Boosting furnace performance in Mexico

Molycop has partnered with a mining operation in Mexico to commission and optimise its FurnStar control system — delivering safer, more efficient furnace performance through hands-on training, local adaptation and ongoing technical support.

Key Facts

• Molycop’s FurnStar system gives the site in Mexico precise control over electrode penetration, furnace power and operational safety limits.
• Local furnace crews received tailored, hands-on training and an easy-to-use interface to maximise confidence and daily performance.
• The project sets the foundation for continuous improvement, with future automation and optimisation already planned in collaboration with the site team.

Two Molycop specialists have spent time at a mining site in Mexico commissioning and fine-tuning Molycop’s FurnStar control system, a powerful tool designed to make furnaces run more efficiently, safely and consistently.

Kobus Oosthuizen, Manager: Advanced Process Control based in the Perth office, and Peter Czel, Process Engineer based in the Mexico office, spent a week at the site bringing advanced furnace control technology to life.
Kobus has years of international experience in commissioning and optimising advanced control systems for the mining and metals industry. He has extensive experience leading projects across multiple continents, always focusing on combining innovation with practical results at the plant level. 

He says getting results means ensuring technology meets the requirements of the site and is understood by the people using it:

Our focus is always on making technology practical and effective for the people using it. It’s not just about installing a system – it’s about making sure it works for the site team every single day.
Peter's hands-on approach to process engineering and his ability to translate complex systems provides confidence to operators. He says optimisation is a process that delivers cumulative value:

Optimisation is never a one-time event – it’s a process. By working closely with the site team, we can make sure each improvement delivers real value.
Together, their complementary expertise make them the ideal team to guide a project of this nature – from technical configuration to operator training.

FurnStar brought to life

Over the course of the week, the Molycop team configured the FurnStar system to manage electrode penetration and control furnace power while staying within safe operational limits. They also introduced automated electrode slipping, customised operational strategies and ensured the system was fully translated and adapted for local teams.
To make sure everything ran smoothly from day one, Kobus and Peter provided hands-on training to different furnace crews, set up an easy-to-use operator display and configured access rights to prevent unintentional system changes.

Planning for the future

During the visit, the Molycop team worked with site personnel to plan for the future. Ideas included automating electrode movement for degassing and adjusting resistance settings during tapping to further improve efficiency. These opportunities will be developed during the trial period, with Molycop providing ongoing technical support and custom solutions.

Cutting-edge technology and expert guidance

The project is an example of how Molycop’s global Process Optimisation team supports operations worldwide. Whether it’s in Mexico or elsewhere, Molycop’s mission is the same: combine cutting-edge technology with expert guidance to help its partners achieve safer, more efficient and more productive operations.

Find out more Discover the benefits of Molycop's Furnstar suite of control modules