Overcoming process challenges with expertise, technology and remote support

In Arizona, one smelting company plays a critical role in processing copper concentrate sourced primarily from a mine. During the smelting process, sulphonic acid is generated as a by-product, making the smelter a significant generator of sulfuric acid for leaching operations. However, the company faced significant challenges due to the limited number of instrument technicians and electricians available. The smelter relayed to Endress+Hauser USA and its sales and service representative partner, Instrumentation and Controls, that they needed process instrumentation-related services support in their mining facility. 

With a combination of expertise, reliable technology and modern digitalization methods, Endress+Hauser USA and Instrumentation and Controls helped the company increase overall competitiveness, cost-efficiency and reliability primarily through maintenance and calibration services and remote support. 

Challenge

The smelting company faced significant challenges due to limited personnel resources, which was a mere 20%. As a result, the company struggled to maintain production at full capacity. Across the industry, a shortage of trained and advanced personnel continues to have an impact on preventative maintenance schedules, hindering holistic operational efficiency in plants.

Before implementing Endress+Hauser USA and Instrumentation and Control’s solutions, the smelter struggled to finish projects on time due to reduced plant availability and increased downtime. The company faced the following challenges:

• Commissioning of devices
• On-site verification of instruments
• On-site technical support, diagnosis and troubleshooting
• Accomplishing preventative maintenance
• On-site training for optimization consultancy

Endress+Hauser USA and Instrumentation and Controls provided expertise, reliable technology and modern digitalization methods to mitigate the company’s challenges. With the right sensors, measuring and analysis equipment, and services, the Arizona-based smelting company overcame its operational woes.

Solution

As tenured and trusted industry leaders, Endress+Hauser USA and Instrumentation and Controls were able to help address the smelting company’s challenges and unlock its process potential.

Regarding instrumentation, Endress+Hauser and Instrumentation and Controls supplied the company with the following:

• Flowmeters for reliably measuring the volume flow of liquids, gases and steam
• Level instruments for accurate, continuous level monitoring or point-level detection, helping manage inventory and preventing overflows
• Pressure transmitters and gauges for various applications, from absolute to differential pressure, to improve safety and control
• Liquid analysis instruments for analyzing pH levels, chemical properties and other critical parameters for quality control and compliance
• Optical analysis instruments for gas detection and safety in monitoring hazardous gases, providing early warnings and helping prevent accidents
• Actuators and valves for precise control of flow and process automation
• Controllers and recorders for facilitating data acquisition, process control and historical data logging to integrate with field instruments and enhance overall performance

In addition to providing flow, level, pressure, temperature, analytical, gas detection, actuator and valves and controllers and recorders tools and expertise, Endress+Hauser USA and Instrumentation and Controls provided on-site and remote support, maintenance and calibrations to increase uptime and decrease production interruptions. Specialized technicians were also critical to the solution, offering continuous support and problem-solving capabilities by being embedded right into their team. 

When scouting potential partners to address their needs, the smelting company discovered competitors only had electricians available. By working with Endress+Hauser USA and Instrumentation and Controls, the company had access to more than 280 specialized experts who could work on motors, VFD drives, calibrations, actuators, and valve work, and at the top of the company’s list, troubleshooting. 

Results

Holistically, the smelting company now has less downtime, embedded expertise on-call and on-site with knowledge that will benefit them for years. As a result of less downtime, the company can increase its cost-efficiencies, giving it room to grow even more competitive within its industry. Furthermore, the company can now confidently ensure that their operations are more reliable with the maintenance, calibration and remote support services at their fingertips.