgas rate 5,000 - 80,000 m3(STP)/h
The further dust separation takes place in a also be used as a pressure relief door to compen- Offgas temperature at boiler inlet 1,300 - 1,550 C
baghouse or an electrostatic precipitator. When sate small pressure fluctuations of the offgas. Offgas temperature at boiler outlet 350 - 750 C
Steam pressure 30 - 70 bar
Steam rate 4 - 60 t/h
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Our Market is the World

Cyclone smelting and

waste heat boilers
for zinc residue and steel dust recycling
The metallurgical treatment of residues in
the non-ferrous metallurgical industry becomes
more and more important. Smelting in a cyclone
is a future-oriented technology for the recovery
of metal contained in residues. This technology
has been used for iron, lead, copper and zinc and
is based on the CONTOP-system. In the present
application the cyclone serves for recycling of
steel flue dust and Zn retort residues containing
ZnO and PbO.
The steel mill dust and zinc retort residues
are wastes that contain Zn and Pb, other heavy
metals, coal and slag formers (CaO, SiO2 and
FeO). Dust and residues need to be cleaned and
deposited in an environmentally acceptable way.
During the process the residues are melted to
slag in a cyclone, Zn and Pb are fumed. The
fumed metals are post-combusted in a waste
Steel dust and zinc residue recycling with
cyclone smelting and waste heat boiler
Waste gas cooling systems
downstream fluidized bed roasting
for zinc, pyrite (gold) and copper
Roasting of zinc, pyrite and
copper concentrates is carried out
Smelting reactor, CONTOP-system by Siemens VAI in fluidized beds. For this process
Oschatz supplies waste heat boilers
including the coils for the fluidized
heat boiler to oxides and recovered as dust from beds. The hot roaster gases (800 to
the gas flow. The gas cooling system for the 1,000 C) with a high dust load (up to 400 g/Nm3)
smelting and fuming cyclone and the waste heat are cooled in Oschatz boilers to approximately
boiler for this process have been supplied by 350 C.
Oschatz. Only a small quantity of mechanical In general, these boilers are being equipped
dust results from cyclone smelting. As the cy- with cooled tube walls, evaporation screens and
clones are connected to an evaporation system, super-heater screens. Because of the gas compo-
Fluidized bed roaster with waste heat boiler
the thermal load is better handled than with a sition of the process and the corresponding dust
cooling water system, and the surface tempera- characteristics, a steady operation of the waste
ture of the cooling tubes is always kept above heat boilers can only be achieved by highly effi-
Design range
the dew point of H2SO4 and HCI. cient heating surface cleaning systems which do
not require a shutdown of for the whole plant for Offgas rate 15,000 - 120,000 m3(STP)/h
Offgas temperature at boiler inlet 800 - 1,000 C
Benefits: maintenance purposes. Cleaning of boiler heating Offgas temperature at boiler outlet 350 - 400 C
surfaces by the Oschatz hammering system has Feed water temperature 105 - 140 C
very high energy density, been proven to be very successful. (see page 10) Steam pressure 42 - 70 bar
Steam temperature 250 - 400 C
optimal reaction conditions and mass and
Steam rate of boiler 6 - 50 t/h
heat exchange by high turbulence intensity, Fluidized bed cooling coils 3 - 50 t/h
reduced reactor dimensions with high

throughput,
high smelting temperatures (> 2.000 C)
Waste heat boiler downstream
are possible, for instance in reactions with roaster for gold recovery
oxygen enrichment, in Newmont, USA
larger particle size than in comparable

entrained flow reactors possible.

Design range

Cyclone smelting Waste heat boiler

Cyclone diameter 1-3 m Offgas rate 5,000 - 50,000 m3(STP)/h
Feed rate of solids 10 - 100 t/h Dust at boiler inlet 0.7 - 7 t/h
Offgas temperature at cyclone outlet 1,200 - 1,800 C Offgas temperature at boiler inlet 1,200 - 1,800 C
Steam pressure 30 - 70 bar Dust at boiler outlet 0.8 - 8 t/h
Steam rate 3 - 10 t/h Offgas temperature at boiler outlet 240 - 380 C
Steam pressure 30 - 70 bar
Steam rate 6 - 60 t/h
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Our Market is the World

Oschatz Services & Solutions s.r.o.

Test unit of a cooling
surface cleaning system Expert support around the clock

Even the best product can go wrong some

time; parts may need to be repaired or replaced.
In such instances, our customers can rely on the
expert service provided by Oschatz. Our subsidi-
ary Oschatz Services & Solutions s.r.o. (OSS)
pulls out all the stops to keep downtimes at your

Cleaning of waste heat plant to an absolute minimum. The speedy avail-

ability of spare parts, which can be installed on
site by our specialists if required, helps us ensure
boiler cooling surfaces that your plant can resume production as quickly
as possible. The components are built or repaired A waste heat boiler downstream ISASMELT process is manufactured.
Innovative hammering cleaning systems in the OSS manufacturing facility in Vysoany,
Praha. Total floor space: 1,650 m2 (17,760 ft2).

The Oschatz boiler hammering cleaning Oschatz offers heating surface cleaning What our service provides:
system is the result of 50 years of development systems for: The quickest possible plant availability

and experience. The special patented hammering in the event of breakdown or repair
system provides an extraordinary cleaning effect boiler walls, Highly qualified repair personnel

for slag and dust, without damaging the boiler. screens, with plant-specific know-how
Oschatz hammers hit the heating sur- evaporator bundles. 24/7 emergency service

faces of the boiler within the tensile

strength limits of the steel. Hammer, For the boiler wall cleaning system a hammer hits Consulting services from our team:
anvil, boiler and buckstays are not an anvil that is directly mounted on the boiler Optimization of operating costs
Our service team is ready to help you around the clock.
overstressed and show no sign of wall. For a screen bundle each screen has its own Improved technical and personnel planning

plastic deformation of the steel when subject hammer positioned outside of the boiler at the of resources and costs
to high impacts. Oschatz hammers hit on well- top. This hammer hits in the direction of the gas Planning of environmental protection

defined points permitting maximum acceleration flow. The evaporator bundles are hammered at measures
and have a variable cleaning vibration frequency. the bottom with one hammer hitting two Conversion of furnaces

bundle layers. The Oschatz hammering Performance-enhancing

cleaning system is used successfully adjustment of steam parameters

for the dust removal in waste
heat boilers downstream
flash smelting, ISA-
SMELT, Ausmelt and
The OSS manufacturing facility in Vysocany Praha ensures the speedy
roasting processes. availability of spare parts.
Oschatz GmbH
Westendhof 10 -12
45143 Essen
Germany
Phone +49 201 1802-0
Fax +49 201 1802-165
info@oschatz.com
www.oschatz.com

Production plant in Kocaeli, Turkey Production plant in Nanjing, China

Oschatz has been producing boilers and waste
heat systems in the Turkish region of Kocaeli,
close to Istanbul, since 1997. In 2011, production
was expanded and relocated to a new site:
Site area: 60,000 m (646,000 ft)
Production area: 10,000 m (108,000 ft)
Four production workshops up to
22 metres high
To serve the markets in Asia, Australia and
Oceania quickly and cost-effectively, Oschatz
has operated a production plant in Nanjing,
China, since 2005 (second stage of construction
in 2008):
Site area: 50,000 m (538,000 ft)
Production area: 15,000 m (161,000 ft)
Seven production workshops

Deep-water port close by Link to the port of Changjian

Production in accordance with ASME Production in accordance with Chinese GB

standards, the Pressure Equipment Directive, standards, ASME standards, AD standards

AD standards and ISO 9001 and ISO 9001
Second stage of construction (four additional

workshops / 10,000 m) in progress

Production plant in Prague, Czech Republic

The Oschatz production location in Prague was established in 2012
for the production of pipe work, smaller boiler components and
spare parts:

Production area: 1,650 m (17,760 ft)

Certified in accordance with SCC** 2006 and EN 3834-2
Centrally located, and well connected to international highways