Project Background
In the Central African Copperbelt, one of the world's most important copper and cobalt producing regions, a copper-cobalt alloy smelting plant has been expanded in four consecutive phases. Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. was selected as the furnace equipment supplier for every phase, delivering refining and depletion furnaces that convert low-grade copper-cobalt concentrates and secondary materials into high-value alloy ingots.
Equipment Scope Across Four Phases
| Phase | Equipment Supplied | Total Capacity |
|---|---|---|
| Phase I | 2 x 4000kVA copper-cobalt alloy refining furnaces | 8000kVA |
| Phase II | 2 x 4000kVA refining furnaces + 1 x 2600kVA depletion furnace | 10600kVA |
| Phase III | 2 x 2500kVA copper-cobalt alloy refining furnaces | 5000kVA |
| Phase IV | 2 x 4000kVA copper-cobalt alloy refining furnaces | 8000kVA |
In addition to the furnace bodies, Chengda manufactured and shipped two sets of heat-exchange type flue gas settling chambers, completing the gas handling chain from furnace hood to dust collection.
Technical Highlights
- Submerged arc refining design - graphite electrode operation with adjustable power input, allowing the plant to treat fluctuating concentrate grades without changing the furnace body.
- Depletion furnace integration - the 2600kVA depletion unit recovers residual copper and cobalt from slag, lifting overall metal recovery of the plant.
- Modular shell and hood structure - water-cooled panels and sectional shells that can be replaced on site with locally available lifting equipment.
- Heat-exchange settling chamber - reduces flue gas temperature and captures coarse dust before the bag filter, protecting downstream equipment.
Execution and Results
Each phase followed the same disciplined route: basic design review, workshop fabrication under Chengda quality control, water pressure testing of all water-cooled components, pre-assembly, export packing and site commissioning support. Because the four phases reused a common technical platform, the customer was able to standardise spare parts, operating procedures and training across the whole smelter.
The plant now operates multiple refining lines in parallel, giving the operator flexibility to run high-grade and low-grade campaigns simultaneously. Chengda's continued involvement across four phases is the clearest proof of equipment reliability in a remote, high-temperature, high-dust operating environment.
Why It Matters
For copper-cobalt producers, furnace availability directly determines revenue. Chengda's phased delivery model - design once, replicate and upgrade - shortens each expansion cycle and keeps capital expenditure predictable. It is a practical template for African smelters planning step-by-step capacity growth.
Service and Support
Beyond hardware, Chengda provided commissioning engineers, water pressure test reports, general arrangement and electrical drawings, and operator training for each phase. Spare parts lists were aligned across phases so that the smelter keeps one common inventory. Remote technical support continues after handover, with response through Chengda's international service team.