Process Control Technology Asarco Hayden Arizona Copper Smelter

"Remaining competitive in today's metal markets requires that copper smelters utilize the latest technology offered in process control, data acquisition, and process optimization. State-of-the-art tools like minicomputers, personal computers, and microprocessor based controllers provide real time process information that assist in making proper adjustments to the overall control strategy of an operating plant. The database accumulated by such systems broaden process knowledge, thereby reducing costly errors and plant downtime.IntroductionThe ASARCO Hayden Plant is located approximately 80 miles southeast of Phoenix, Arizona. The plant was commissioned in 1912 for the purpose of smelting copper concentrates from the surrounding mining district. Copper was produced for many years using calcining, reverberatory smelting and copper converting techniques. With the stricter environmental controls of the 1970's, the smelter experienced substantial declines in efficiency and productivity. It became necessary to identify and install a new smelting technology to maintain the viability of the Hayden plant.In 1980, after evaluating several smelting techniques, ASARCO management selected flash smelting as developed by International Nickel Company (INCO). One hundred and thirty-two million dollars was allocated for the project and construction began in 1982. Construction was completed and the new plant came on line in November of 1983."