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Sterlite: Smelter capacity upgrade 2004

Supplier: MIPAC
28 June, 2011

Sterlite Industries was the first private sector smelter in India and has a reputation for focussing on efficient, environmentally friendly operations.

Project Overview:

In 2003/2004 Sterlite decided to upgrade their process control operations and increase copper smelter production capacity. This required a new larger ISASMELT furnace and associated Waste Heat Boiler, Rotary Holding Furnace, ESP, Acid plant and Refinery.

MIPAC Scope:

  • Control system and instrumentation design for ISASMELT Furnace and Feed Preparation Area
  • Control system configuration for ISASMELT, Feed Preparation, ESP, Waste Heat Boiler
  • Control System Training
  • Supply of Lance Hoist control equipment packages
  • Commissioning Assistance

Technical Highlights:

  • Yokogawa Centum CS3000 DCS
  • Siemens PLC for hoist package
  • Siemens Flux Vector Drive.


As a result of the project Sterlite Industries can now boast a smooth operation with an increase in production capacity from 150,000 to 300,000 tonnes per year. Sterlite was recently awarded a five star rating by the British Safety Council. This is the first time a Copper Smelter has been awarded such a high rating.

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