Full Plant Wide Control System for a Greenfield 1.2MTPA Copper Smelter

Kansanshi Smelter Project

Full Plant Wide Control System for a Greenfield 1.2MTPA Copper Smelter

  • Solwezi, Zambia
  • Kansanshi Smelter
  • Control System - Siemens PCS7
Kansanshi is located in the North western province of Zambia near the bustling town of Solwezi. The Smelter is 80% owned by First Quantum Minerals (FQM). The Kansanshi smelter was a greenfield site adjacent to the Kansanshi open cast mine and concentrator. When in full operation, the smelter is designed to process 1.2 Mtpa of concentrate, producing over 300,000 tpa of copper metal. The smelter produced its first anode in December 2014 after a 36-month construction period.

Project scope

  • Full plant wide control system (PWCS) and ISASMELT™ smelter design and configuration
  • Development of PWCS software standards
  • Procurement of ISASMELT™ smelter packages
  • FAT(Factory Acceptance Test), site commissioning and operator training
  • OSI PI System™ server configuration and testing

Project highlights

  • The project's total CAPEX value was ~$800M
  • Kansanshi architecture is a full dual redundant Siemens SIMATIC PCS7 system. The system comprises of 5 control rooms and 12 operator stations
  • The software development phase involved close collaboration with FQM and specialist vendors. A strong simulation and intensive FAT phase ensured an exceptionally high-quality software was sent to site for the commissioning phase
  • 77 Mipac-designed DCS cabinets were built in Australia and South Africa, passing rigorous FAT before delivery to site
  • Mipac developed a plant-wide control system simulation for the site that is being used at the smelter as a training tool for plant operations staff
  • Development of site application specific eLearning tool to enable self-learning by plant operations and maintenance staff
  • Mipac also delivered an OSIsoft PI System™ to site and integrated it with the Siemens system to facilitate generating automated reports to inform management decision making

Feedback from the client

First Quantum’s proven Project Execution model aims to build and commission our own plants with the recent start-up and smooth ramp-up of the Cobre Panama project being our latest success. For this project, FQM engaged Mipac as the main automation contractor to provide Cobre Panama with a world class digital control infrastructure. Just as importantly however, it was the mineral processing, commissioning and plant optimisation knowledge that Mipac brought with them that was one of the various key enablers that allowed a successful ramp-up of the plant.

Zenon Wozniak Director, Projects / First Quantum Minerals

Mipac have been none other than a trusted partner throughout our Cobre Panama project where they were engaged to provide around-the-clock support for the OSIsoft PI System, RtDuet and MPA. Not only did Mipac provide an easy-to-use service desk portal where we were able to log issues and simply find solutions to common problems through a library of rich how-to articles, they also offered a direct line in the need for emergency support. The Mipac team has continuously demonstrated a high standard of excellence, providing Cobre Panama the best products, services and support. The attention to detail in designs and implementation is outstanding. Mipac’s genuine and dedicated engineers supported our team from inception of implementation of the PI system and new PI components (including a PI Integrator and Power BI reports), all the way through to concept development of a new architecture that helped boost performance and reliability and increased security to meet the growing demands and requirements for 24x7 support. Mipac has worked side by side with me and team on all challenges during and after implementation. Not a milestone was missed through the course of the project due to the commitment Mipac demonstrated as a pivotal partner helping us achieve optimal results. Mipac has understood the requirements and demands of our site and have delivered equally as demanded.

Ravindran Pillay Principle Engineer, First Quantum Minerals.

We are very pleased with the performance of the smelter. The achievement of over 100% of nameplate capacity, in just three months from startup, is unprecedented. It is a credit to the design and project teams and illustrates the strong capabilities of the operations management and staff.

Philip Pascall Chairman and CEO, First Quantum
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