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Miami Project Execution

The Miami Smelter is an operating facility and is expected to continue operations through the execution of 

this project. As much of the work as possible will be completed while the plant is operating. However, 

some construction work will necessitate interruptions in production and will have to occur during planned

plant shutdowns. Currently the schedule for the main plant shutdowns is dictated by the frequency of 

Smelting Furnace relining. Other shutdown activities are scheduled around these relines. The campaigns 

between full relining tasks can range from 12 to 18 months in length, with an average campaign length of 

14 months. In addition to full relining, the Miami Smelter schedules mid-campaign kettle repairs where 

only the kettle portion of the vessel is relined. The mid-campaign kettle repairs typically occur halfway 

between full relines. A typical duration for a full reline is 21 days, while a mid-campaign kettle repair is 10 

days.

Although the exact timing of plant shutdowns is difficult to predict, the project has been developed on the 

smelter’s current shutdown plan. The current smelter shutdown plan is as follows:

 September 2014 – Smelter Shutdown, 21 days

 May 2015 – Mid Campaign Kettle Repair, 10 days

 November 2015 – Smelter Shutdown, 21 days – Final tie-in of 2015 construction

 June 2016 – Mid Campaign Kettle Repair, 10 days

 March 2017 – Smelter Shutdown, 40 days – Final tie-in of 2016-2017 construction (normal shutdown 

length: 21 days)

The majority of the construction that will occur in 2015 will be executed in advance of the November 2015 

shutdown with final tie-ins occurring during the planned November 2015 shutdown. The majority of the 

construction that will occur in 2016 and 2017 will be executed in advance of the planned March 2017 

shutdown with final tie-ins occurring during the March 2017 shutdown. Some early works will be 

completed ahead of the main construction for each phase. In addition, some activities will carry on after 

the main shutdown for each phase; this is primarily for demolition and non-critical work. The project 

schedule estimates a 40 day shutdown will be required in March of 2017, which is longer than the normal 

21 day shutdown. 

A schedule outlining the construction timeline for each phase is shown below. The main planned smelter 

shutdowns have been indicated by an ‘X’, with mid-campaign kettle repairs designated by an ‘o’.
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2015 Construction

The 2015 construction is deals with both preparatory work in advance of the expansion as well as 

reducing ambient SO2 emissions. 

This work will be tied to the planned shutdown in November of 2015. As much work as possible will be 

completed in advance of the shutdown. The early works consists of a small amount of work to be 

completed during the planned shutdown in September 2014 as well as the Converter Mouth Cover 

installations. The work in September 2014 is required to relocate existing operating equipment to enable 

pre-shutdown construction to commence in mid-2015. The Converter Mouth Cover installations have 

been coordinated with planned converter rebuilds. 

The main scope of the 2015 construction includes:

 Paddle Mixers and Conveyors.

 Converter Mouth Covers (4).

 Vent Fume Scrubber conversion to caustic.

 Centralized Caustic Receiving and Distribution System.

 Consolidated Maintenance Shop (required primarily to facilitate construction of the Aisle Scrubber in 

Phase 2).

2016-2017 Construction

The majority of the project scope will be installed during the construction that will be completed leading up 

to and during a shutdown in March of 2017. This shutdown will be longer than a typical smelter shutdown 

– currently estimated at 40 days. 

D

2015 Construction

Detailed Engineering o X o X o X

Procurement Packages (Major) o X o X o X

Development, Tender, Eng/Fab o X o X o X

Construction Contract Packages (Major) o X o X o X

Development, Tender o X o X o X

Construction Early Works (Site) o X o X o X

Construction (Site) o X o X o X

2016-2017 Construction

Detailed Engineering o X o X o X

Aisle Scrubber Package o X o X o X

Development, Tender, Eng/Fab o X o X o X

Smelting Furnace Engineering o X o X o X

Negotiation, Eng/Fab o X o X o X

Acid Plant Upgrades Package o X o X o X

Development, Tender, Eng/Fab o X o X o X

Procurement Packages (Major) o X o X o X

Development, Tender, Eng/Fab o X o X o X

Construction Contract Packages (Major) o X o X o X

Development, Tender o X o X o X

Construction Early Works (Site) o X o X o X

Construction (Site) o X o X o X

Q 3 Q 4 Q 1 Q 2

2014 2015 2016 2017

Q 1 Q 2 Q 3 Q 4 Q 1 Q 2 Q 3 Q 4 Q 1 Q 2
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Some critical portions of this work will be executed during the November 2015 shutdown. This work is 

referred to as the 2016-2017 construction early works. This work is preparatory and will assist with 

reducing the duration and congestion of the shutdown in March of 2017. Two elements identified for these 

early works include Smelting Furnace building structural steel modifications to facilitate the new furnace 

installation and Mold Barrel foundations for the replacement vessel. 

The main scope of the 2016-2017 construction includes:

 Covered Concentrate Storage.

 Smelting Furnace Crucible Replacement, Intense Cooling, Cooling Water System, Lance Seal and 

Feed Port Hood.

 Waste Heat Boiler Modifications.

 Converter Aisle Roofline Gas Collection.

 Mold Barrel Replacement.

 Anode Furnace Gas Handling System, Mouth and Slag Skim Bay Covers (6).

 Acid Plant Converter Bed, Final SO3 Cooler, IAT Cooling Upgrades.

 Tail Gas Scrubber conversion to caustic and Stack replacement.

 Vent Fume Wet ESP’s and Stack replacement.

 Aisle Scrubber and Aisle Scrubber Substation.

 Smelter Oxygen Line Replacement.