SERVICES Introduction Dickinson Group of Companies was founded in - PowerPoint PPT Presentation

COPPER SMELTER PROJECTS & SERVICES

Introduction Dickinson Group of Companies was founded in 1910 as a building construction company, followed by the establishment of its furnace service business in 1928. The company has 90 years experience in providing Specialist Furnace and Industrial Services to the mining, metals smelting, mineral processing, thermal power generation and petrochemical refining industries. VISION Dickinson Group of Companies’ Vision is to be a global Leading provider of Furnace and Industrial Services MISSION Dickinson Group of Companies’ purpose is to provide an integrated and multidisciplinary “ One Personalised Solution ”, by offering essential furnace and industrial services, which increase productivity and performance together with reducing costs for our customers. STRATEGY The company’s strategy is to develop the Group’s current position as a leading specialized furnace and industrial solutions company, with a global reach and to deliver long-term sustainable growth through the continued expansion of the company’s services and markets.

Dickinson Geographic Footprint Office Locations • South Africa • Zambia • Mauritius • Tianjin, China • Egypt • Namibia Business Operations • Democratic Republic of Congo Business Experience • Russia Business Alliance Locations • Brazil

Dickinson Head Office & Workshops 14,000 m 2 Total land area: Total buildings (including offices, workshops & warehouses): 8,500 m 2

Industries We Serve  Aluminium Smelting  Glass  Platinum & Nickel  Iron, Steel & Coke Making  Copper & Cobalt  Ferrochrome & Ferromanganese  Heavy Sands  Nickel  Power Generation  Cement & Lime  Chemical & Petrochemical  Ceramic  Refractory Manufacturing  Food & Beverage Manufacturing  Fertilizer Manufacturing  Water & Municipal Services  Telecommunications

Safety Policy  Dickinson Group of Companies operates according to international best practices to achieve the highest practical levels of Safety, Health, Environmental Control and Quality , and adheres to BS OHSAS 18001:2007 accreditation.  The safety of our employees and contractors is an integral part of our business, with the goal of ZERO HARM.  The Group strives to:  Demonstrate strong leadership and direction in all conceivable SHEQ issues.  Ensure a consistent approach to the management of SHEQ in all locations.  Consult and communicate with all employees and stakeholders.  Educate the workforce in risk management, safety, health and environmental principles.  Respect the right of all staff to work in an environment where they know that risks are adequately controlled.  Promote the health and wellbeing of all its staff.  Measure SHEQ performance.

Furnace Solutions Industrial Solutions

Copper Smelter Services

Copper Smelter Services  Turnkey Furnace Rebuild Project Services  Project and Construction Management  Demolition of Furnaces, Removal of Refractory Linings and Waste Management  Refractory Materials and Industrial Plant Spares Management, including Selection, Procurement and Testing  Salamander Tapping, Controlled Furnace Decommissioning and Cool Down  Mechanical, Structural, Steel and Piping Dismantling, Fabrication and Erection  Quality Assurance and Control Systems  Design, Manufacture and Installation of Anchor Systems  Installation of Refractory Materials  Hot Sealing and Insulation  Drying and Curing of Refractory Linings  Furnace Start-ups and Commissioning  Industrial Vacuum & Silo Cleaning Services  Drilling and Installation of Thermocouples  Hot and Cold Furnace Repairs  Manufacture of Customised Precast Refractory Shapes

Primary & Secondary Vessels Dickinson Group offers a complete range of services on the following Copper Smelter Vessels:  Isasmelt, Ausmelt & Smelting Furnaces  Anode Furnaces  Matte Settling Electric Furnaces  Flash Furnaces & Slag Cleaning Furnaces  Six-in-Line / Three-in-line / Two Electrode Furnaces  PS Converters / Teniente Converters  Mould Twin Casting Wheel

Primary & Secondary Vessel Services  Partial, major or full demolition of refractories  Partial, major or full refractory installation  Refractory materials supply & coordination  Shell repairs or replacements  Tap hole repairs or replacements  Cleaning service on the boiler and transition piece  Launder replacements  Stack cleaning and maintenance  Platform repairs or replacements  Cleaning Copper & Ferronickel spills  Precast launder tiles

Refractory Demolition Isasmelt Demolition utilizing Brokk Machine Only 48 hours for complete demolition

Refractory Installation

Isasmelt Refractory Installation with Suspended Platform Isasmelt Refractory Installation by use of 6061-T6 Aluminium Multi-point Suspended Platform

Anode Furnaces Maintenance  De-bricking 3.5 days for a full reline and 2.5 days for a partial repair.  Refractory installation 13 days for a full reline and 8 days for a partial repair.  Anode Furnace shut-down full reline and partial repair.

Matte Settling Furnaces  Total project duration 33 days including demolition and refractory installation.  Dickinson removed the top floor and repaired the MSEF from the skew back of the permanent lining.

Converters  Auxiliary maintenance (handrails, walkways)  Off-gas maintenance and repairs  Growth monitoring  Cleaning copper spills  Pouring lip cleaning with the Brokk

Converters  Full reline hot to hot rebuilds within 15 days  Partial repair hot to hot repairs within 12 days

Converters – Rebuilds Track Record COMPLETED OVER 80 CONVERTER REBUILDS IN PAST 9 YEARS

Converters

Mould Twin Casting Wheel Maintain the refractory on the:  Receiving launder  Long lasting launder  Y-piece  Launder tip  Intermediate ladle  Spoons

Mould Twin Casting Wheel Maintenance on spoons, launders and intermediate launders utilizing recycled brick lining grog to reduce refractory consumption up to 50%.

Spoons, Launders & Intermediate Ladle

Precast Launders  Pre-dried up to 650 o C  Ready to use with no drying out required  Ease of installation and removal  Reduce time required to replace the blocks  Reduce labour required for launder maintenance  Increases refractory lining life cycle  Reduces need to constantly repair launder refractories  Modular design with capability to remove only damaged sections  Less skill required as installation & removal is rigging activity  Ability to keep pre-cast launders in stock Precast Matte Launder Life Time of 9 months

Precast Launders

Copper Recovery – Vacuum Services  Recovery of copper concentrate from Ducts, Conveyor Spillages, Walk-ways and Plant Floor Space  Solid and Liquid Recovery and Disposal  Recovery from Slag Pits

Copper Recovery – Vacuum Services Advantages  Mechanised  Fast and safe  Most efficient  Quality priority service  Cost reduction Applications  Wet material  Dry material

Catalyst Handling Services

Catalyst Handling Services  Dickinson Group of Companies offers an extensive range of catalyst handling services coupled with a wide range of support services.  The company stands out as a service provider of choice; anchored by over 90 years of experience in providing the specialist furnace and industrial services to mining, metals smelting, mineral processing, thermal power generation and petrochemical refining industries.

Scope of Services  Catalyst Unloading  Catalyst Screening and Materials Handling  Catalyst Loading  Reactor & Maintenance Works  Catalyst Supplies  Strategic Stocking of Catalysts  Reactor Maintenance Works  Corrosion Protection Services  Acid Resistant Brick Linings and Anti-Corrosion Coatings

Catalyst Unloading  Through excellent project planning, monitoring, control, communication, coordination and management, Dickinson Group of Companies ensures that catalyst layers are separated according to age and (or) type without cross contamination, harm to personnel and endangering the convertor structural integrity.  Special barriers are constructed inside convertors for personnel movements while vacuuming to avoid catalyst damage. Vacuumation suction pressure and catalyst velocity are also carefully controlled by our team of experts to avoid catalyst breakage. In addition the team ensures that all ceramic ball layers are vacuumed separate from the catalyst.

Catalyst Unloading