Metso upgrades Ausmelt Top Submerged Lance test work facility to explore hydrogen's role in smelting decarbonization

The Ausmelt® TSL Process is known for its efficiency, sustainability, and adaptability in treating a variety of feed materials across numerous smelting applications. At its test work facility located in Melbourne, Australia, Metso’s TSL team conducts pilot scale testing to mitigate potential risks, confirm process operating parameters and examine the treatment of various feed materials with Ausmelt TSL technology.

“One of the major advantages of Ausmelt TSL technology is its inherent flexibility to use a range of fuels and reductants,” says Alexander Glinin – Senior Project Manager, TSL Delivery. “It is one of the most versatile smelting technologies when you consider the range of applications. Copper, nickel, lead, zinc, tin, and metallurgical residues can all be processed under different conditions. Whether you want to run oxidizing processes, reducing processes or even a combination of both, it can be a single-stage continuous or multi-stage batch operation, it has that flexibility.”

After a lengthy construction and commissioning process, regulatory approvals enabling the use of gaseous hydrogen at the test work facility in Melbourne were received in November 2023. This potentially marks one of the first times in Victoria - and possibly Australia - that a company has ventured to use hydrogen in a fuel fired appliance such as this. This further highlights how at Metso, we are passionate about making a positive change in the world, and can do so through our sustainable innovations.

Pioneering hydrogen integration

Starting in early 2020, David Wilson - Process Engineer, TSL Technology, spearheaded the investigative journey that led to this upgrade. Initial enquiries with Australian hydrogen suppliers initiated investigation into applicable hydrogen related regulatory and installation requirements along with relevant Australian standards. Navigating uncharted territory, David and the Ausmelt team (Ivor Donaldson, James Coveney, Alexander Glinin, Jacob Wood and many more) meticulously engaged with technology partners, and regulatory bodies to ensure the safety and regulatory compliance of the proposed pilot plant upgrades. By working together, the project proved to be a learning opportunity for all involved.

“It was a long process due to unfamiliarity with hydrogen usage in a fuel fired application and there being no hydrogen specific standards in place. We had to work together with the regulatory bodies to ensure everything was done safely and that relevant regulations and standards were adhered to,” says David. “There was a lot of back and forth between the regulatory bodies, technology partners and ourselves before we received approval to begin modifications to the plant in May 2023.”

The modified pilot test work facility is now equipped to investigate and explore opportunities to revolutionize and decarbonize the non-ferrous pyrometallurgical industry. A mutual dedication to safety, efficiency and sustainability allowed the collaborative effort to transform what was once an initial concept into a complete realization.

“This is what we call an exploratory life cycle,” says Alexander. “David and the team had a vision, that turned into analysis and preparation, all the way through to eventual deployment. And because this was new to the regulatory bodies, it was not an easy task. It required liaising with different vendors who were also adjusting to new requirements and learning alongside our team.”

Driving sustainability

Amid mounting pressure on smelters to reduce carbon footprints, Metso aims to play an active role in the decarbonization of the pyrometallurgical industry. The team’s motivation for pursuing pathways for green metals production led them to research alternatives and substitutes to the current fossil fuel sources, opening the possibility of a furnace operating with minimal carbon footprint.

“We are all passionate about decarbonizing the TSL process and presenting a greener alternative to what's currently on the market,” says David. “Many of the customers we talk with are looking for greener alternatives to fossil fuels used in smelting applications, and we want to be able to support them in this direction.”

The team in Melbourne has always pursued sustainable innovations. Before exploring alternative fuels and reductants, extensive optimization of the Ausmelt TSL process was completed to decrease fossil fuel requirements. These technological optimizations include the injection of dried feed material via the Ausmelt Lance, and increased use of oxygen to achieved process intensification and consequently a sizeable reduction in the carbon footprint associated with the technology. After successfully developing and adopting these intensification measures– the team began to step into the world of alternative fuels and reductants to explore avenues for further decarbonization of the Ausmelt TSL Process.

“Use of green hydrogen is one means which the smelting industry is pursuing to decarbonize metal production,” says Jacob Wood – Technology Manager, TSL Smelting. “Therefore, we are very excited about the new opportunities our pilot test work facility offers to support our customers. We can now perform smelting trials utilizing fossil fuel substitutes including gaseous hydrogen, including co-firing with natural gas, biochar, or consumer waste streams such as Tyre Derived Fuel (TDF).”

By substituting the primary fuel source for furnaces utilizing hydrogen (derived from green electricity) the environmental impact of the smelting processes can be decreased considerably or eliminated completely. The team aims for hydrogen to serve not only as a fuel but also as an effective chemical reductant, potentially supplanting conventional options such as coal.

“There was not much information out there about hydrogen in this application, so we decided to do it ourselves, and see how it will work,” says David.

Diverse testing capabilities

Metso’s upgraded Ausmelt TSL pilot test work facility offers a comprehensive platform to explore the behavior and efficiency of gaseous hydrogen across a diverse range of process applications. It not only facilitates the investigation of hydrogen as a fuel and reductant but also contributes to furthering research and development for the decarbonization of pyrometallurgical processing.

“Whether it’s nickel smelting, copper smelting, tin fuming or even zinc fuming, the plant has the capacity to explore a variety of processes and recovery methods for different metals,” says David.

“With Ausmelt, the flexibility has always been a major benefit, and this upgrade enables that even more,” says Alexander. “For example, we have a customer who initially implemented the Ausmelt TSL process for tin smelting, then when they saw the benefits of the technology, they bought technology licenses, designs, and equipment for a lead smelting project and subsequently a copper smelting project. This is an example of the technology’s proven versatility and functionality.”

It is no secret that decarbonization is at the forefront of discussion within the smelting industry. With a strong R&D and innovation power, Metso is continuously looking for new ways to introduce innovations for our customers’ benefit. Aligned with these values, the testing conducted in the plant will also play a crucial role in future education relating to the safe storage, distribution, and combustion of hydrogen in direct-fire applications.

“This upgrade gives us a competitive edge to our technology,” says Alexander. “Traditionally, Ausmelt TSL technology would use fossil fuels such as natural gas, coal, diesel, etc – but now, we have an environmental advantage over other technologies by allowing the use of hydrogen.”

The future looks promising as Metso gears up for the implementation stage, already attracting interest from customers eager to engage in exploring hydrogen’s applicability in the smelting industry. With regulatory approvals received and the technology ready to go, the team is equipped to begin the test work and steer non-ferrous smelting applications in the right direction, towards improved environmental efficiency.

Getting it done – together

The journey from ideation to deployment was a team effort, involving Metso personnel from multiple disciplines across electrical, process control, project management, and more.

“I'm really interested in seeing how hydrogen works in this application,” says David. “The entire process was done safely, effectively and efficiently – and now we are ready to put it to the test.”

The journey to integrate hydrogen into smelting processes not only marks a technological leap but symbolizes Metso's commitment to sustainability, innovation, and collaborative progress. With commercial partners secured to do joint test work at Melbourne’s pilot plant facility, this is already a pioneering step for an industry-wide shift towards greener, more efficient metallurgical processes. That’s why, together, we are the partner for positive change.