Top blowing bottom stirring process for

Reduction of sulfur dioxide emissions has been a continuous endeavor in the copper smelting industry, particularly during the transition from the 1970s to the 1990s at Inco's Ontario Division. This study aims to present the development and operational outcomes of a novel oxygen top-blowing and nitrogen bottom-stirring process for producing blister copper. The methodology included an extensive research and development program which was conducted in collaboration with Inco's J. Roy Gordon Research Laboratory and other facilities, culminating in a redesigned smelter that met emerging environmental regulations while maintaining production capacity. Key results indicated significant operational efficiencies, including the successful removal of slag and alloy, and a marked reduction in fugitive emissions. Following its completion in the third quarter of 1993, the new copper smelting process became fully operational in November 1993, demonstrating both technical feasibility and economic viability under steady-state conditions. The advancements made through this R&D program not only contributed to regulatory compliance but also optimized production processes within the context of stringent environmental standards.