Common Challenges in Smelter Projects

Many smelter projects face critical issues during early operation:

• Slow ramp-up after commissioning

• Unstable furnace operation

• Frequent equipment failure in early stage

• Lack of experienced O&M team

How Reksame Solves It

We deploy experienced smelter teams to support EPC, commissioning, and full operation.

Our approach ensures safer start-up, faster ramp-up, and stable plant performance — avoiding costly early-stage failures.

Our team supports critical smelter stages to ensure stable operation, efficient heat recovery, and optimized plant performance.

Smelter Process Expertise & Operational Focus

Our focus areas:

• Furnace operation & stability

• Converter performance

• Cooling & refractory reliability

• Commissioning and ramp-up

Bridging EPC execution with real operational performance in smelter plants.

Nickel • Copper • Precious Metals

Our Scope

EPC Support

• Engineering review

• Installation supervision

Commissioning & Start-up

• Dry commissioning

• Hot commissioning

• Start-up stabilization

Operation & Maintenance

• Full O&M outsourcing

• Maintenance system implementation

Furnace System

• RKEF

• Flash Smelting (FSF)

• Converter

Cooling & Refractory

• Cooling system integration

• Refractory installation & maintenance

Why Reksame

• Experienced smelter professionals with real field exposure

• Strong safety culture in high-risk industrial environment

• Proven approach for faster and more stable ramp-up

• Prevent costly early-stage failures through experienced O&M execution

Selected Smelter Experience

Smelter Commissioning Support – Indonesia

Scope:

• Commissioning and start-up support

• Furnace and converter stabilization

• Maintenance and operational support

Challenges:

• Slow ramp-up after commissioning

• Unstable furnace operation

Approach:

• Deployment of experienced smelter team

• On-site troubleshooting and process optimization

Outcome:

• Improved operational stability

• Faster ramp-up performance

Ready to Support Your Smelter Project

Let’s discuss how we can improve your plant performance.