Copper smelters have two central operations: smelting, followed by converting.  Firstly, the smelting operation is continuous, and is usually over-dimensioned compared to the downstream operations.  Secondly, the converting operation is performed in discrete batches that may be performed in parallel, and must share a limited set of resources.  However, typically, the converting throughput is constrained by the offgas handling capacity; this is indeed a major operational bottleneck in conventional copper smelters.

In recent decades there have been considerable technological enhancements that focus on different aspects of copper smelters, such as sensors, wireless communication, expert control systems, high pressure injection and waterless matte granulation. Nonetheless, copper smelters are reluctant to implement these technologies unless they are adequately justified, both qualitatively and quantitatively.

The current paper adapts the Theory of Constraints to describe the bottlenecking phenomena that occur within copper smelters, and how they may be resolved using incremental technological upgrades. The resulting benefits are quantified using a Discrete Event Simulation framework. Particular reference is made to the Rönnskär smelter (Sweden), as well as the Chuquicamata and Altonorte smelters (Chile).  However, the approach can be adapted to all conventional copper smelters, and certain nickel smelters.