Onça Puma Furnace 1 Rebuild

Onca Puma Furnace 1 Rebuild project — 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 schedule
85 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)