Onça Puma Furnace 1 Rebuild
Vale | Brazil | 2006–2010
220,000 tpa
production capacity ferronickel
53,000 tons
of nickel
2.2 million
man hours with 0 LTIs
65 weeks
project duration (to first metal)
Challenges
- Vale’s first ferronickel operation in Brazil and one of the largest in the world
- When smelting operations halted due to the failure of two furnaces from another supplier, we investigated the facility
- Completely rebuilt the furnace crucible, calcine transfer system, and slag handling and upgraded to the cooling water system
- Schedule and reliability were paramount due to already significant production losses
Solutions
- We provided engineering, procurement, and construction management services. Maximized the reuse of existing equipment with parallel engineering and fabrication activities to save time
- Our binding-system design was adapted to the existing crucible. An innovative new spring-loaded system provided the necessary binding forces and ensured furnace integrity during cycling and upset conditions
- Water piping below the furnace and open-film-water cooling from the lower sidewall were removed. This improved overall plant safety by avoiding metal and slag leaks or run-outs
- Monitoring and control systems were installed to facilitate corrective action and protect furnace integrity during upset conditions and furnace shutdown
Highlights
- Work was successfully conducted in the plant’s limited space and completed in just over a year, compared to 3 years for the original furnace ... a world record for projects of this nature!
- A record production of 24.4 thousand tons of Ni in 2015
- Remote community of Ourilandia do Norte had its economy restored
- Project was executed on time with an 11-month schedule and on budget
Project numbers
US$219 million CAPEX on an 11-month schedule85 MW the highest sustained average power of operation
400 m² furnace size
1,200 tons of steel structure
2,900 tons of refractory
270 copper cooling elements
44 weeks project duration (to first feed)
Services & technologies provided