PT Smelting - Gresik

Acid Plant Database January 27, 2024

Owner	PT Smelting
Location	30 kilometers north of the city of Surabaya, East Java Desa Roomo, Kecamatan Manyar PO. Box 555 Gresik 61151 Jawa Timur - Indonesia
Background	Ownership: 60.5% - Mitsubishi Materials 25% - PT. Freeport Indonesia 9.5% - Mitsubishi Corporation 5.0% - Nippon Mining and Metals Co. Ltd.
Website	www.ptsmelting.com www.mmc.co.jp/sren/Gresik.htm
Plant	Gresik Copper Smelter and Refinery - Plant 1	Gresik Copper Smelter and Refinery - Plant 2
Coordinates*	7° 8' 27" S, 112° 38' 12" E	7° 8' 20.5" S, 112° 38' 9" E
Type of Plant	Metallurgical	Metallurgical
Gas Source	Copper Mitsubishi Continuous Smelting Process	Copper Mitsubishi Continuous Smelting Process
Gas Cleaning	Washing Tower - Venturi Scrubber - (3) Gas Coolers - 1st Stage WESP - 2nd Stage WESP
Plant Capacity	2300 MTPD	1328 MTPD
SA/DA	4 DA	3/1 DA
Status	Operating	Operating
Year Built	1998	2023
Technology	Outotec	Chemetics
Contractor	Mitsubishi Heavy Industries
Remarks	Acid Cooling - Sea water - Tube Material: Super-ferritic Cr-Mo-Ni stainless steel - Tubesheet Material: Duplex Cr-Mo-Ni stainless steel	Converter with 2 internal heat exchangers Modular converter design
Pictures	Video
Pictures
General	The smelter is adjacent to Petrokimia Gresik, a government owned fertilizer company, which utilizes all of the smelter sulfuric acid. - Smelter and refinery will treat copper concentrate produced by PT Freeport Indonesia in Irian Jaya (Papua) - Total Project cost: $626 million - Design capacity: 200,000 metric tons of copper metal Sulfuric Acid & Waste Water Treatment Plant are as a part of Copper Smelter Project and electrolytic refinery Complex at Gresik, near Surabaya in North Eastern Java, Indonesia. The Plant site is located at shoreline in the industrial area North of the town of Gresik. IKPT’s scope is for designing and constructing the Sulfuric Acid and Waste Treatment Plant, using MHI and Sumitomo processes.The Acid Plant is consist of 3 areas: Gas and Cleaning Section Strong Acid Section Waste Water Treatment Section The wet gas cleaning section is to prepare the feed gas for acid manufacture. Its capacity is 2,280 Ton/day of sulfuric acid (as 100 wt.% H₂SO4), at 148,200 Wet Nm³/h SO₂ 14.35 vol%. A separate Waste Water Treatment Plant (WWTP) will process the waste water to produce a salable gypsum and treated water for plant use. This project was spent 3,587,368 man-hours.
References	Goto, M., Konda, K., Muto, T., Yamashiro, A. and Matsutani, T.,"Gresik Copper Smelter and Refinery - Current Operation and Expansion Plan", Sulfide Smelting 2002, TMS, pp. 61-72.
News	December 14, 2023 - Indonesian copper smelter operator PT Smelting, a joint venture between Mitsubishi Minerals Corp and PT Freeport Indonesia, inaugurated on Thursday an expansion in capacity of its smelter facility in East Java. The processing capacity was expanded to 1.3 million metric tons of copper concentrate, from 1 million tons previously. It was unclear when production at the expanded facility would commence. The expansion was to meet demand for domestic processing of copper concentrates as Indonesia is set to ban exports of the raw material next year. Combined with Freeport’s upcoming $3 billion smelter in another part of East Java, Indonesia will have smelting capacity of 3 million tonnes per year next year, said President Joko Widodo at the inauguration. “This means value add will be created in Indonesia and new industries will emerge, such as for copper coil that is currently in development process,” Jokowi, as the president is known, said. Development of processing industries for Indonesia’s natural resources is the main economic agenda for Jokowi, whose second term in office will end next year. February 22, 2023 - Indonesian copper smelter PT Smelting (Gresik) is scheduled to start a 75-day maintenance in mid-2023 to complete an expansion project to increase its capacity from 280,000 mt to 330,000 mt. June 20, 2019 - Copper refining company PT Smeltign (PTS) plans to produce 291,000 tonns of copper cathodes this year, a 21% increase from last year's 242,000 tons. PTS president director Hiroshi Kondo said on Thursday that the firm was committed to processing 1.1 million tons of copper concentrate this year. The 1.1 million tons of copper concentrate will be process to become 291,000 tons of cathode, 1.04 million tons of sulfuric acid, 850,000 tons of copper slag, 31,000 tons of gypsum and 2,000 tons of anode slime. In 2019, PTS is to recieve teh 1.1 million tons of copper concentrate from two of its suppliers, namely golf and copper mining corporation PT Freeport Indonesia (PTFI) which holds a 25% stake in PTS and PT Amman Mineral. July 16, 2015 - Indonesian copper smelter Gresik has shut down due to a technical problem and it is not clear when the smelter will reopen, a spokesman at majority owner Mitsubishi Materials Corp said on Thursday.Takuya Kitamura said that the shutdown at the smelter was due to a broken pipe system, but he was not able to give a timetable for how long the outage would last.Mitsubishi Materials owns 60.5 percent of the operator of the facility, PT Smelting. The Indonesian unit of U.S.-based Freeport-McMoRan Inc holds a 25 percent stake.Two sources with knowledge of the shutdown said the plant has already been shut for several weeks, and that they expected the closure to last for at least one more.The Gresik smelter produced 230,000 tonnes of refined copper last year running at about 75 percent of its capacity."They were hoping to get it fixed, but they couldn't. Another week or so and it would nearly be a month," said a trader in Asia."It hasn't hurt them too much because of the slowdown in Indonesia, during Ramadan, when people tend to push back on deliveries. Still, it's gone on long enough now that ... it probably will affect deliveries."Kitamura was not able to say whether the company was looking for alternatives for themselves or their customers for sourcing replacement supply.Traders said that customers were unlikely to be hurt, since PT Smelting could easily buy metal from an amply supplied spot market to replace any contracted shipments. March 2, 2015 - Newmont Mining Corp's Indonesian copper export permit will not be renewed beyond March 19 unless it strikes a deal with Freeport-McMoRan Inc to invest in the latter's planned smelter, a mines ministry official said on Monday."For an export permit extension for Newmont, we are still awaiting an agreement between Freeport and Newmont," Coal and Minerals Director General Sukhyar told a news conference."It will depend how serious Newmont's commitment to co-operate with Freeport is and how much they will share the investment," Sukhyar said.Indonesia has been in talks with miners about their plans to develop domestic smelting and processing facilities.Early last year, Jakarta put in place export restrictions aimed at forcing mining firms to develop smelting and processing facilities so that Indonesia could refine all of its raw ores and concentrates."We share the government's stated goal of increasing value-added mineral processing in Indonesia," said Newmont spokesman Omar Jabara."As part of our MoU (memorandum of understanding) with Freeport, we continue working with them in support of their plans to develop a smelter. (Newmont) also has concentrate supply agreements with two Indonesian companies planning to build domestic smelters."Although fellow U.S.-based miner Freeport is pushing ahead with expansion plans at Indonesia's sole copper smelter at Gresik, Newmont has said multiple studies show its Batu Hijau mine cannot sustain a smelter on its own.The Indonesian government has long urged the companies to cooperate on a smelter.After a fractious nine-month export tax dispute, Newmont signed a deal with the government last year that allowed for the resumption of copper concentrate exports. But this agreement is set to end unless Newmont can show it is serious about domestic processing."If they really commit, they will be given an export permit extension," Sukhyar said. "The time limit for us to give an export permit extension is March 19."Newmont and Freeport account for 97 percent of Indonesia's copper output."We continue to advance our discussions with the government of Indonesia on an agreement for our long-term operating rights," said Freeport spokesman Eric Kinneberg, adding the talks include such issues as royalties and taxes, domestic processing and refining, divestment, and local content."In parallel, we are advancing plans to construct new smelter capacity in Indonesia. A site has been identified and we are actively engaged in discussions on technical, commercial and partnership arrangements." February 16, 2015 - Indonesia has dropped its demand that Freeport-McMoran Inc build a $1.5 billion copper smelter in Papua province, saying a regionally owned enterprise would take on the project instead, website Detik.com reported, quoting the mining minister.The ministry in December said Arizona-based Freeport, which runs the world's fifth-largest copper mine in Indonesia, should agree to build the Papua smelter in five years if it wanted a mining contract extension beyond 2021.The latest decision could ease pressure on Freeport, which has already agreed to a $2.3-billion expansion by 2017 of its copper smelting facility in East Java, currently the only one in the country.The government has been pushing the company to comply with rules that force miners to process and refine minerals domestically."If Freeport is burdened in two locations it would be uneconomical," Energy and Mineral Resources Minister Sudirman Said said on Sunday, according to the Detik website.A regionally owned enterprise would build the Papua smelter and could team up with other investors on the project, the ministry said in a document obtained by Reuters.An investor from China has already approached the Papua administration, Detik's report cited Said as saying, without providing details."A smelter on its own is not economical so we are building an (industrial) zone to make it more attractive," Said said.A ministry spokesman was not immediately available to confirm the comments.The 650-hectare industrial zone in Papua's Mimika area is not far from Freeport's concentrate pipeline and already has a port and eletrical infrastructure, according to the document.The zone will also include a cement packaging plant, a liquefied petroleum gas filling plant, a fertilizer plant and a petrochemicals plant."This is a win-win solution," Said said, adding that Freeport would be contractually required to supply copper concentrate to the Papua smelter."Whoever is tasked to build the smelter in Papua, Freeport Indonesia will form a business-to-business contract with them to supply concentrate," Freeport Indonesia CEO Maroef Sjamsuddin said in the document.Freeport is expected to produce 2 million tonnes of copper concentrate from its Indonesian operations in 2015, up from 1.4 million tonnes in 2014.Indonesia aims to develop 4.5 million tonnes of copper concentrate processing capacity nationally, Said said, up from 1.2 million tonnes at present.

MTPD - Metric Tonne per Day STPD - Short Ton per Day
MTPA - Metric Tonne per Annum STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption

* Coordinates can be used to locate plant on Google Earth


Sulphuric Acid on the Web^TM	Technical Manual	DKL Engineering, Inc.