Thermodynamic simulation of complex Pb-Bi concentrate oxidative bath smelting process

The element partitioning in a Pb-Bi concentrate oxygen-rich bath smelting process was studied using thermodynamic equilibrium simulation method. Effects of oxygen to feed ratio(OFR) and sulfur dioxide partial pressure(pSO2) on the partitionings of Bi, Pb, As, Sb, Cu and Ag were analyzed and compared with industrial data. The results suggested that the optimal OFR was between 6.3 and 6.8 kmol/t to maximize Bi, Pb, Cu and Ag partitioning in the metal phase. Further increase of OFR led to the drop of metal partitioning and increase of slag liquidus temperature. High pSO2 led to high deportment of Bi and Pb in the gas phase mainly in the form of sulfides, suggesting that a low pSO2 was conducive for reducing the dust ratio.

Iron extraction from lead slag by bath smelting

A new bath smelting process was proposed to recover iron for solid wastes reduction.99.79%of iron metallization,99.61%of iron recovery,pig iron with93.58%Fe,0.021%S,0.11%P,1.38%C,0.22%Si,0.01%Pb and0.031%Zn were achievedafter the wastes were smelted at1575°C for20min under C/Fe molar ratio of1.6and basicity of1.2.The produced pig iron could beused in steel-making.This study provides a way for recycling iron from smelting slag and hydrometallurgical residue.

Study on Foaming Behaviour of Molten Slag during Smelting Reduction with Iron Bath

The molten slag in smelting reduction with iron bath has peculiar behaviour for its high FeO concentration. Slag foaming is effected by the concentration and reduction rate of FeO, basicity of slag and temperature. Addition of granulated coke can greatly decrease slag foaming extent in the process of smelting reduction with iron bath. The anti-foaming capacity of granulated coke is the best when the ratio of coke used for coke layer to total coke used in smelting reduction is controlled at about 20%.

SELECTION OF THE PROCESS PARAMETERS FOR BATH AUTOGENOUS SMELTING OF COPPER

The process parameters for bath autogenous smelting of copper were selected based on dynamic analysis of the experimental data and calculation of the mathematical model. Selecting the slag composition of SiO2/Fe=0.80 and CaO％=16. desulphur ratio less than 80 wt.-％ in system. and the copper content of matte less than 60 wt.-％, it is able to limit Fe3O4 formation and obtain a high desulphurization. The critical oxygen content of the blast increased with decrease of the sulphur content of the concentrate and increase of copper contents of the matte. If the copper contents of the concentrate are respectively of 30 and 35 wt.-％, the critical oxygen contents of the blast will be 48 and 69 wt.-％ respectively. The smelling rate increases linearly with the blast intensity. When the sulphur content of the concentrate is 30 wt.-％, the oxygen content of the blast 70 vol.-％ and the copper content of the matte 60 wt.-％, a blast intensityy of 700 Nm3/m2·h results in a smeling rate of 48.81 t/m2·d.

Corrosion of Magnesia-chrome Brick by Smelting Reduction Slag with Iron Bath

Effects of FeO content （0, 5%, 10%, and 15% in mass, respectively ） in lab-synthesized smelting redttc- tion slag with iron bath and test temperature （1 450, 1 500, 1550, anti 1 600 ℃ ） on corrosion am,amount and microstructure of fused rebonded magnesia - chrome brick with 26.02 massqc of Cr2O3 were researched by rotary cylinder method. The results show that ： （ 1 ） the corro- sion amolult of magnesia -chrome brick by slag without FeO is higher than that by the slag with 5% FeO, and the vorrosion amount increases when FeO content increa- ses from 5% to 15% ; （2） the test temperature is one of the important factors affecting the slag corrosion resist- ance of magnesia - chrome brick, and the corrosion of smelting reduction slag to brick increases with the temperature rising.

STUDY ON THE NON－STOICHIOMETRIC METALLURGICAL PROCESS－A MODEL FOR THE BATH－SMELTING PROCESS

model based on the bath-smelting process for the production of quality steels has been developed considering non-stoichiometric system. The thermodynamic function of slag has been used to calculat the activities a(i) of components present in the slag and metal.To determine the valency of the elements in bath slag and metal phase, an experimental method has been suggested.

大型侧吹熔池熔炼炉内铜渣双向对流过程中挡渣板的数值研究

本研究设计了具有短熔炼搅拌区和渣室沉降区的35万吨侧吹熔炼炉。探索了挡渣板的存在及其安装位置对大型熔炼炉内气-渣多相搅拌特性的影响。研究表明:短熔炼搅拌区保证了射流对位于熔炼区上方的渣层的充足搅拌,有利于熔池内的渣金分离。当挡渣板存在时,渣层内的搅动对渣室区域几乎没有影响,可以保证铜锍与炉渣的静置沉淀和分离。中部渣室带挡渣板的炉型方案的平均湍动能较中部出渣无挡渣板提升14%,较部端头出渣无挡渣板提升47%。

铜熔炼渣的火法回收工艺与铅锌锑富集规律

铜精矿火法冶金后产生的熔炼渣经浮选回收铜后,尾渣含Pb、Zn和Sb,仍具有一定回收经济价值。浮选法对铜熔炼渣中Pb、Zn和Sb的回收率低,而火法熔炼通过高温和碳热还原可以有效分离这些元素。对直接还原熔炼、造锍还原熔炼和氧化-还原熔炼3种典型的火法回收工艺进行了对比中试试验。结果表明:火法回收工艺可达到理想的铜回收率,但不同工艺对Pb、Zn和Sb的回收效果不同;直接还原熔炼提高了Pb的回收率;造锍还原熔炼提高了Zn的回收率;熔炼法需消耗大量还原剂和能源,经济性需慎重考虑。火法熔炼适合作为铜回收的备用工艺进行研究。

富氧双侧吹铜熔池熔炼炉上升烟道结渣的矿物学分析

富氧双侧吹铜熔池熔炼炉上升烟道烟尘结渣严重,阻塞烟道,是制约熔炼炉长周期高负荷高作业率生产的关键因素。分别利用X射线荧光光谱仪、X射线衍射仪、扫描电子显微镜和电子探针显微分析仪,研究富氧双侧吹铜熔池熔炼炉上升烟道结渣烟尘的化学成分、物相组成及微观形貌。结果表明,上升烟道烟尘的主要元素为Fe、Cu、Pb、Zn和O,主要物相是(Cu, Zn, Fe)Fe_(2)O_(4)和Fe_(3)O_(4),表面微观形貌呈致密无孔洞。结合生产过程工况条件,对烟道结渣原因进行分析,认为富氧双侧吹铜熔池熔炼炉生产过程中,富氧空气通过喷嘴鼓入炉内,强烈搅动熔体,熔体中的气泡破裂逸出,喷溅形成的小颗粒熔渣与冰铜被热气流带入上升烟道,熔渣与冰铜被氧化为高熔点的(Cu, Zn, Fe)Fe_(2)O_(4)和Fe_(3)O_(4),在烟道壁面遇冷凝结形成结渣;同时,熔炼炉负压运行,入炉原料水分低,铜精矿等未反应的粉料被烟气带入到上升烟道高温段,在氧化气氛下反应生成黏结结渣;此外,原料中Pb、Zn、As等易挥发性物质进入烟道,被氧化为低熔点化合物后与高熔点的(Cu, Zn, Fe)Fe_(2)O_(4)和Fe_(3)O_(4)黏结在一起,形成致密的结渣烟尘。因此,在冶炼生产中,建议通过控制入炉原料水分和杂质含量,减少粉料入炉;控制渣型和熔炼温度,减少熔体喷溅;使用喷嘴燃烧重油,烧熔结渣烟尘,保证生产正常稳定运行。

双侧吹熔池熔炼炉内气液两相流数值模拟

为了探索铜双侧吹熔池熔炼过程增产增效的实现途径,以赤峰云铜有色金属有限公司的实际双侧吹熔池熔炼炉为原型,运用VOF等方法构建了炉内气液两相流动过程数值模型,据此对不同送风流量(1300、1500、1700 m^(3)/h,标态)条件下的熔炼过程进行了数值模拟。结果表明,提升送风流量能够在一定程度上提高熔炼效率,但同时也可能导致烟尘发生率增大等问题,因此,送风流量的增幅不宜过大。

白银炼铜法工艺优化思路

白银炉攻关团队系统对比其它先进铜熔炼工艺优缺点并科学评判“白银炼铜法”铜熔炼工艺存在的问题,通过炉型优化、氧气浓度提升等一系列试验和改造,实现了我国唯一原创具有自主知识产权的“白银炼铜法”炉床面积增大至106 m^(2),单炉粗铜冶炼能力超过了20万t,各项指标达到了同行业先进水平。

Breaking the Fe_(3)O_(4)-wrapped copper microstructure to enhance copper-slag separation

The precipitation of Fe_(3)O_(4)particles and the accompanied formation of Fe_(3)O_(4)-wrapped copper structure are the main obstacles to copper recovery from the molten slag during the pyrometallurgical smelting of copper concentrates.Herein,the commercial powdery pyrite or anthracite is replaced with pyrite-anthracite pellets as the reductants to remove a large amount of Fe_(3)O_(4)particles in the molten slag,resulting in a deep fracture in the Fe_(3)O_(4)-wrapped copper microstructure and the full exposure of the copper matte cores.When 1wt%composite pellet is used as the reductant,the copper matte droplets are enlarged greatly from 25μm to a size observable by the naked eye,with the copper content being enriched remarkably from 1.2wt%to 4.5wt%.Density functional theory calculation results imply that the formation of the Fe_(3)O_(4)-wrapped copper structure is due to the preferential adhesion of Cu_(2)S on the Fe_(3)O_(4)particles.X-ray photoelectron spectroscopy,Fourier transform infrared spectrometer(FTIR),and Raman spectroscopy results all reveal that the high-efficiency conver-sion of Fe_(3)O_(4)to FeO can decrease the volume fraction of the solid phase and promote the depolymerization of silicate network structure.As a consequence,the settling of copper matte droplets is enhanced due to the lowered slag viscosity,contributing to the high efficiency of copper-slag separation for copper recovery.The results provide new insights into the enhanced in-situ enrichment of copper from mol-ten slag.

铅冰铜富氧侧顶吹熔炼中试研究

针对铅冰铜复杂物料熔炼效率低、Cu与Pb分离不彻底、粗铜品位不高等技术难题,采用自主开发的富氧侧顶吹熔炼试验装备开展了中试试验。试验结果表明,在温度1250℃、氧气浓度60%的条件下,铅冰铜侧顶吹熔炼可一步产出粗铜,粗铜含Cu量达到94.03%,含Pb量为0.11%,主要杂质Pb、As和Sb的脱除率分别约为99%、90%和85%。采用该工艺,熔炼造渣+吹炼造铜可在同一反应器内完成,冶炼周期缩短至24 h,煤率9.6%,相较于传统工艺,冶炼效率大幅提升、操作环境好、能耗低,该工艺具有较好的应用前景。

四氧化三铁在造锍熔炼铁橄榄石炉渣中的行为

造锍熔炼是火法炼铜的关键工序,通常采用铁橄榄石炉渣体系(SiO_(2)-FeO_(x)-MO,M代表金属)。系统讨论了四氧化三铁的性质、生成、溶解、析出、作用,以及危害与其消除方法等,并指出以往“在造锍熔炼中,四氧化三铁熔点高、黏度大,其生成将对造锍熔炼过程产生严重不利影响”这一观点是不全面的。在造锍熔炼中,四氧化三铁的生成及过饱和析出与温度、炉渣FeSiO_(2)质量比、体系中FeS和Cu_(2) S活度、SO_(2)分压等因素相关;Fe(Ⅲ)在炉渣中的溶解度决定于渣温。四氧化三铁过饱和析出于炉渣中后,炉渣黏度应按Einstein-Roscoe公式计算。此外,还对不同熔炼方法中炉渣温度和Fe SiO_(2)质量比不同的原因进行了分析。

铜冶炼火法过程中锑的分布与走向研究

采用某厂的工艺生产数据,对锑杂质的分布走向进行研究,对产出料中间品的锑的物相组成进行表征分析,结果显示冶炼渣中锑主要以高价锑化合物、Sb_(2)O_(3)与其他化合物聚合形式存在,冰铜中主要以Sb_(2)O_(3)及少量复杂锑化合物形态存在,艾萨烟尘中主要以Sb_(2)O_(3)、高价锑化合物、锑硫化物形式存在,转炉烟尘主要以Sb_(2)O_(3)形式存在。

浅谈冰铜粒化区域雾气的成因及安全治理

风、水淬是冶炼厂常用的粒化方式,但在潮湿天气,尤其是冬季该过程会不同程度地产生雾气,降低了生产现场能见度,既影响生产连续又产生安全隐患。为此,针对某冶炼厂风淬粒化的实际情况,分析其雾气产生的原因。结果表明:减少雾气的有效办法为降低空气湿度和提高空气温度,降低空气湿度是重点,而粒化室系统负压、冷却程度、设备结构、所处环境及设施所处位置等均一定程度影响空气湿度,其中系统负压是主要因素,并针对性提出了相应的安全治理方案。

闪速熔炼渣含铜影响因素分析及优化措施

福建某铜业公司闪速熔炼原料成分波动大,渣含铜难以控制,对后续铜渣浮选的生产操作和工艺指标控制均有一定影响。针对此问题,分析了闪速熔炼渣的化学成分和物相组成,研究了金属铜在渣中的损失形式及其对渣含铜的影响,并从优化闪速熔炼炉况、干精矿成分和铁硅比等方面提出了降低渣含铜的控制措施。实践表明:通过控制炉渣中的Fe_(3)O_(4)质量分数在9%以下,铁硅比在1.25左右,冰铜品位在61%~62%,可以将闪速熔炼渣中的铜质量分数维持在1.1%以下,获得了较好的闪速熔炼渣渣型,并能保持稳定,降低了金属铜的损失。

Relationship between copper content of slag and matte in the SKS copper smelting process

In the newly developed oxygen-enriched bottom-blowing copper smelting process(also known as the SKS copper smelting process), Cu loss in slag is one of the most concerning issues. This paper presents our research results concerning the relationship between the Cu content of the matte and slag in the SKS process; the results are based on actual industrial production in the Dongying Fangyuan copper smelter. The results show that the matte grade strongly influences Cu losses in slag. The dissolved and entrained losses account for 10%–20% and 80%–90% of the total SKS industrial Cu losses in slag, respectively. With increasing matte grade, the dissolved and entrained Cu losses in the SKS slag both increase continuously. When the matte grade is greater than 68%, the content of Cu in the smelting slag increases much more dramatically. To obtain a high direct recovery of copper, the matte grade should be less than 75% in industrial SKS copper production.

ANINTELLIGENT DECISION SUPPORTSYSTEM（IDSS） ONTHEPROCESSOFNICKELMATTESMELTER

This paper describes the structure and function of the intelligent decision support system (IDSS) on the process of nickel matte smelter. The knowledge and model base system based on fuzzy-decision rules ale specially suggested. The IDSS possesses the self-learning and adaptive properties, andhas been used for managing and analyzing the production information, optimizing the composition of the charge mixture, and deciding the optimal operational conditions. Electric energy consumption has been reduced remarkably and the yield of nickel has been increased.

Intelligent prediction model of matte grade in copper flash smelting process

Due to the importance of detecting the matte grade in the copper flash smelting process, the mechanism model was established according to the multi-phase and multi-component mathematic model. Meanwhile this procedure was a complicated production process with characteristics of large time delay, nonlinearity and so on. A fuzzy neural network model was set up through a great deal of production data. Besides a novel constrained gradient descent algorithm used to update the parameters was put forward to improve the parameters learning efficiency. Ultimately the self-adaptive combination technology was adopted to paralleled integrate two models in order to obtain the prediction model of the matte grade. Industrial data validation shows that the intelligently integrated model is more precise than a single model. It can not only predict the matte grade exactly but also provide optimal control of the copper flash smelting process with potent guidance.