Uzbek Innovation Revolutionizes Global Metallurgy: Copper Losses Halved

Revolutionary Automation Technology Takes Copper Production to a New Level

A sensational technological breakthrough has shaken the global metallurgical industry. Uzbek engineers have created a unique automatic slag formation control system that radically transforms converter production. The main achievement is impressive: copper losses in slags have been reduced from critical 2.5-3.5% to record 1.0-1.3%.

Long-standing Challenge and Breakthrough Solution

For decades, metallurgists worldwide have grappled with the problem of colossal copper losses during smelting. Traditional visual control allowed shocking fluctuations in copper content in slag -- from 0.05% to 15%. Uzbek specialists found an elegant solution based on measuring slag mass electrical conductivity at temperatures of 1350-1500°C.

Technological Breakthrough in Detail

The innovative system analyzes slag conductivity, which for the base composition (SiO₂, Al₂O₃, CaO, and MgO) is 0.1-0.2 Ohm⁻¹cm⁻¹. The addition of FeO, MnO, TiO₂, and Cr₂O₃ can increase this indicator to 2.1-12.0 Ohm⁻¹cm⁻¹. Safety is ensured by a special transformer reducing voltage to 12V. An innovative intermediate relay automatically controls converter rotation when critical conductivity values are reached.

Impressive Production Results

The technology's effectiveness is confirmed by revolutionary indicators of converter slag composition. Using the new system, copper content decreases to a record 1.2%, iron reaches 15.4%, silicon dioxide is fixed at 31.2%, calcium oxide comprises 19.2%, aluminum oxide -- 6.6%, and magnesium oxide -- 1.8%. Implementation of the automated system leads to copper loss reduction by more than 55%, substantial productivity growth, and significant energy savings. Moreover, all technology investments pay off in a short period -- from 8 to 12 months.

Scientific Breakthrough and Development Prospects

During research, a crucial discovery was made: increasing silicon oxide content from 29.5% to 45.5% leads to a fivefold reduction in slag conductivity at 1500°C. This enabled the creation of a precision slag formation control system, applicable in both copper and nickel metallurgy. Leading enterprises in Uzbekistan are already actively implementing this innovative system, planning future artificial intelligence integration for even more precise control of the converting process.

The Uzbek innovation opens a new chapter in the history of global metallurgy. The technology not only demonstrates outstanding results but also confirms Uzbekistan's status as a technological leader capable of solving the most complex industrial challenges. This fundamental breakthrough can change the economics of the metallurgical industry on a global scale, defining the future of heavy industry for decades to come.