Sensors and Process Control in Copper Smelters: A Review of Current Systems and Some Opportunities

Abstract

Despite the widespread and extended use of sensor systems in different industries, there is an important gap to reach equivalent conditions in pyrometallurgical processes for primary production. In the specific case of copper pyrometallurgy, the situation is particularly challenging to incorporate the Industry 4.0 concept for the optimization of their operations. Currently, only two instruments can be identified at the commercial level: the Noranda pyrometer and the Online Production Control (OPC) system. The iron-making and steelmaking industries, however, present an advanced level of control based on monitoring and sensing networks throughout the entire process. This reality has served as a basis for developing a series of solutions based on radiometric sensors for copper pyrometallurgy. We present two types of sensing concept. The first one is applied to smelting and converting reactors based on the measurements of the radiation of the oxidation of different copper and iron sulfides. The second one considers hyperspectral imaging of molten phases flow during operations. The idea of this proposal is to transfer some commercial sensing technologies already in use in the steelmaking industry. In this article, the fundamentals of the sensor design, proofs of concept, and the initial industrial validations are reviewed. Finally, a discussion on the contribution of this knowledge and development opportunities within the framework of Industry 4.0 are addressed.