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

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

Aug 23, 2022 126 likes •572 views

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

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SLIDE 1

COPPER SMELTER PROJECTS & SERVICES

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SLIDE 2

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.

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SLIDE 3

Dickinson Geographic Footprint

Office Locations

  • South Africa
  • Zambia
  • Mauritius
  • Tianjin, China
  • Egypt
  • Namibia
  • Democratic Republic of Congo
  • Russia
  • Brazil

Business Operations Business Experience Business Alliance Locations

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SLIDE 4

Dickinson Head Office & Workshops

Total land area: 14,000 m2 Total buildings (including offices, workshops & warehouses): 8,500 m2

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SLIDE 5

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
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SLIDE 6

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.
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SLIDE 7

Furnace Solutions Industrial Solutions

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SLIDE 8

Copper Smelter Services

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SLIDE 9

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
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SLIDE 10

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 Vessels

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SLIDE 11

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
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SLIDE 12

Isasmelt Demolition utilizing Brokk Machine Only 48 hours for complete demolition

Refractory Demolition

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SLIDE 13

Refractory Installation

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SLIDE 14

Isasmelt Refractory Installation with Suspended Platform

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

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SLIDE 15

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.
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SLIDE 16

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.

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SLIDE 17
  • Auxiliary maintenance (handrails, walkways)
  • Off-gas maintenance and repairs
  • Growth monitoring
  • Cleaning copper spills
  • Pouring lip cleaning with the Brokk

Converters

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SLIDE 18
  • Full reline hot to hot rebuilds within 15 days
  • Partial repair hot to hot repairs within 12 days

Converters

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SLIDE 19

COMPLETED OVER 80 CONVERTER REBUILDS IN PAST 9 YEARS

Converters – Rebuilds Track Record

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SLIDE 20

Converters

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SLIDE 21

Maintain the refractory on the:

  • Receiving launder
  • Long lasting launder
  • Y-piece
  • Launder tip
  • Intermediate ladle
  • Spoons

Mould Twin Casting Wheel

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SLIDE 22

Mould Twin Casting Wheel

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

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SLIDE 23

Spoons, Launders & Intermediate Ladle

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SLIDE 24

Precast Launders

  • Pre-dried up to 650 oC
  • 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
  • nly 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

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SLIDE 25

Precast Launders

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SLIDE 26

Copper Recovery – Vacuum Services

  • Recovery
  • f

copper concentrate from Ducts, Conveyor Spillages, Walk-ways and Plant Floor Space

  • Solid and Liquid Recovery and Disposal
  • Recovery from Slag Pits
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SLIDE 27

Copper Recovery – Vacuum Services

Advantages

  • Mechanised
  • Fast and safe
  • Most efficient
  • Quality priority service
  • Cost reduction

Applications

  • Wet material
  • Dry material
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SLIDE 28

Catalyst Handling Services

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SLIDE 29

Catalyst Handling Services

  • Dickinson Group of Companies offers an

extensive range of catalyst handling services coupled with a wide range

  • f

support services.

  • The company stands out as a service provider
  • f 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.

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SLIDE 30

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

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SLIDE 31

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.

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SLIDE 32

Catalyst Unloading

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SLIDE 33

Catalyst Screening and Materials Handling

  • Catalyst

screening eliminates process dust, catalyst fines and small catalyst particles that are generated over time and tend to affect catalyst reaction surface area as well as

  • ther

process parameters.

  • The

Screening is considered a critical factor to the success of an entire catalyst handling job as catalysts may easily be damaged by errors in the choice of equipment

  • r settings.
  • Our highly competent technical and

field teams have successfully conducted several screening campaigns.

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SLIDE 34

Catalyst Screening and Materials Handling

  • Plant data is collected prior to the works and proper

screens mesh selection is done

  • ffsite.

Continuous monitoring of screening conditions is observed in order to consistently ensure quality in every bag or drum.

  • The team ensures that accumulations in the divisional

plates under the grids are removed completely from pass to pass. Where meshes are employed, their condition is also closely and continuously monitored

  • Misplacement of bags or drums may have detrimental

effects, as such, every screened or collected catalyst bag

  • r drum from the different passes and layers of the

convertor is well labelled and stored/stacked in well- defined locations.

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SLIDE 35

Catalyst Loading

  • Dickinson Group of Companies performs both sock

and dense catalyst loading. Like in every other stage

  • f the catalyst handling process, quality assurance is

given a critical attention.

  • Given the hygroscopic nature of catalysts, exposure

to the environment is minimized at all costs..

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SLIDE 36

Catalyst Loading

  • Throughout the loading process, an even distribution
  • f

ceramic balls and catalysts

  • n

each bed in accordance with the loading diagram is closely monitored and ensured.

  • The

loading team puts in place all necessary measures to minimize catalyst breakages, channelling and high pressure drops due to loading errors.

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SLIDE 37

Haldor Topsoe Agency

  • Dickinson

Group

  • f

Companies has been appointed exclusive agent for Haldor Topsoe.

  • Haldor Topsoe is a world leader in catalyst manufacturing and
  • technology. The company was founded 1940 with a vision to tap

the potential of catalysis and scientific results and apply this to industry; this still stands and remains the backbone of the company.

  • Haldor Topsoe A/S enables establishments in the chemicals, oil &

gas industries to get the most out of their processes and products, using the least possible energy and resources.

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SLIDE 38

Catalyst Supplies Product Range

The Group supplies the following range of performance catalysts for Sulphuric acid production:

  • VK38
  • VK48
  • VK59
  • VK69VK-WD
  • VK-WH
  • VK-WL
  • VK-WSA
  • VK-WSX
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SLIDE 39

Industrial Corrosion Protection Services

SPECIALISED COATING APPLICATIONS PLANT-WIDE REFURBISHMENT SHEETING REMOVAL & REPLACEMENT ACID & FIRE PROOFING HIGH & ULTRA-HIGH PRESSURE WATER JETTING TANK REFURBISHMENT & LINING STORAGE TANK CLEANING ABRASIVE & SHOT BLASTING

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SLIDE 40

Global References

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SLIDE 41

Global Alliances

USA FRANCE SOUTH AFRICA UK GERMANY DENMARK EGYPT SOUTH AFRICA BELGIUM BELGIUM DRC / BELGIUM SOUTH AFRICA BRAZIL RUSSIA

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SLIDE 42

“One Personalised Solution” Global Footprint Global Alliances State of the Art Equipment Certification: OSHAS 18001 Inherent Innovative Culture Specialist and experienced personnel

+ + + +

=

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SLIDE 43

Dickinson Group of Companies provides a “One Personalised Solution” and strives to be your preferred business partner. www.dgrpint.com DICKINSON GROUP OF COMPANIES Corporate Head Office 10 Smuts Avenue P.O. Box 63 Vereeniging 1930 South Africa Tel: +27 16 421 3720 Fax: +27 16 422 1038 Email: sales@dgrp.co.za