{"product_id":"delmer-tbrc-furnace-top-blowing-rotary-converter","title":"Delmer TBRC Furnace (Top Blowing Rotary Converter)","description":"\u003cp\u003eThe TBRC Furnace, also known as the Top Blowing Rotary Converter, is an advanced and versatile smelting and refining furnace used for precious metal recovery, copper refining, and e-waste recycling applications. Designed to perform both smelting and oxidation refining in a single operation, the TBRC offers a high degree of efficiency, adaptability, and metal recovery rates—making it a preferred solution for processing printed circuit boards (PCBs), black copper, anode slime, and various metal residues.\u003c\/p\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eWorking Principle\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eThe TBRC Furnace operates on a continuous rotary smelting mechanism that maintains constant movement during the smelting process. This rotation ensures uniform heating, effective impurity removal, and efficient mixing of alloy and slag. The dynamic motion also helps minimize the inclusion of precious metals into slag, thereby enhancing overall metal recovery efficiency and concentrating platinum group metals (PGMs) into the copper alloy.\u003c\/p\u003e\n\u003cp\u003eDuring operation, the TBRC passes through three main working positions — feeding, smelting, and slagging\/casting.\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cstrong\u003eFeeding: \u003c\/strong\u003eCan be done vertically through the furnace top or via an online charging system.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eSmelting: \u003c\/strong\u003eCrushed PCB materials and flux are continuously fed into the furnace through an overhead bunker and feeding pipe.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eSlagging \u0026amp; Casting: \u003c\/strong\u003eAfter smelting, impurities are removed as slag, and molten black copper is cast into moulds for further refining.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eSmelting of PCB Materials\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eBefore charging into the TBRC, PCB scrap is crushed to 1–3 cm in size and separated magnetically to remove iron components. The crushed material (bulk density 0.6–0.9 t\/m³) is continuously fed at a rate of 0.4–0.6 m³\/h. Each smelting cycle lasts 6–8 hours, including:\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003eSmelting: 5–7 hours\u003c\/li\u003e\n\u003cli\u003eClarification: 30–40 minutes\u003c\/li\u003e\n\u003cli\u003eSlagging and Casting: 10 minutes each\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003eDuring this process, impurities like Fe, Si, and Al are removed in the slag-forming stage, while trace elements such as Pb and Sn are partly carried away in the off-gas. Continuous furnace rotation improves the separation of metal and slag, ensuring a low copper content (below 0.2%) in slag and nearly zero loss of valuable metals. The resulting black copper alloy is collected and cooled for subsequent refining.\u003c\/p\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eOxidation Refining of Black Copper\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eThe black copper ingots (approximately 2 tons per batch) are charged back into the TBRC Furnace for oxidation refining.\u003c\/p\u003e\n\u003col\u003e\n\u003cli\u003eThe burners heat the charge to the desired temperature.\u003c\/li\u003e\n\u003cli\u003eA compressed-air oxidation lance injects air at supersonic speed to oxidize impurities such as lead, tin, and nickel.\u003c\/li\u003e\n\u003cli\u003eThese impurities combine with flux to form slag, while refined blister copper is poured into moulds and sent to the anode furnace for electrorefining.\u003c\/li\u003e\n\u003c\/ol\u003e\n\u003cp\u003eRefining slag and off-gas dust can also be reprocessed in the TBRC to extract any remaining metals, reducing environmental waste.\u003c\/p\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eFurnace Design and Mechanical Structure\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eThe TBRC furnace comprises:\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cstrong\u003eFurnace Vessel:\u003c\/strong\u003e Made from high-temperature-resistant steel plates, continuously welded using submerged-arc technology and heat-treated to prevent deformation under extreme heat.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eBase Frame and Tilting Device: \u003c\/strong\u003eProvides full hydraulic-driven movement for precise control during charging, smelting, and pouring.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eHydraulic Power Unit (HPU): \u003c\/strong\u003ePowers the rotation and tilting of the furnace using hydraulic motors and cylinders equipped with lockup valves for safety in case of pressure failure.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eControl and Safety Systems: \u003c\/strong\u003eEquipped with a UPS-backed PLC control cabinet for safe operation during power outages.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eCombustion and Oxidation Systems\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eThe TBRC Furnace integrates both combustion and oxidation refining systems:\u003c\/p\u003e\n\u003cp\u003e\u003cstrong\u003e1. Oxy-Fuel Combustion Burner: \u003c\/strong\u003e\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003eCapacity: 1500 kW\u003c\/li\u003e\n\u003cli\u003eFuel: Natural Gas (NG) or LPG with 90% pure oxygen\u003c\/li\u003e\n\u003cli\u003eEquipped with flame detectors and automatic shut-off safety valves to prevent accidents.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003e\u003cstrong\u003e2. Oxidation Lance: \u003c\/strong\u003e\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003eConstructed from a heat-resistant alloy with a Laval nozzle.\u003c\/li\u003e\n\u003cli\u003eInjects compressed air (1.5–2 Mach) into the molten bath for strong stirring and efficient oxidation.\u003c\/li\u003e\n\u003cli\u003eAssists in removing residual impurities to produce high-purity copper.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003eBoth systems are skid-mounted and include advanced automation for flow control, temperature monitoring, and combustion management.\u003c\/p\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eAutomation and Control\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eThe TBRC Furnace is controlled through a Siemens PLC system with a touchscreen interface for local and remote operation. The system displays:\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003eReal-time operational status\u003c\/li\u003e\n\u003cli\u003eValve and burner conditions\u003c\/li\u003e\n\u003cli\u003eTemperature profiles\u003c\/li\u003e\n\u003cli\u003eGas flow rates and alarms\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003eA wireless remote controller is provided for furnace movement and burner management, ensuring safe and flexible operation.\u003c\/p\u003e\n\u003ch2\u003e\u003cbr\u003e\u003c\/h2\u003e\n\u003ch2\u003e\u003cstrong\u003eTechnical Specifications\u003c\/strong\u003e\u003c\/h2\u003e\n\u003ctable\u003e\n\u003ctbody\u003e\n\u003ctr\u003e\n\u003ctd\u003e\u003cstrong\u003eParameter\u003c\/strong\u003e\u003c\/td\u003e\n\u003ctd\u003e\u003cstrong\u003eSpecification\u003c\/strong\u003e\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eEffective Volume\u003c\/td\u003e\n\u003ctd\u003e1500 L\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eRaw Materials\u003c\/td\u003e\n\u003ctd\u003ePCB boards, black copper ingots, anode slime\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eFurnace Vessel Dimension\u003c\/td\u003e\n\u003ctd\u003eΦ2600 mm × 2400 mm\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eHearth Size\u003c\/td\u003e\n\u003ctd\u003eΦ1770 mm × 1985 mm\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eRefractory Type\u003c\/td\u003e\n\u003ctd\u003eMg-Cr refractory bricks with heat insulation layer\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eRotation Speed\u003c\/td\u003e\n\u003ctd\u003e0–15 rpm (variable)\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eBurner Type\u003c\/td\u003e\n\u003ctd\u003eOxy-fuel burner (1500 kW)\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eNatural Gas Consumption\u003c\/td\u003e\n\u003ctd\u003eMax. 150 Nm³\/h\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eOxygen Consumption\u003c\/td\u003e\n\u003ctd\u003eMax. 825 Nm³\/h (O₂ \u0026gt; 90%)\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eAir for Oxidation\u003c\/td\u003e\n\u003ctd\u003e400 Nm³\/h\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eAir for Oxidation\u003c\/td\u003e\n\u003ctd\u003e400 Nm³\/h\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eOff-Gas Flow Rate\u003c\/td\u003e\n\u003ctd\u003eMax. 12,000 m³\/h (at 1,350°C)\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eCooling Water\u003c\/td\u003e\n\u003ctd\u003e40 m³\/h (inlet \u0026lt; 28°C)\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003ePower Requirement\u003c\/td\u003e\n\u003ctd\u003e30 kW\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003ctr\u003e\n\u003ctd\u003eControl System\u003c\/td\u003e\n\u003ctd\u003eSiemens PLC with Touchscreen Panel\u003c\/td\u003e\n\u003c\/tr\u003e\n\u003c\/tbody\u003e\n\u003c\/table\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eEnvironmental Control and Safety\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eThe TBRC Furnace is enclosed in a sealed steel casing with an integrated flue gas suction port, directing exhaust gases to an off-gas cleaning system for safe emission management.\u003c\/p\u003e\n\u003cp\u003eAll exhaust is processed through multi-stage filtration and scrubbers, ensuring compliance with international environmental standards.\u003c\/p\u003e\n\u003cp\u003eSafety mechanisms include:\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003eAutomatic emergency shutdown\u003c\/li\u003e\n\u003cli\u003eHydraulic lock valves\u003c\/li\u003e\n\u003cli\u003eFlame monitoring sensors\u003c\/li\u003e\n\u003cli\u003eUPS backup for uninterrupted operation\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eApplications\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cp\u003eThe TBRC Furnace is suitable for:\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cstrong\u003eE-Waste Recycling Plants \u003c\/strong\u003erecovering copper, silver, gold, and PGMs from printed circuit boards.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003ePrecious Metal Refining Units\u003c\/strong\u003e processing black copper, anode slime, and metal residues.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eMetallurgical and Copper Refineries\u003c\/strong\u003e performing oxidation refining of copper alloys.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eSustainable Metal Recovery Operations \u003c\/strong\u003eseek high efficiency and low environmental impact.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003e\u003cbr\u003e\u003c\/p\u003e\n\u003ch2\u003e\u003cstrong\u003eKey Advantages\u003c\/strong\u003e\u003c\/h2\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cstrong\u003eHigh Recovery Rate:\u003c\/strong\u003e Up to 99% metal recovery efficiency.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eDual Functionality: \u003c\/strong\u003eCombines smelting and oxidation refining in one system.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eFlexible Raw Material Handling: \u003c\/strong\u003eSuitable for e-waste, copper scrap, and anode residues.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eEnergy Efficient: \u003c\/strong\u003eOxy-fuel combustion system optimizes heat utilization.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eEnvironmentally Friendly:\u003c\/strong\u003e Integrated gas treatment and slag depletion minimize waste.\u003c\/li\u003e\n\u003cli\u003e\n\u003cstrong\u003eAdvanced Automation: \u003c\/strong\u003eSiemens PLC for precise control and monitoring.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003eDurable Design: Built with heat-resistant steel and refractory lining for long operational life.\u003c\/p\u003e","brand":"Delmer Group","offers":[{"title":"Default Title","offer_id":43854247231581,"sku":"DLMFRN0001","price":181402320.0,"currency_code":"INR","in_stock":true}],"thumbnail_url":"\/\/cdn.shopify.com\/s\/files\/1\/0299\/3163\/4781\/files\/Delmer_TBRC_Furnace_Top_Blowing_Rotary_Converter.jpg?v=1781256576","url":"https:\/\/delmergroup.com\/ta\/products\/delmer-tbrc-furnace-top-blowing-rotary-converter","provider":"Delmer Group","version":"1.0","type":"link"}