Flowability of various dusts collected from secondary copper smelter off-gas

Stable flow of off-gas dust from dust collector hoppers and storage silos is important for smooth operation. Flow properties of the collected off-gas dust are critical to achieve suitable flow. Various dust samples collected from secondary copper smelter off-gases were studied. The median diameter of the fine-grained dusts varied from 0.8 to 1.4 μm and the flowability ranged from ＂cohesive＂ to ＂very cohesive＂. The flowa- bility of shaft and anode furnace dust improved slightly with increasing consolidation stress and their wall friction angles decreased, which is a typical behavior. In contrast, the flowability of converter dust decreased with increasing consolidation stress and its wall friction angles increased. Pre-shear treatment of converter dust worsened its flowability, increased the wall friction angle, and improved the flowabil- ity with increasing consolidation stress. This is believed to occur because pre-shear treatment fragments small agglomerates in the dust that improve flowability. The presence of such agglomerates was con- firmed by sieving tests. A diagrammatic representation of the flowability showing that the unconfined yield strength is dependent on consolidation stress can be improved by using logarithmically scaled axes.

Enhancing XRF sensor-based sorting of porphyritic copper ore using particle swarm optimization-support vector machine(PSO-SVM)algorithm

X-ray fluorescence(XRF)sensor-based ore sorting enables efficient beneficiation of heterogeneous ores,while intraparticle heterogeneity can cause significant grade detection errors,leading to misclassifications and hindering widespread technology adoption.Accurate classification models are crucial to determine if actual grade exceeds the sorting threshold using localized XRF signals.Previous studies mainly used linear regression(LR)algorithms including simple linear regression(SLR),multivariable linear regression(MLR),and multivariable linear regression with interaction(MLRI)but often fell short attaining satisfactory results.This study employed the particle swarm optimization support vector machine(PSO-SVM)algorithm for sorting porphyritic copper ore pebble.Lab-scale results showed PSO-SVM out-performed LR and raw data(RD)models and the significant interaction effects among input features was observed.Despite poor input data quality,PSO-SVM demonstrated exceptional capabilities.Lab-scale sorting achieved 93.0%accuracy,0.24%grade increase,84.94%recovery rate,57.02%discard rate,and a remarkable 39.62 yuan/t net smelter return(NSR)increase compared to no sorting.These improvements were achieved by the PSO-SVM model with optimized input combinations and highest data quality(T=10,T is XRF testing times).The unsuitability of LR methods for XRF sensor-based sorting of investigated sample is illustrated.Input element selection and mineral association analysis elucidate element importance and influence mechanisms.

Pressure leaching technique of smelter dust with high-copper and high-arsenic

The application of pressure leaching technology in the treatment of high-copper and high-arsenic dust was studied.The pressure leaching technique was determined as follows:the liquid to solid ratio(mL/g)of 5:1,the leaching temperature of 453 K,the retention time of 2 h,the initial sulfuric acid concentration of 0.74 mol/L,the oxygen partial pressure of 0.7 MPa,and the agitation speed of 500 r/min.Under these conditions,95%of copper and 99%of zinc and only 6%of iron in the dust were leached,while about 20%of arsenic was also leached.The leaching technique was optimized further to restrain the leaching of arsenic by adding a small quantity of ferrous iron into the leaching system(c(Fe2 +)=0.036 mol/L).Copper and zinc can be effectively separated from arsenic and iron in the leach.The optimal pressure leaching technique of high-copper and high-arsenic smelter dust is proved to be effective.

Preparation of Granulated Adsorption Material of Water-quenched Slag/rectorite Composite for Removal of Cu(Ⅱ)Ions from Copper Smelter Wastewater

The preparation of granulated adsorption material of water-quenched slag/rectorite composite and the treatment of Cu （ Ⅱ ）-containing copper smelter wastewater with the adsorption material were studied. The experimental results showed that under the conditions with the mass ratio of water-quenched slag to rectorite of 1：1, 10% additive of industrial starch （IS）, and 50% water, and a calcination temperature of 400 ℃, the granulated adsorption material prepared had a density of 1.06 kg/m^3, a porosity of 62.29%, water absorption rate of 58.82%, and compressive strength of 2.22 MPa. The efficiency of wastewater treatment was the best, whereas the rate of spallation loss was low. Under the conditions of natural pH, with the addition of the granulated adsorption material of 0.05 g/mL, a reaction time of 40 minutes, and temperature of 25 ℃, the efficiency of the granulated adsorption material for the removal of Cu （ Ⅱ ） ions from the copper smelter wastewater attained 98.2%, and the quality indexes of the wastewater after treatment conformed with the first level of integrated wastewater discharge standard （GB8978-1996）. The reclamation of the used granulated adsorption material was carried out by de-sorption of the Cu （ Ⅱ） ions from the surface with 1 mol/L sodium chloride solution. The de-sorption rate was 96.4%, and the adsorption material can be reused many times to treat copper smelter wastewater.

铜冶炼车间回用水分盐中试试验研究

为实现废水的近零排放和资源化处理,采用“生物制剂与双碱法协同脱钙+反渗透装置浓缩+纳滤装置分盐+电渗析装置浓缩+蒸发结晶装置出盐”工艺处理某铜冶炼车间回用水.结果表明,SO_(4)^(2-)截留率>99%,Na_(2)SO_(4)浓水溶解性总固体(TDS)质量浓度达179 g/L,NaCl浓水TDS质量浓度达150 g/L,浓缩液蒸发结晶后得到Na_(2)SO_(4)与NaCl产品盐.Na_(2)SO_(4)达到GB/T 6009-2014《工业无水硫酸钠》二类合格品要求,NaCl满足GB/T 5462-2015《工业盐质量标准》中一级标准.解决了回用水浓水浓度低、Na_(2)SO_(4)产品为杂盐等问题,为有色行业经济高效地处理高含盐废水奠定了工程化基础.

Pyrometallurgical Removal of Arsenic from Electrostatic Precipitators Dusts of Copper Smelting

This work describes the experimental results of pyrometallurgical removing of arsenic from the dust collected in the electrostatic copper precipitators within the gas cleaning system of a Copper Flash Smelting Furnace. The generation of dust in the copper smelting worldwide ranges from 2 - 15 wt% per ton of a copper concentrate. In Chile, copper smelters produce approximately 110 kt/y of dust with a concentration of arsenic between 1 and 15 wt%. The dust is a complex of metals oxides and sulfurs with copper concentrations greater than 10 wt% and relatively high silver concentrations. Since its high arsenic concentration, it is difficult to recover valuable metals through hydrometallurgical processes or by direct recirculation of the dust in a smelting furnace. Thus, the development of pyrometallurgical processes aimed at reducing the concentration of arsenic in the dust (<0.5 wt%) is the main objective of this study, giving particular attention to the production of a suitable material to be recirculated in operations of copper smelting. The work provides a detailed characterization of the dust including the Quantitative Evaluation of Minerals by Scanning Electron Microscopy (QEMSCAN), Scanning Electron Microscope-Energy Dispersive X-ray Analysis (SEM/EDS), X-Ray Diffraction (XRD), the elemental chemical analysis using Atomic Adsorption (AAS), and X-Ray Fluorescence (X-RF). By considering that arsenic volatilization requires a process of sulfidation-decomposition-oxidation, this work seeks to explore the roasting of mixtures of copper concentrate/dust, sulfur/dust, and pyrrhotite/dust. By the elemental chemical analysis of the mixture after and before the roasting process, the degree of arsenic volatilization was determined. The results indicated the effects of parameters such as roasting temperature, gas flow, gas composition, and the ratio of mixtures (concentrate/dust, sulfur/dust, or pyrrhotite/dust) on the volatilization of arsenic. According to the findings, the concentration of arsenic in the roasted Flash Smelting dust can be reduced to a relatively low level (<0.5 wt%), which allows its recirculation into an smelting process.

Investigation of Dioxin/Furans, PAHs and Heavy Metals in Sarcheshmeh Copper Complex Soil, Iran

Surface soil samples were collected from Sarcheshmeh Copper Smelter Plant and analyzed for 16 Polycyclic Aromatic Hydrocarbons (PAHs), polychlorinated dibenzo-p-dioxin/furans (PCDD/Fs), and heavy metals to determine their concentrations, distributions, and probable sources of contamination. The mean concentrations of ΣPAHs, As, Pb, Zn, Se, Cd, and Cr in the soil samples were 878.8, 850, 2185, 2455, 21, and 24 mg/kg, respectively. Besides, their Toxic Equivalents (TEQs) were calculated. The samples generally displayed elevated concentrations of heavy metals when finding the toxic values of dioxin/furan compounds in comparison to the limit values for industrial uses. The background concentrations, molecular indices, and ring classes of the heavy metals indicated that their sources and those of PAHs were both geogenic and pyrolitic. The mean concentrations of total PAHs, PCDD/Fs, and heavy metals were compared with the reports from industrial areas throughout the world and the contamination rates at Sarcheshmeh Copper Plant were found to be moderate.

Characterization and Pyrometallurgical Removal of Arsenic from Copper Concentrate Roasting Dust

This paper describes the experimental results of removing arsenic from the dust collected in electrostatic precipitators of a fluidized bed roasting furnace (RP dust). The fluidized bed roasting process generates 600 kilotons of copper concentrate per year with 3 - 6 wt% of concentration of arsenic, producing a roasted product with a low content of arsenic below 0.3 wt%. The process generates 27 kilotons of RP dust per year with a concentration of arsenic of the order of 5 wt% and copper concentration of around 20 wt%. Subsequently, the dust collected in the electrostatic precipitators is treated by hydrometallurgical methods allowing the recovery of copper, and the disposition of arsenic as scorodite. This work proposes to use a pyrometallurgy process to the volatilization of arsenic from RP dust. The obtained material can be recirculated in copper smelting furnaces allowing the recovery of valuable metals. The set of experiments carried out in the roasting of the mixture of copper concentrate/RP dust and sulfur/RP dust used different ratios of mixtures, temperatures and roasting times. By different techniques, the characterization of the RP dust determined its size distribution, morphology, and chemical and mineralogical composition. RP dust is a composite material of small particles (<5 μm) in 50 μm agglomerates, mostly amorphous, with a complex chemical composition of sulfoxides. The results of the roasting experiments indicated that for a 75/25 weight ratio of the mixture of the copper concentrate/PR dust under 700℃, 15 minutes of roasting time with injection of air, the volatilization of arsenic reached 96% by weight. The arsenic concentration after the roasting process is less than 0.3% by weight. For a 5/95 mixture of sulfur/RP dust, at 650℃, the volatilization of arsenic reached a promissory result of 67%. Even that this study was carried out for a particular operation, the results have the potential to be extended to dust produced in the roasting of concentrates of nickel, lead-zinc, and gold.

现代铜冶炼厂电气设备自动化研究

当今新时代技术发展下,电力装备的自动控制已经成为提高生产效率,降低生产成本,保证生产安全的主要途径。本文主要论述了铜矿冶炼过程中电力装备自动化的产生背景和意义,以及目前电力装备自动化的现状,并对电力装备自动化的有关技术进行了评述,对电力装备自动化的应用情况作了较详尽的说明,最后对今后如何发展提出重要建议。

高铜高砷烟灰加压浸出工艺

研究了加压浸出在高铜高砷烟灰浸出中的应用。结果表明：高铜高砷烟灰加压浸出较优的工艺条件为，液固比（mL／g）为5：1，初始硫酸浓度为0．74mol／L，浸出温度453K，氧分压0．7MPa，浸出时间2h，搅拌转速500r／min；在该条件下，Cu、Zn浸出率分别约95％和99％，As浸出率约20％，Fe浸出率仪6％左右：Cu、Zn与As、Fe的分离效果较好，该浸出工艺运行效果良好且稳定。

固体废物铜熔炼渣的快速鉴定

鉴定进口矿渣是否为海关监管的固体废物主要根据行业标准《进口矿渣的鉴定通则》(SN/T 3107-2012)。根据本通则进行外观检查、主要物相等特征分析,仅满足对常见矿渣样品的初步筛查。对复杂的"非常规"的矿渣样品,研究表明,通过增加X射线衍射法与X射线荧光光谱法在样品分析中的应用,再深入分析铜矿冶炼过程中的反应机理,对照常见FeOFe2O3-SiO2铜熔炼渣体系相图,同时参考《固体废物属性鉴别案例》,可实现对复杂矿渣样品是否为固体废物的准确和快速鉴定。

铜闪速炉数值仿真

利用欧拉法求解气相方程 ,利用拉格朗日法求解颗粒相方程 ,并用PSIC法耦合气固两相方程 .通过仿真得到反应塔内部的流场、温度场、浓度场、燃烧释热场以及颗粒的轨迹与温度 .可视化结果表明 :闪速炉内部流场存在 2个大涡 ;闪速炉内部温度除喷嘴下部外 ,基本分布均匀 ;反应塔中含硫铜精矿在反应塔上部 2m处就基本反应完全 ,在距离精矿喷嘴不到 5m处 ,所有颗粒达到峰值温度 ;反应塔内部温度场、浓度场、流场以及颗粒的轨迹表明反应塔内部的各种场并非轴对称 ,不能将反应塔简化为二维轴对称来处理 ;仿真结果和现场试验结果相符 ,温度校验点的相对误差小于 2 % .

中国火法铜冶炼污染物排放情景分析

基于目前中国火法炼铜的污染物产生特点,即冶炼过程中污染物产生差别主要体现在熔炼阶段工艺技术水平的高低,本文根据产业发展战略导向,对现行的熔炼工艺即先进熔池炉、闪速炉熔炼技术和传统鼓风炉熔炼技术设定情景:当2015年精炼铜产量达到500万t时,熔池、闪速、鼓风熔炼三种工艺的比重分别为:情景一50%、40%和10%,情景二60%、40%和0,情景三70%、30%和0。以2007年的冻结情景为基准,对污染物的产生量与排放量进行情景分析。结果表明,情景三是最优方案,在铜产量大幅增加的同时,通过工艺结构调整、促进废物资源化利用,基本可以实现主要污染物的排放不增加,这对火法炼铜行业污染物减排管理决策具有参考价值。

水淬渣作吸附剂处理含铜冶炼工业废水的研究

研究了以水淬渣为吸附剂对含Cu(Ⅱ)的铜冶炼工业废水进行处理。实验结果表明,在不调节铜冶炼废水pH值的条件下,水淬渣用量为0.05g/mL,作用时间为30min,温度为25℃,Cu(Ⅱ)的去除率达96.91%,处理后的水符合国家污水综合排放标准(GB8978-1996)一级标准,达到以废治废的目的。

累托石处理铜冶炼工业废水研究

研究了以累托石为吸附剂对含Cu(Ⅱ)的铜冶炼工业废水进行处理。实验结果表明,在不调节铜冶炼废水pH值的条件下,累托石用量为0.03g/ml,作用时间为30min,温度为25℃,Cu(Ⅱ)的去除率可达96.70%,处理后水质符合国家污水综合排放标准(GB8978-1996)中的一级指标。

我国闪速炼铜厂的清洁生产

从清洁的原料和能源、清洁的生产过程和清洁的产品等方面对国内外闪速炼铜厂清洁生产状况分析基础上,探讨了我国闪速炼铜厂的清洁生产方向。

贵溪闪速炉造锍熔炼过程计算机模拟

利用作者建立的贵溪闪速炉造锍熔炼过程的热力学模型，对贵溪闪速炉造锍熔炼过程进行了计算机模拟，并对贵溪闪速炉控制的３个关键参数即冰铜品位、冰铜温度及渣中ｍＦｅ／ｍＳｉＯ２进行模拟，取得了良好效果．此外，还进一步讨论了富氧体积分数、反应塔油耗、粉煤代油、精矿成份等因素对贵溪闪速炉熔炼过程的影响．

膨润土吸附去除铜冶炼废水中的铜离子

研究以膨润土吸附铜冶炼废水中的Cu2+。结果表明,不需要调节pH,膨润土用量为0.1g/mL,搅拌时间为10-15min,操作温度为30-40℃,铜冶炼废水中的Cu2+的去除率达99.44%,处理后水中残留Cu2+浓度为0.025g/mL,远低于国家污水综合排放标准(GB8978-1996)的一级标准。相对于其他处理方法,该方法具有工艺简单、成本低廉、处理效果好等优势,具有良好的应用前景。

铜冶炼企业重金属污染物粒径分布特征研究

对某铜冶炼企业铜冶炼有组织源和无组织源进行监测研究,并利用AERMOD空气质量模型对企业重金属污染物扩散情况进行模拟,通过对铜冶炼企业环境空气质量浓度预测值与监测值的拟合结果来验证铜冶炼企业废气中重金属污染物粒径分级的合理性。结果表明,污染源粒径分级参数的选择对铜冶炼企业重金属污染物的空气质量浓度计算结果有显著影响;当采用"双闪"工艺的铜冶炼企业重金属污染物铅、铜、砷、锌粒径参数质量百分比为25%、质量中位径为8μm时,AERMOD空气质量模型能较好地模拟该企业重金属污染物的扩散。

累托石-粉煤灰颗粒吸附剂的制备及除铜性能

研究了累托石-粉煤灰颗粒吸附剂制备工艺条件及其去除铜冶炼废水中Cu(Ⅱ)的条件。实验结果表明:累托石与粉煤灰的比例为7∶3,另加入15%的添加剂(St)和50%的水,焙烧温度为500℃时,制成的颗粒吸附剂不仅吸附效果最佳,而且其散失率较低。在不调节铜冶炼工业废水pH值的条件下,颗粒吸附剂用量为0·01g/mL,作用时间为60min,温度为25℃(常温)时,Cu(Ⅱ)的去除率达99·5%,处理后的水符合国家污水综合排放标准(GB8978-1996)一级标准。