Smelting and refining

As smelting and refining facilities modernize infrastructure and optimize processes to meet rising demand for metals like copper, nickel, aluminum and titanium, as well as battery materials, they face dynamic challenges and opportunities. This includes integrating new technologies, adapting to sustainability standards and navigating complex regulations.

Smelting and refining

  1. YOUR CHALLENGES

    • YOUR CHALLENGES Smelting and refining

      Balancing energy-intensive processes and sustainable development goals

      Managing energy-intensive processes while pursuing sustainability goals is a multifaceted challenge. Many smelting and refining facilities, which have been operational for decades and were built before current environmental standards, must now integrate new technologies within evolving regulatory frameworks and shifting economic contexts.

      With a broad range of technology options available, navigating and selecting the right solutions for your specific needs can be complex. Additionally, fluctuations in feedstock can significantly impact process stability, making waste reduction and energy optimization more challenging. Ensuring worker safety in environments with extreme temperatures, hazardous materials and sophisticated machinery add another layer of complexity. Effectively managing these factors is crucial for optimizing production performance and adhering to stringent industry standards.

  2. OUR EXPERTISE

    • OUR EXPERTISE Smelting and refining

      Bridging legacy systems and innovation through seamless integration

      BBA’s expertise in smelting and refining is distinguished by our ability to seamlessly integrate innovative solutions with existing systems. We bring a holistic approach to process optimization, leveraging advanced technology and deep industry knowledge to address the complex challenges faced by smelters and refiners. Our tailored strategies bridge the gap between legacy infrastructure and emerging advancements, driving both performance and sustainability.

      Process design, execution and optimization

      With over 25 years of experience in smelting and refining, BBA excels in designing and executing advanced processes. We focus on optimizing process design and execution to enhance efficiency and performance, particularly in upgrading and enhancing existing systems. Our extensive onsite experience ensures that our solutions are practical, effectively implemented and adhere to the highest safety and regulatory compliance standards.

      • Comprehensive process design: Tailoring solutions for contamination control and modern process control systems, adaptable to both new and existing equipment.
      • Continuous optimization: Using real-time data analytics for predictive maintenance and performance enhancement, relevant to both contemporary and aging systems.
      • Expertise in furnace operations: Delivering technology-agnostic solutions for various furnace technologies, ensuring optimal performance in both new installations and retrofits.

      Optimization of power systems and off-grid/backup generation

      With 40 years of expertise in electrical engineering and power management—where BBA made its mark from the start—we excel in optimizing power loading and generation systems. We effectively address the challenges of aging infrastructure, ensuring reliable power management for high-demand refining processes.

      • Efficient power management: Enhancing power loading and off-grid/backup generation for facilities with existing systems and aging infrastructure.
      • Handling high power demands: Expertise in managing startup loads and power spikes, crucial for optimizing performance in complex environments.
      • Advanced energy management: Implementing energy-efficient technologies compatible with both new and legacy systems.
      • Leveraging digital power system: Testing in our technology labs ensure interoperability, reliability and security.

      Emission and off-gas management

      We specialize in emission and off-gas management, using our knowledge of the industry to focus on solutions that optimize capital and operating efficiencies while enhancing environmental compliance today and for the future.

      • Emission reduction strategies: Advanced solutions for managing emissions and optimizing energy use, with consideration of using operational strategies to meet targets.
      • Off-gas treatment: Tailoring treatment solutions to both new installations and existing systems, ensuring effective management of off-gases.
      • Decarbonization and efficiency: Implementing strategies to improve sustainability and operational uptime in challenging environments.

      Material handling

      Effective material handling is crucial for minimizing downtime and ensuring a consistent feed for furnace operations. We address material handling challenges with solutions designed to integrate with existing infrastructure, optimizing performance and reducing waste.

      • Optimized material handling: Solutions for material storage, dust control and consistent feed timing while minimizing the downtime that that hampers many operations.
      • Advanced recycling strategies: Efficient handling of complex materials, including scrap and battery materials, to maximize material reuse and minimize rehandling and process upsets.
      • Waste reduction: Using slag and other by-products to reduce environmental impact and enhance operational efficiency.
      • Advanced material testing: Whether through our in-house material self-heating (MASH) lab or through management of third parties, we can ensure the right information is available to avoid downstream problems.

      Complete solution for automation and industrial technologies

      We offer comprehensive automation and IT/OT design services, including system design, programing and configuration, in-house testing, commissioning and optimization. Our approach ensures seamless integration with existing infrastructure, addressing the complexities of managing large startup loads and power spikes.

      • Instrumentation: Extensive field experience that allows us to select and implement the best technologies to measure process variables even in the most challenging environment.
      • Integration of DCS and PLC systems: Expertise in integrating modern solutions and technologies in both new and legacy control systems.
      • Cybersecurity: Our integrated approach will reduce vulnerability and ensure the reliability of your automation systems.
      • Technology-agnostic approach: Providing adaptable solutions that future-proof operations and minimize risks, even in facilities with established systems.
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