Protecting Burner Management Systems in a Copper MineCase Study
Spartan Controls, located in Calgary, Alberts, Canada, is a leading provider of automation solutions in all process industries, including oil and gas, mining, chemical, pipeline, and municipal. Recently, Spartan installed new burner management systems (BMS) and fuel trains for a superheater and a concentrate dryer located in a copper mine near Salt Lake City, UT.
Spartan chose to use two Shelter Works fiberglass enclosures to protect the burner management systems (BMS) and fuel trains from the corrosive conditions and extreme weather found at the mine.
The first shelter, installed in an outdoor area of the mine, houses the burner management system for a superheater that takes saturated steam generated by a boiler and increases its temperature. This is known as “superheating” the steam, which imparts more thermal energy to the steam, allowing it to do more work. The superheated steam is then used to generate electricity in a downstream turbine.
The second shelter protects the BMS for a concentrate dryer that reduces the amount of water in the copper feed before smelting. This lowers energy consumption, exhaust gases, and emissions produced during the smelting process. It also provides a more concentrated stream of SO2, which is less costly to convert to sulfuric acid.
Both 8’ x 20’ x 8’ fiberglass shelters have 2.5” foam in the walls and roofs to help maintain optimal operating temperatures inside the shelters. The additional insulation also helps reduce outside noise for operators working inside the building. Each shelter also features two skylights and two doors with windows for interior illumination. The doors are located on the short walls of the enclosures. One end has a 3’ door, and the other has a 4’ door. The difference in door sizes allows flexibility for moving equipment in and out of the shelters.
Each fiberglass shelter has thoughtfully placed bulkheads to accommodate the piping for the fuel trains and the cable entries for the wall-mounted control panels. Bulkhead placement is determined during the design and submittal process to ensure their correct location during manufacturing. Bulkheads allow for infield penetrations and modifications that will not affect the shelter’s structural integrity by exposing insulation or cutting through wood.
Why Shelter Works
Sean Morris, Project Manager at Spartan Controls, explained that they selected fiberglass shelters because they can withstand aggressive environments that would cause typical metal buildings to rust.
When asked about his experience working with Shelter Works on this project, Sean Morris stated that it was a seamless transition from concept design to installation. ‘Working with the Shelter Works team was professional, and they were accommodating on some minor changes that had to be made last minute’, said Sean Morris. He wouldn't hesitate to work with Shelter Works again on future projects.
Overall, Spartan Controls and Shelter Works successfully collaborated to protect the new BMS and fuel trains from the harsh conditions in the copper mine. Their solutions will improve the efficiency, reliability, and safety of the existing furnaces and the mine.