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Mopani: Mufulira smelter upgrade – PWCS

Supplier: MIPAC
28 June, 2011

Upgrade of existing copper smelter involving replacement of core smelting technology and installation of associated oxygen plant, acid plant, electric holding furnace and services.

“...MIPAC [engineers] have conducted themselves with a professionalism and integrity that would suggest the Mufulira Smelter is their asset.”  John Ross, Metallurgical Manager, Smelter & Concentrator, Mopani Copper Mines

MIPAC scope:

  • Design, specification, configuration and commissioning of full plant-wide control system for the upgraded smelter. (ISASMELT and waste heat boiler; oxygen plant; sulphuric acid plant; electric furnace; materials handling area; services and utilities)
  • Development of plant-wide measurement and control standards for the project and upgraded smelter
  • Detailed instrumentation design for the ISASMELT plant and waste heat boiler areas
  • Electrical design and procurement specification for associated low voltage motor control centre
  • Client training in control system configuration and maintenance.

Technical highlights:

  • Strong focus on simplicity and reliability for maintenance groups
  • Transfer of knowledge from multiple technology providers into common control system to provide consistent operations interface
  • Fast-tracked project with control system on critical path.


  • Reduced project costs through economical project implementation by one group with minimised design group interfaces
  • Efficient and cost-effective ongoing control system maintenance due to commonality of equipment and consistency of design
  • Minimised project risk
  • Cohesive approach to instrument design standards, control system design and configuration.