Project Overview:

Sterlite Industries was the first private sector smelter in India and has a reputation for focussing on efficient, environmentally friendly operations. In 2003/2004 Sterlite decided to upgrade their process control operations and increase copper smelter production capacity. This required a new larger ISASMELT™ furnace and associated Waste Heat Boiler, Rotary Holding Furnace, ESP, Acid plant and Refinery.

MIPAC Scope:

• Control system and instrumentation design for ISASMELT™ Furnace and Feed Preparation Area
• Control system configuration for ISASMELT™, Feed Preparation, ESP, Waste Heat Boiler
• Control System Training
• Supply of Lance Hoist control equipment packages
• Commissioning Assistance

Technical Highlights:

• Yokogawa Centum CS3000 DCS
• Siemens PLC for hoist package
• Siemens Flux Vector Drive.

Results:

As a result of the project Sterlite Industries can now boast a smooth operation with an increase in production capacity from 150,000 to 300,000 tonnes per year. Sterlite was recently awarded a five star rating by the British Safety Council. This is the first time a Copper Smelter has been awarded such a high rating.

Sterlite: Smelting Expansion 2004 [project profile]