PHILIPPINE ASSOCIATED SMELTING AND REFINING CORPORATION Leyte Industrial Development Estate (LIDE), Isabel, Leyte 6539 Philippines pasar.com.ph +63 53 525 1000 TERMINAL REPORT Submitted by: Isaiah James B. Perez (MSU-IIT) In-Plant Trainee Table of contents I. Company Data i. Brief History / Background of the Company / Company Profile ii. Inclusive Dates of Training iii. Names of Personnel (supervisor, liaison officer, training/instructors, etc.) involved in the training program with their respective designations II. Brief Description of the Training Program i. Objective a. General b. Specific ii. Schedule / Timetable iii. Areas of Training iv. Reference Materials (e.g. manuals, textbooks, etc. ,) used during the training III. Personal Evaluation of the Training Program i. Reaction paper by the trainee to include comments on the following areas: a. Significant Achievements b. Technical skills and new technology learned c. Equipment, machinery, testing apparatus, etc. handled d. Experiences of the company personnel involved in the training e. Strong points f. Weak points and suggested solutions IV. Recommendations i. Potential of the company as a training ground a. Availability and appropriateness of facilities, equipment and machinery b. Company personnel cooperation ii. Duration of training (too long or too short) iii. Suggestions for the improvement of the training program iv. Advise to the future In-Plant Trainees V. Appendices i. Copy of the endorsement letter ii. Copy of the In-Plant Training/Practicum Agreement and Liability Waiver iii. Trainees Curriculum Vitae iv. Certificate of Completion v. Evaluation Form I. Company Data a. Brief History / Background of the Company / Company Profile The Philippine Associated Smelting and Refining Corporation, known throughout the metals world as PASAR, is one of the largest copper smelters in the Asia/Pacific region. Completed in 1983 at the cost of US$300 million, PASAR’s 138,000-mtpy plant facilities in Isabel, Leyte were subsequently expanded by 25% in 1993 to raise capacity to 172,500mtpy of electrolytic copper cathodes at the cost of US$52 million. PASAR is the only copper smelter and refinery in the Philippines and the first in Southeast Asia. PASAR operates using state-of-the-art facilities and equipment and maintains a high standard of compliance in terms of environment protection, safety practices and community relations. Its people is its greatest asset. It encourages the exchange of ideas and develops the skills and talent of its people. Although established primarily to process domestic copper concentrates, PASAR has been active in the international custom concentrates market since 1987. Today, PASAR takes copper concentrates from mines in Canada, USA, Chile, Papua New Guinea, and Indonesia. Its copper cathodes, which are registered with the London Metal Exchange (LME) and Commodity Exchange of New York (Comex) as Grade A and Grade 1 Copper, respectively, are shipped to Japan, Taiwan, South Korea, China, Southeast Asia, and the domestic market. Other by-products sold in commercial quantities include dore metal, sulfuric acid, selenium powder, granulated slag, gypsum, and nickel sulfate. PASAR uses the flash smelting process developed by Outokumpu Oy of Finland (with process improvements introduced by Mitsui Mining and Smelting Company of Japan) and the electrolytic copper refining process using the periodic reverse current technology. b. Inclusive Dates of Training Start: June 11, 2019 End: July 25, 2019 c. Names of Personnel (supervisor, liaison officer, training/instructors, etc.) involved in the training program with their respective designations Capability Development Superintendent: Team Leader : : : Jose Jasper Yap Mart Mervin D. Vinco Chares T. Aquino Rod Patricio Secondary Smelter Operations Superintendent: Rowen B. Bening Team Leaders : Ace Marc M. Tutor Junrie Martinez Alfred Bancale Alvin Tabarra Oscar Maclang Eliora Medrano Bryan Amolib Artvin Bolledo Mai Molo II. Brief Description of the Training Program a. Objective a. General To acquire knowledge on different plant processes with their corresponding operations (Smelter, Refinery and Ancillary Plant). b. Specific To recognize and practice safety at the workplace Describe the specific processes involved in the area of assignment Identify different types of emergency and procedure in responding to any emergency situation Identify different types of documents used in the workplace and its application Identify the different types of equipment and its functions Identify the different types of the process parameters and limits Provide hands-on experience and additional learning experience Appreciate the importance and application of the principles and theories Enhance technical knowledge and skills b. Schedule / Timetable Activity / Topics Program Orientation PASAR Plant Processes Safety Orientation Area Specific Induction/Review Emergency Procedures Workplace Documentation Process Equipment Familiarization Operational Controls Work Immersion (Specific Assignment) Process Overview (Other Areas) Presentation c. Areas of Training i. Primary Smelter a. Storage House and Blending Bins (SHBB) b. Flash Smelting Furnace (FSF) ii. Secondary Smelter a. Converter Furnace (CF) b. Anode Furnace and Casting (AFCA) iii. Refinery iv. Ancillary Plants a. b. c. d. Slag Flotation Plant Acid Plant Waste Acid Neutralization Plant (WANP) DORE Plant Duration (320hrs) 06/11/19 06/11/19 06/12/19 06/13/19 06/13/19 06/14/19 06/14/19 06/15//19 06/17/19 – 07/16/19 07/16/19 – 07/24/19 07/25/19 d. Reference Materials (e.g. manuals, textbooks, etc. ,) used during the training i. ii. iii. iv. v. vi. vii. viii. III. PPT Presentation (Safety) Work Permits Work Instructions TARP P&ID Logsheets Process Flow Diagram Operating Manuals a. Converter Furnace Reference Manual b. Pyrometallurgical Refining of Copper in an Anode Furnace c. Extractive Metallurgy of Copper 5th Edition by M.E Schlesinge, M.J. King, K.C. Sole & W.G. Davenport d. Development of a Process Model for a Peirce-Smith Converter by A. Lennartsson Personal Evaluation of the Training Program The In-Plant Training provided by PASAR was filled with learnings and fun. IPTs have experience both the technical and operational activities occurring in the vicinity of the plant. I was assigned in the Secondary Smelter and had a chance to experience both the work in the CF and AFCA department. During our stay in the field we were given different tasks, two tasks to be exact, and had it reported at the end of our work immersion. I had learned about PASAR’s goal of benchmarking their operations and they indeed had achieve such a feat in the area of benchmarking for the mold life and the rejection rate of anodes. We weren’t allowed to do the actual operation since one must undergo a lengthy training to be authorized to operate the equipment. We were only limited to observation and data gathering such as keeping inventory of available assets and assisting the field operators in their inspection of equipment performance. In the AFCA department more specifically in the LECO Analyzer room, we were allowed to actually operate the equipment. The main use of the LECO analyzer is to determine the sulfur and the oxygen content of the sample given by both the converter furnace and the anode furnace. We were granted a rotation to other areas and were fortunate to experience using the flotation device, filter press and other laboratory apparatus. In our university we lack equipment such as flotation device and during our stay in the Slag Flotation Plant we conducted an experiment of recovering of specific metals from iron tails. Most of the time we are only allowed to observe. Although only limited to observation it served as an enrichment with the knowledge we gained from our school. To see the actual equipment while studying them is quite different from simply reading the book. With regards to work relations, the people from the area were accommodating and we had blended in perfectly with them. We learned a lot from the team leaders through asking them questions and by letting us accompany them in the field work. We were able to learn the general process and the actual operation in the CF and AFCA through interviewing the different personnel assigned within the specified departments. The workers were also intrigued of our background as to where we are from and where we are doing our studies. It was both good and bad that we were able to have this program in the duration of pre-PTA activities. Since PTA is expected to be done in the very last day of the program, it is given that the team leaders of the different areas are quite busy with their preparations. But with the effort of everybody, the program ended with success. We, IPTs, had experience the actual work and was fortunate to be granted this opportunity by PASAR. Although successful, there were some aspects of the training that can be done for improvement to ensure the best learning experience for future IPTs of PASAR. Take for example, the rotation are to be done weekly. It was supposed to be implemented during our stay but due to the fact that PTA is fast approaching we were only given a week to rotate to other areas having a day to learn the process flow and the operations of the specified area. One day is not enough to learn all the things in a single plant. As to compensate for this, one can asked if he/she can acquired reference like operation manuals and other references to be studied at home or during free time. The overall program was successful and during our stay in PASAR as IPTs I personally don’t have any regrets. I can even see myself being an employee of PASAR in the near future and hoping that the companies’ expectation of us to apply will come to reality. Thank you PASAR. IV. Recommendations PASAR had been operating for 35 years already one a lot of IPTs like us had experiences like us also. The success of the program was dependent on the competency of the mentors in the assigned areas. As per availability and appropriateness of facilities, equipment and machinery of PASAR, it serves as an ideal training ground for young engineers. In the field of metallurgy, almost all of the concept acquired in the university can be applied in the plant. In terms of pyrometallurgy and adaptive metallurgy, there is the copper smelter. In electrometallurgy, the refinery is present. Hydrometallurgy and mineral processing can be applied in the slag flotation plant. PASAR is a metallurgical plant and being a training ground for metallurgical engineers is quite appropriate and the personnel in the plant are more than willing to help in mentoring and imparting their expertise to the younger generation. The duration of the training was too short and was not enough to learn in depth the operation and process of PASAR. But within the 40-days of training, one can say that he/she acquired sufficient information and experience which cannot be obtained at school. To all future IPTs, you are very fortunate to experience your training here in PASAR. In the field, most of the time the people are occupied with their respective jobs. As a trainee you are to take the initiative to start conversations that are related to both your work and personal life to get closer to the workers and build good relations with them. Lastly, if there is an opportunity to learn something new grab it and don’t let it be put to waste. Hope you will also in enjoy your stay in PASAR.
