The Fiery Refinement from Blister Copper to Copper Anode: A Record of Overcoming Challenges in the Energy-Saving and Emission-Reduction Project for Anode Refining at Yimen Copper Industry

Since the operation of the 100,000 mt blister copper environmental protection and efficient technological transformation project on April 16, 2017, Yimen Copper Industry has seen continuous growth in production and profits, leveraging its advantages in "processing low-grade and miscellaneous materials" in production processes. Facing the favorable development situation, Yimen Copper Industry did not rest on its laurels but focused on the long-term development of the enterprise, deeply analyzed its shortcomings, and actively met challenges. Considering the small production capacity, short industry chain, weak risk resistance, environmental risks in the blister copper casting process, the need for remelting of blister copper ingots in the next process, and severe heat energy waste, the company initiated the anode refining energy-saving and emission-reduction project and incorporated it into the enterprise's "14th Five-Year Plan" for follow-up and implementation.

Through scientific demonstration, the construction content of Yimen Copper Industry's anode refining energy-saving and emission-reduction project includes the construction of two 180 mt anode furnaces and one set of 70 mt/h double disc casting system, along with the improvement of auxiliary facilities such as flue gas treatment systems, water supply and drainage systems, and power supply and distribution systems. After the completion of the project, blister copper will be purified into anode copper, further compensating for the short industry chain, achieving energy-saving and emission reduction, promoting green circular development, enhancing the core competitiveness of the enterprise, and embarking on a path of sustainable development. In advancing the project, great efforts were made in feasibility studies, energy assessments, and environmental impact assessments. The cadres and employees always kept the project construction goals in mind, worked overtime to perfect the approval documents for each link, and vigorously pushed forward the pre-construction preparations. With the coordination and promotion of the parent company and local government, and the hard work of the project personnel, the project received the environmental impact assessment approval on November 20, 2024.

On December 30, 2024, the anode refining energy-saving and emission reduction project of Yimen Copper Industry received approval to commence and started smoothly, with a construction period of six months. Thanks to thorough preparation in advance, the project entered a "decisive battle" state right from the start. As construction fully unfolded, challenges arose one after another. The first issue was the difficulty in maneuvering lifting equipment due to the relatively narrow site, along with the complexity of managing safety for multiple overlapping operations. Additionally, the tight schedule and heavy workload, compounded by the fact that the construction period spanned the Chinese New Year holiday, led to significant personnel turnover and disruptions in equipment transportation. The construction proceeded concurrently with ongoing production, creating a "dual-front" operation that posed significant on-site management difficulties. In the face of these challenges, the cadres and employees of Yimen Copper Industry and the contractors treated the construction site as their home, working, eating, and often staying there around the clock. Overtime became the norm, and they willingly gave up holidays and rest days, working in shifts 24/7, writing many touching stories of dedication.

The contractor's workers showed great effort, like tireless "spiders," climbing cylindrical furnaces and towering beams, battling at various work sites, building a steel fortress of the project with their hard work and sweat.

Yimen Copper Industry saw the full participation of its veteran, middle-aged, and young staff. Deputy Chief Engineer Qi Yonghui and Project Technical Director Feng Gao, both born in the 1970s, arrived early every morning and left late at night, steadfastly overseeing safety on the project site. Despite being in their 50s, they demonstrated strong will and rigorous conduct, setting an example for the younger generation. Qian Hongsen, head of the Equipment and Energy Department, born in the 1980s, was involved in the entire process from project initiation, approval, construction, to commissioning. He worked tirelessly, much like an indefatigable perpetual motion machine, dedicating himself to the project. Fu Duyi, a mid-level manager born in the 1990s, threw himself into the work with the zeal of a "workaholic." He followed up on the project progress daily, often working until three or four in the morning, and then reporting to work on time the next day. His disheveled hair, a sign of frequent late nights, bore witness to his dedication. Even when his wife needed prenatal check-ups, he missed them, feeling guilty but never backing down.

The company's Party, labor union, and youth league organizations all pitched in. The "Zhongtong Pioneer" Party member task forces of each branch planted the Party flag on the front lines of the project, participating in urgent and challenging tasks such as cable laying and safety supervision alongside the contractors. The labor union provided food and drinks, showing deep care for the workers toiling in high temperatures. Young members of the Communist Youth League, wearing "volunteer red," helped move materials and clean the environment, contributing their youthful sweat to the project.

At the construction site, touching stories were abundant, embodying Yimen Copper Industry's team culture of "being together, heart and soul, and working together," forming a powerful force driving the safe and efficient advancement of the project. After all staff worked day and night, the anode furnace was started for preheating on April 2. On April 10, the project was completed in exactly 100 days, 80 days ahead of schedule.

After one day of on-site integration, commissioning, and debugging, at 1:56 a.m. on April 12, as the first batch of molten copper was successfully poured into the sizzling 180t anode copper mold, the project's load test with material feeding was a success. At 7:36 p.m. on April 12, with the completion of heating and commissioning of the backend process, Yimen Copper produced its first batch of anode copper. During the days of trial production and debugging, the on-site staff were excited, full of anticipation, and faced immense hardships. To ensure the success of the load test, Yu Xiaolv, the factory director of the pyrometallurgy plant, and Ding Yonghua, the operations manager, led the operations team to work continuously for three days and nights, taking only short naps when exhausted. At the production debugging site, several newly recruited college graduates from the "post-90s" and "post-00s" generations followed the on-site mentors, busy with various tasks—sometimes lifting and installing the guide chutes, sometimes cleaning the copper molds, and sometimes moving heavy objects on site. Despite blisters forming on their hands, they persevered. They learned the key points of production technology from their mentors while working, actively immersing themselves in the project's "crucible." At this moment, "melting top-tier technology and refining top-tier talents" became tangible.

The trial production and debugging work received strong support from the parent company and sister units. Southwest Copper, Southeast Copper, and others dispatched capable personnel to provide on-site support. They debugged equipment while mentoring apprentices, working tirelessly from dawn to dusk, silently contributing their efforts and expertise. Southwest Copper and Yunnan Zhongse Nonferrous Metals provided strong support to Yimen Copper in cultivating talents for anode copper smelting.

As the debugging work progressed, the quality and daily production of Yimen Copper's anode copper continued to improve. Since April 15, multiple batches of anode copper have been delivered, with the products receiving positive feedback and favour from downstream enterprises. Since the load test of the entire project began, there have been no unplanned shutdowns. Daily copper production has continued to rise, demonstrating a safe, stable, rapid construction, smooth commissioning, and effective outcome.

For many smelters that have already achieved cathode copper production, anode copper production is merely a front-end process. However, for Yimen Copper, which has been in operation for 30 years, it represents not only a product upgrade but also the culmination of 30 years of steady and unremitting efforts, serving as the cornerstone for the company's long-term development. Looking back at Yimen Copper, since the production of its first batch of blister copper on October 29, 1995, it has undergone multiple technological transformations. The annual production capacity of copper products has increased from 10,000 mt to 50,000 mt, 100,000 mt, and now 150,000 mt. Although the scale of improvement may seem relatively small, each step has been taken with solid determination. Each step represents Yimen Copper's commitment to green and low-carbon development, a vivid practice of promoting new quality productive forces, and a testament to the hard work and dedication of Yimen Copper's cadres and employees in creating happiness through their efforts.