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    Non-Ferrous Metal Smelting

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    gtdombo
    This document discusses non-ferrous smelting processes. It focuses on copper smelting, which involves a multi-stage process to oxidize iron impurities and produce high copper matte. Direct smelting of some ores like copper is possible, but for others like zinc it is not. Industrial copper smelting uses large reverberatory or flash furnaces to produce matte, which is then sent to converters to remove sulfur and produce blister copper through oxidation.

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    Non-Ferrous Metal Smelting

    Uploaded by

    gtdombo
    258 views47 pages
    This document discusses non-ferrous smelting processes. It focuses on copper smelting, which involves a multi-stage process to oxidize iron impurities and produce high copper matte. Direct smelting of some ores like copper is possible, but for others like zinc it is not. Industrial copper smelting uses large reverberatory or flash furnaces to produce matte, which is then sent to converters to remove sulfur and produce blister copper through oxidation.

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    This document discusses non-ferrous smelting processes. It focuses on copper smelting, which involves a multi-stage process to oxidize iron impurities and produce high copper matte. Direct smelting of some ores like copper is possible, but for others like zinc it is not. Industrial copper smelting uses large reverberatory or flash furnaces to produce matte, which is then sent to converters to remove sulfur and produce blister copper through oxidation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    258 views47 pages

    Non-Ferrous Metal Smelting

    Uploaded by

    gtdombo
    This document discusses non-ferrous smelting processes. It focuses on copper smelting, which involves a multi-stage process to oxidize iron impurities and produce high copper matte. Direct smelting of some ores like copper is possible, but for others like zinc it is not. Industrial copper smelting uses large reverberatory or flash furnaces to produce matte, which is then sent to converters to remove sulfur and produce blister copper through oxidation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 47

    3F03 Lecture 11

    Non Ferrous Smelting

    Non-Ferrous Ores
    Sulphides
    Zinc, Lead, Copper, Nickel

    Oxides
    Aluminum, Magnesium, Nickel (laterites), Tin, Titaniumn Niobium, Vanadium

    Sulphide Ores
    Want to Smelt Directly
    Makes use of heat of reaction Single stage process

    Complications
    Solution behaviour( Lead/Lead Sulphide) Major impurities (Copper/Iron)

    Sometimes Thermodynamics say no

    MS

    MO2 M

    Can We Smelt Directly?


    Copper? Yes! Lead? Maybe Nickel? No Zinc? Absolutely Not!

    Copper Smelting
    Can smelt directly Major Impurity Iron
    Cannot be removed by Mineral Dressing Can be removed by Oxidation Oxidation product magnetite (solid) Flux with Silica (fayalite slag)

    Seems straight forward


    Oxidise iron to slag, copper to metal ? But!----

    Complications
    Iron Sulphide Soluble in Matte Copper Oxide Soluble Slag Lines on Diagram Move As you make Richer Copper Matte More Copper Oxide Dissolved in Slag Solution?

    Multi Stage Process


    Ore Smelted to Produce High Copper Matte with Some Iron Remaining Slag Removed Matte Charged to Converting Vessel Oxidise Remaining Iron Remove Slag Oxidise to Copper

    Single Stage Continuous Process


    The way of the Future Need Imaginative Solutions

    MS
    MeS MeO

    M
    Me

    MO2

    A B MeS

    MS

    MeO

    M
    Me

    MO2

    A B MeS

    MS

    MeO

    M
    Me

    2%MO2

    MO2

    Care Over Losses!


    AC AB lose 2% MO2 use flux to absorb MeO deslag then
    send matte to convertor.

    Copper Making
    Matte Smelting
    Concentrates Cu2S Makes Richer Matte Use SiO2 to absorb FeO inhibit Fe3O4

    Converting
    Get Rid of Last Fe make pure Cu2S(white metal) Deslag Make Cu(blister copper)

    Thermodynamics of Copper Smelting


    Initial process gradual oxidation of FeS
    FeS(matte)+3/2O2=FeO(slag)+SO2 Below certain temperature will ppt solid magnetite 3FeS+5O2= Fe3O4(solid)+3SO2 Undesireable interferes with furnace performance

    Thermodynamics of Copper Smelting


    Coexistence of Magnetite, Slag and Matte 3Fe3O4+ FeS(matte)=10FeO(slag)+ SO2 Silica saturated fayalite slag aFeO=~0.3 See Figure 12.5 Rosenquist for Equilibria

    Thermodynamics of Copper Losses


    (%Cu)=30(aCu2O)1/2
    For medium copper matte 0.3wt%Cu in slag For converting white metal to blister 7%Cu in slag

    Dont convert with high slag volumes

    Inustrial Copper Smelting


    Feedstock
    Chalcopyrite (FeCuS2) Bornite(Cu5FeS4) Also FeS and FeS2

    Quartz (flux to form a slag with FeO) Matte; 30-70% Cu Largely decided by concentrate grade and economics.

    Industrial Furnaces
    Reverberatory Furnace
    Long Flat bath ~12000C Charged one end Heated by burner at one end Slag tapped from opposite end Matte tapped from sides

    Electric Furnace
    Similar to reverberatory heated by submerged electrodes

    Industrial Furnaces
    Flash Smelting
    Inco Outokumpo Sulphide oxidation supplies heat Use fine grained concentrate

    Flash Smelting
    Problem: N2 in air absorbs heat, cant reach 1200-1300 needed Two Solutions Inco
    Pure Oxygen

    Outokumpo
    Preheated air Still requires some Fuel

    Flash Smelting
    Inco
    Pure Oxygen Higher SO2 concentration easier to scrub

    Outokumpo
    Preheated air/sometimes oxygen enriched Still requires some Fuel Very versatile

    Flash Smelting
    Inco
    Matte 55-60%Cu Slag 1% Cu Off-gas 70-80%SO2

    Outokumpo
    Matte up to 65%Cu Slag 2.5%Cu

    Noranda and Teniente Furnace


    Furnace: Cylinder 5 mdia x 20m long Charge: Solid through end-wall or blown in through tuyeres Oxidant:40%O2 enriched air Matte: 70-75%Cu( originally designed to make copper!) Slag: 3-7% Cu (need slag cleaning!) Off gas:~15% SO2

    Noranda and Teniente Furnace


    Energy
    From Sulphur augmented by coal or molten matte

    Productivity
    ~2000t/day

    Process
    Continuous charging coal & pelletized conc Blow O2 enriched air Intermittent tapping of slag at one end Matte tapped from bottom

    Copper Converting
    Matte 99%Cu Oxidise S from matte using air (sometimes O2 enriched) Product: Blister Copper (requires firerefining)

    Pierce Smith Converter


    Cylinder 4m dia by 10m long Productivity:
    200-500 t matte/day 150-250t blister 200-300t slag

    Tuyeres:
    50 along one side 4-cm dia, 500-700Nm3 air/min total. Must be punched! To remove magnetite

    Rotated 1200 about axis for charging and deslagging!

    Pierce Smith Converter


    Slag: 2-15% Cu, 20-30%SiO2, 37-45%Fe Process:
    Charge 160t matte 50t SiO2 40-50t cold scrap Blow 12 hrs g Get 65t blister copper Done in stages

    Pierce Smith Converter


    Stages of Blow
    Charge Blow to white metal Deslag Charge more matte Blow again Repeat till converter full of Cu2S Blow to pure copper

    Continuous Blister Prduction


    Originally two processes
    Noranda(no longer makes copper) Mitsibushi(not strictly continuous)

    Continuous Blister Prduction


    Mitsibushi Three linked reactors: 1/ Matte Production 2/ Converting 3/ Electric slag cleaning furnace

    Mitsubishi Process
    Smelting Furnace
    Autogenous 8.5m dia x1.1m deep Charge: dried conc, silica and recycled converter slag, blown with oxygen enriched air via vertical lances Produce 65%Cu matte and slag Slag matte emulsion flows to electric slag cleaning furnace

    Mitsubishi Process
    Slag Cleaning Furnace
    Heated by three pre-baked graphite electrodes Slag separated (0.5-0.6%Cu) discarded Coke plus FeS charged C+Cu2O(slag)+FeS=Cu2S(matte)+CO Matte flows to converting furnace

    Mitsubishi Process
    Converter
    Oxygen Enriched Air (26%O2) Limestone flux Slag 15% CaO, 15-20% Cu recycled to smelting furnace. Only copper making furnace using a lime flux.

    Fire Refining
    Final Refining of Copper Electrolytic Before Casting Anodes Must Refine Blister Copper(0.5%O 0.03-0.05%S) Refining in Anode Furnace(reverberatory or rotary ) with one or two small tuyeres for air injection
    S+O=SO2 , k=90 at 11000C Other oxidisable elements also removed Precious metals remain

    Poling-Deoxidation
    Final stage of refining
    Bubble hydrocarbons through melt Produce CO, CO2 and H2O Source used to be green-wood poles, hence the name Some dissolved H2 in final product (0.1%O, 2*10-6H) Cast into 300-400kg anodes

    Electro-Refining
    Impure Anodes Pure Cathodes Electrolyte:H2SO4(170-200kg m-3)

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