Primary & Secondary Smelting

Primary & Secondary Smelting: Trusted Partner for Complex Operations

For more than 35 years, IAC has supported primary and secondary smelting facilities with solutions that balance operational performance and environmental compliance. Smelting operations face intense challenges—high temperatures, abrasive materials, strict air quality standards, and the need to maintain steady production. IAC’s integrated EPC and OEM capabilities address these demands by delivering engineered systems that improve throughput, control emissions, and reduce downtime.

From large-scale furnace ventilation and emissions control systems to bulk material handling, thermal processing, and automated controls, IAC provides the expertise and equipment needed for safe, efficient, and compliant smelting operations. As a single-source partner with global project experience, we bring the assurance that every phase—from design through commissioning and ongoing service—is built to maximize reliability and long-term value.

Industry Challenges

Smelting operations—whether processing ore in primary facilities or recycling scrap in secondary plants—face some of the harshest operating environments in industry. High temperatures, corrosive gases, and abrasive materials create significant wear on equipment, while the pressure to maintain continuous throughput leaves little margin for downtime.

At the same time, emissions compliance has become more stringent. Regulations governing particulate matter, SO₂, NOx, mercury, and heavy metals require advanced air pollution control solutions with proven reliability. Energy efficiency is another critical concern, as smelting furnaces and support systems consume large amounts of fuel and electricity.

Balancing production demands with regulatory compliance, cost control, and worker safety requires equipment and systems that are not only durable, but also engineered for long-term performance, adaptability, and ease of maintenance.

Core Capabilities for Smelting

IAC delivers a full range of engineered systems designed to meet the demanding requirements of smelting facilities. Our vertically integrated model—engineering, OEM equipment, fabrication, and construction—ensures that every solution is optimized for reliability, compliance, and throughput.

Air Pollution Control Systems

High-capacity baghouses, reverse air collectors, and dry sorbent injection systems engineered for capturing furnace off-gases, fumes, and fine particulates.

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Thermal Processing Equipment

Rotary dryers and custom thermal systems for ore preparation, slag handling, and byproduct processing.

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Pneumatic & Mechanical Conveying

Material transport solutions for dust, slag, additives, and recycled feedstock, designed for durability in abrasive conditions.

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Bulk Storage & Loadout

Silos, domes, and automated truck and rail loadouts that safely manage raw inputs and finished materials.

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With proven expertise across these critical areas, IAC equips smelting facilities with integrated systems that reduce emissions, safeguard uptime, and support long-term operational efficiency.

Solutions for Smelting Segments

Every smelting operation has unique requirements depending on feedstock, furnace type, and regulatory environment. IAC provides tailored solutions for each segment:

• Primary Smelting (Ore-Based Production)
  Ventilation and emissions capture systems designed for blast furnaces, electric arc furnaces (EAF), and ferronickel smelters. Our large-capacity baghouses, canopy hoods, and ducting networks handle millions of cubic feet per minute of furnace off-gas while meeting stringent global emission standards.
• Secondary Smelting (Recycling and Re-Melting)
  Dust control and material handling systems that support scrap-based operations. IAC designs alloy additive systems, automated controls, and efficient dust handling processes to help plants meet NESHAP and OSHA requirements while maximizing recovery of valuable metals.
• Specialty and Nonferrous Metals
  Custom-engineered APC and thermal systems for lead, zinc, nickel, and other nonferrous smelting processes. From high-temperature baghouses with advanced filtration media to rotary drying and conveying systems, IAC builds solutions that withstand harsh environments while ensuring reliability and compliance.

By tailoring our approach to primary, secondary, and specialty applications, IAC enables smelting operators to achieve consistent performance, safe working conditions, and regulatory confidence.

EPC Expertise for Smelting Facilities

IAC stands apart as a fully integrated EPC partner, managing every stage of smelting projects from design through commissioning. By combining in-house engineering, OEM equipment manufacturing, fabrication, and construction, we reduce project complexity and ensure seamless execution.

Our track record includes large-scale furnace ventilation and emissions control systems for both primary and secondary smelting plants. These projects often require massive baghouse installations, ductwork exceeding 20 feet in diameter, and rail or truck loadout systems capable of handling high-tonnage byproducts.

With our subsidiary Adelphi Construction, IAC self-performs civil, mechanical, and electrical scopes—keeping critical work under direct control. This allows us to fast-track schedules, minimize risk, and maintain the highest standards of quality and safety. For smelting operators, this means projects delivered on time, on budget, and built for decades of reliable performance.

Field Services & Aftermarket Support

Smelting facilities operate in harsh conditions where equipment reliability directly impacts production and compliance. IAC provides full lifecycle support to keep systems running at peak performance:

Maintenance & Repair Services

• Scheduled bag change-outs, cage replacements, and leak testing for all baghouse brands
• Mechanical repairs including valve, damper, and fan replacement
• Equipment conversions to upgrade older reverse-air or shaker systems to modern pulse-jet technology

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Training

• On-site or virtual seminars covering baghouse operation, troubleshooting, and maintenance scheduling
• Hands-on instruction from experienced IAC engineers to extend equipment life and avoid unplanned downtime

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System Optimization

• Burner tuning and dryer flighting analysis to improve efficiency
• Airflow balancing and ductwork inspections to reduce emissions and wear
• Dust control retrofits for improved compliance and product recovery

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Parts & Components

• 55,000+ stocked parts for baghouses, dryers, conveying systems, and controls
• Rapid shipment from strategically located warehouses to minimize downtime
• OEM and compatible parts available for multi-brand systems

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By combining parts availability, proactive maintenance, operator training, and responsive service, IAC helps smelting operators reduce downtime, safeguard compliance, and extend the life of their critical process systems.

Partnering with IAC

Choosing IAC means working with a partner who understands the unique demands of smelting operations. Our experience spans large-scale primary smelters, secondary metal recyclers, and specialty facilities worldwide, giving us the expertise to design systems that balance performance, safety, and compliance.

With fully integrated EPC services, OEM equipment manufacturing, and aftermarket support under one roof, IAC eliminates the gaps that often slow projects and increase risk. Our teams deliver projects on fast-track schedules while maintaining strict quality and safety standards.

Beyond project execution, we provide the parts, maintenance, training, and lifecycle services needed to keep smelting facilities operating at peak performance year after year. For operators, project managers, and engineers alike, IAC is the trusted partner who brings confidence, reliability, and long-term value to every engagement.

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