Pyrometallurgical Furnaces

Smelting, converting, and refining solutions using pyrometallurgical furnaces

At Hatch, we design, supply, install, commission, start-up and support the operation of advanced pyrometallurgical furnace systems that meet the most demanding requirements of the metals industry. Our expertise spans electric furnaces, flash furnaces, top-submerged lance furnaces, top blown rotary converters, iron and steelmaking facilities, and kilns, delivering solutions that optimize productivity, safety, and sustainability across the entire value chain.

With decades of experience and a global track record, we help clients achieve stable, predictable operations, extend campaign life, and reduce environmental impact all while improving efficiency and lowering costs.

Furnace Solutions

End-to-End Furnace Solutions

Hatch provides end-to-end furnace solutions from concept and design to commissioning and performance optimization. These innovations improve safety, reduce downtime, and optimize energy use.

Our solutions include

Furnace Crucible

Core systems

Copper Cooling Systems

Hatch pioneered copper cooling technology with external water passages and high-intensity cooling for tapholes, plate coolers, waffle coolers, and water-cooled roofs. Since 2016, we’ve led the industry with graphite composite cooler designs to minimize corrosion and extend furnace life.

Air-Cooling Systems

Forced-air cooling using copper fins and internal air-cooling pipes integrated with custom refractory designs for enhanced hearth durability.

Binding Systems

Adjustable tensioned binding systems—spring or hydraulic—apply compressive forces to maintain refractory integrity and minimize gaps from start-up to shutdown.

Furnace Refractory Design

Tailored rectangular and circular refractory designs engineered for high-intensity smelting and unique process challenges.

Furnace Feed Systems

Material handling

Customized feed systems designed for precise material handling and optimized thermal performance.

Electrode Columns and Seals

Efficiency

Advanced electrode regulation systems and patented Sleeve Seal technology for electric furnaces, improving gas sealing, off-gas recovery, and operational efficiency.

Process Control Technologies

Controls & monitoring

Proven control modules for furnace power regulation, electrode slipping, feed control, power-feed coordination control (radar feedback), and furnace monitoring. Advanced monitoring includes automated leak detection and fiber-optic temperature monitoring.

Our services include

Planning and Development

FEL Studies
Advanced Modelling and Analysis
Novel Process Development and Piloting

Execution

Modernization, Upgrades, Retrofits
Custom Design
Spares and Quality Insurance
Construction, Commissioning and Startup
Operational support

Asset Performance Management

Leveraging our pyrometallurgical equipment design knowledge, proprietary condition monitoring technologies, and specialized integrity engineering expertise to deliver comprehensive asset management services that enhance the safety, performance, and lifecycle value of assets.

Protect and enhance performance across the full lifecycle
Provide proactive, data-driven insights that reduce failures and downtime
Enable better operational and capital decisions with condition and risk intelligence
Strengthen long-term client relationships through responsive aftermarket services

Talk to our furnace experts

Discuss upgrades, modernization, or performance optimization for your operation.

Contact Hatch

Why Choose Hatch?

✓ Proven Technology

Hatch delivers proven, innovative technologies in pyrometallurgy that optimize efficiency, sustainability, and performance for global metallurgical operations.

⚙ Custom Engineering

From flash and bath smelting furnaces to fluidized bed reactors, we design solutions where standard equipment falls short.

📈 Operational Excellence

Proven methodologies for process optimization, debottlenecking, and brownfield upgrades that deliver measurable results.

🌱 Sustainability Focus

Reduced emissions, improved energy recovery, and extended equipment life for a lower overall carbon footprint.

💡 Digital Innovation

Tools like Hatch Smelter Optimizer and advanced process control systems deliver real-time insights and efficiency gains.