Selecting an oxygen plant for a copper smelter modernization

The selection of an oxygen plant for the Cyprus Miami smelter modernization project began with a good definition of the use requirements and the smelter process variables that can affect oxygen demand. To achieve a reliable supply of oxygen with a reasonable amount of capital, critical equipment items were reviewed and reliability was added through the use of installed spares, purchase of insurance spare parts or the installation of equipment design for 50 percent of the production design such that the plant could operate with one unit while the other unit is being maintained. The operating range of the plant was selected to cover variability in smelter oxygen demand, and it was recognized that the broader operating range sacrificed about two to three percent in plant power consumption. Careful consideration of the plant “design point” was important to both the capital and operating costs of the plant, and a design point was specified that allowed a broad range of operation for maximum flexibility.