Controlling fine particles in flue gas from lead-zinc smelting by plasma technology

With the aim of controlling the problem of fine particles in the flue gas of lead-zinc smelting,a low-temperature plasma-electrocoagulation and electric bag composite dedusting experimental platform was designed by combining electrocoagulation and electric bag composite dust removal technology based on the research of low-temperature plasma technology.Firstly,the properties of fine particles in flue gas from lead-zinc smelting were analyzed,and the effects of input voltage,filter wind speed,dust concentration,and pulse-jet ash-cleaning cycle on the dust collection efficiency of the integrated device were studied.Then,the energy efficiency of the integrated technology was analyzed,and the control mechanism of the fine particles was revealed.The experimental results show that the integrated technology of low-temperature plasma-electrocoagulation and electric bag composite dust removal achieves a fine particle removal efficiency of more than 99.99%and the energy consumption per unit mass of the dust is only 0.008 k W·h/g.The integrated technology has broad application prospects and farreaching practical significance for the lead-zinc smelting industry to achieve ultra-low emission targets for flue gas and achieve energy-saving and emission reduction effects.

Resource utilization of hazardous gypsum sludge in oxidation smelting of lead concentrate

Gypsum sludge,a hazardous waste generated by the non-ferrous smelting industry,presents a significant challenge for disposal and utilization.To investigate the feasibility of substituting gypsum sludge for limestone as a flux for smelting,the effects of calcium sulfate(CaSO_(4))and smelting conditions on oxygen-rich smelting of lead concentrate were studied.The interaction between CaSO_(4)and sulfides facilitates the conversion of CaSO_(4)into CaO,which is crucial for slag formation.The order of the influence of sulfide minerals on the conversion of CaSO_(4)is pyrite>sphalerite>galena.When using gypsum sludge exclusively as the calcium source,under optimal conditions with a CaO/SiO_(2)mass ratio of 0.8,an FeO/SiO_(2)mass ratio of 1.2,a melting temperature of 1150℃,an oxygen flow rate of 1.3 L/min,the recovery rates of Pb and Zn in the lead-rich slag reached 85.01%and 95.69%,respectively,with a sulfur content of 2.65 wt%.The As content in the smelting slag obtained by reduction smelting was 0.02 wt%.Resource utilization of gypsum sludge in lead smelting is a feasible method.

Numerical investigation of sinusoidal pulsating gas intake to intensify the gas-slag momentum transfer in the top-blown smelting furnace

The variation characteristics of bubble morphology and the thermal-physical properties of bubble boundary in the top-blown smelting furnace were explored by means of the computational fluid dynamics method.The essential aspects of the fluid phase(e.g.,splashing volume,dead zone of copper slag,and gas penetration depth)were explored together with the effect of sinusoidal pulsating gas intake on the momentum-transfer performance between phases.The results illustrated that two relatively larger vortices and two smaller vortices appear in the bubble waist and below the lance,respectively.The expansion of larger ones as well as the shrinking of smaller ones combine to cause the contraction of the bubble waist.Compared to the results of the case with a fixed gas injection velocity(V_(g)=58 m/s),the splashing volume and dead zone volume of the slag under the V_(g)=58+10sin(2πt)condition are reduced by 24.9%and 23.5%,respectively,where t represents the instant time.Gas penetration depth and slag motion velocity of the latter are 1.03 and 1.31 times high-er than those of the former,respectively.

Separation of halogens and recovery of heavy metals from secondary copper smelting dust

The separation of halogens and recovery of heavy metals from secondary copper smelting(SCS)dust using a sulfating roasting−water leaching process were investigated.The thermodynamic analysis results confirm the feasibility of the phase transformation to metal sulfates and to gaseous HF and HCl.Under the sulfating roasting conditions of the roasting temperature of 250℃ and the sulfuric acid excess coefficient of 1.8,over 74 wt.%of F and 98 wt.%of Cl were volatilized into flue gas.Approximately 98.6 wt.%of Zn and 96.5 wt.%of Cu in the roasting product were dissolved into the leaching solution after the water leaching process,while the leaching efficiencies of Pb and Sn were only 0.12%and 0.22%,respectively.The mechanism studies indicate the pivotal effect of roasting temperature on the sulphation reactions from various metal species to metal sulfates and the salting out reactions from various metal halides to gaseous hydrogen halides.

Rapid detection and risk assessment of soil contamination at lead smelting site based on machine learning

A general prediction model for seven heavy metals was established using the heavy metal contents of 207soil samples measured by a portable X-ray fluorescence spectrometer(XRF)and six environmental factors as model correction coefficients.The eXtreme Gradient Boosting(XGBoost)model was used to fit the relationship between the content of heavy metals and environment characteristics to evaluate the soil ecological risk of the smelting site.The results demonstrated that the generalized prediction model developed for Pb,Cd,and As was highly accurate with fitted coefficients(R~2)values of 0.911,0.950,and 0.835,respectively.Topsoil presented the highest ecological risk,and there existed high potential ecological risk at some positions with different depths due to high mobility of Cd.Generally,the application of machine learning significantly increased the accuracy of pXRF measurements,and identified key environmental factors.The adapted potential ecological risk assessment emphasized the need to focus on Pb,Cd,and As in future site remediation efforts.

CFD modeling of gas−liquid flow phenomenon in lead smelting oxygen-enriched side-blown furnace

A validated numerical model was established to simulate gas−liquid flow behaviors in the oxygen-enriched side-blown bath furnace.This model included the slip velocity between phases and the gas thermal expansion effect.Its modeling results were verified with theoretical correlations and experiments,and the nozzle-eroded states in practice were also involved in the analysis.Through comparison,it is confirmed that the thermal expansion effect influences the flow pattern significantly,which may lead to the backward motion of airflow and create a potential risk to production safety.Consequently,the influences of air injection velocity and furnace width on airflow behavior were investigated to provide operating and design guidance.It is found that the thin layer melt,which avoids high-rate oxygen airflow eroding nozzles,shrinks as the injection velocity increases,but safety can be guaranteed when the velocity ranges from 175 to 275 m/s.Moreover,the isoline patterns and heights of thin layers change slightly when the furnace width increases from 2.2 to 2.8 m,indicating that the furnace width shows a limited influence on production safety.

钒钛矿PLCsmelt工艺冶炼技术

钒钛磁铁矿的成分和结构复杂,是世界公认的难选冶矿种。与普通铁精矿相比,钒钛磁铁矿的品位偏低,有价组元分散于各矿相中,采矿和选冶都具有较大的难度,钒钛矿资源的有效利用是钢铁行业的关注问题之一。基于此,依据攀西钒钛磁铁矿特性,提出了PLCsmelt炼铁新工艺。首先介绍了PLCsmelt炼铁工艺流程,以气基竖炉-电炉工艺为参照,从工艺流程、成本、资源利用率、碳排放和能耗等方面对两种工艺进行了分析对比,并与高炉工艺进行了碳排放及能耗对比。研究表明,PLCsmelt的工艺成本、钒资源回收率、碳排放及能耗分别为1943.1元/t、75.9%、1009.6 kgCO_(2)/tHM及370.9 kgce/tHM,各参数较高炉及气基竖炉-电炉工艺均有明显优势,证明PLCsmelt炼铁新工艺更有利于钒钛磁铁矿资源综合高效利用。同时对PLCsmelt工艺技术的发展前景进行了展望,也对该技术存在的问题及未来研究的方向进行了讨论。

HIsmelt熔融还原工艺的技术创新及发展现状

简要阐明了HIsmelt熔融还原工艺技术的研究开发历程,结合山东墨龙全球首座HIsmelt连续商业化运行157天的生产实践,从工艺流程、生产装备和操作技术等方面,阐述了HIsmelt熔融还原工艺的技术创新及发展现状,并对生产现状、产品质量和环保排放进行了分析。认为HIsmelt熔融还原工艺取消了烧结、焦化和球团工序,环保优势明显。

Clean production of Fe-based amorphous soft magnetic alloys via smelting reduction of high-phosphorus iron ore and apatite

Separated preparation of prealloys and amorphous alloys results in severe solidification-remelting and beneficial element removal-readdition contradictions,which markedly increase energy consumption and emissions.This study offered a novel strategy for the direct production of FePC amorphous soft magnetic alloys via smelting reduction of high-phosphorus iron ore(HPIO)and apatite.First,the thermodynamic conditions and equilibrium states of the carbothermal reduction reactions in HPIO were calculated,and the element content in reduced alloys was theoretically determined.The phase and structural evolutions,as well as element migration and enrichment behaviors during the smelting reduction of HPIO and Ca_(3)(PO_(4))_(2),were then experimentally verified.The addition of Ca_(3)(PO_(4))_(2)in HPIO contributes to the enrichment of the P element in reduced alloys and the subsequent development of Fe_(3)P and Fe_(2)P phases.The content of P and C elements in the range of 1.52 wt% -14.63 wt% and 0.62 wt% -2.47 wt%,respectively,can be well tailored by adding 0-50 g Ca_(3)(PO_(4))_(2)and controlling the C/O mole ratio of 0.8-1.1,which is highly consistent with the calculated results.These FePC alloys were then successfully formed into amorphous ribbons and rods.The energy consumption of the proposed strategy was estimated to be 2.00×10^(8) kJ/t,which is reduced by 30% when compared with the conventional production process.These results are critical for the comprehensive utilization of mineral resources and pave the way for the clean production of Fe-based amorphous soft magnetic alloys.

HIsmelt工艺熔融还原炉用耐火材料的抗侵蚀性研究

为促进HIsmelt工艺的进一步发展和应用,根据HIsmelt工艺熔融还原炉(SRV)的特点,利用静态坩埚法对比研究了SRV渣在1 500℃下对铬刚玉砖、微孔刚玉-莫来石砖、刚玉-莫来石砖、刚玉-尖晶石砖的侵蚀。结果表明:1)铬刚玉砖抗SRV渣渗透侵蚀能力最强,因为FeO与铬刚玉砖中的Al_(2)O_(3)和Cr_(2)O_(3)反应生成高熔点物,抑制炉渣的渗透和侵蚀。2)微孔刚玉-莫来石砖中镁铝尖晶石与钙铝黄长石的生成在侵蚀层形成保护层,阻止SRV渣的渗透侵蚀,在3种无铬材料中,表现出最优的抗侵蚀性。3)刚玉-莫来石砖中由于大量钙长石的形成产生的缝隙造成渣的不断渗入,使得熔渣对砖的侵蚀较严重。4)刚玉-尖晶石砖中原位生成粒径小、活性高的尖晶石晶粒,能有效吸收熔渣中的铁离子形成镁铝铁复合尖晶石,阻挡SRV渣的侵蚀。

The new green smelting process of CNREG commissioned

A demonstration project of the major scientific and technological project in Inner Mongolia Autonomous Region-"Industrialization Test of New Green Smelting Technology for Rare Earth Concentrate produced from Baiyun Obo ore"was commissioned on November 20th.This project adopts the"new green smelting process for rare earth concentrate"independently developed by China Northern Rare Earth Group(CNREG),and has achieved a new breakthrough in rare earth smelting technology.

锌冶炼过程中提取镓的技术研究及其进展

针对镓从锌冶炼过程中回收占比低的问题,总结分析了锌冶炼过程中镓回收技术研究进展.在鼓风炉炼锌(ISP)工艺中,镓主要富集在鼓风炉炉渣里,其质量分数通常在0.025%~0.031%,从鼓风炉炉渣中回收镓主要有还原蒸发法、高温氯化挥发法、硫酸浸出法、碱熔–浸出法、还原熔炼–电解法和还原熔炼–熔融造渣法等方法,但这些工艺普遍流程长,回收率低,加工成本偏高,部分工艺环境污染大,难以工业化应用.传统的湿法炼锌工艺中,大于93.5%的镓富集在浸出渣中,浸出渣处理以火法还原挥发工艺为主,在回转窑挥发浸出渣工艺中90%的镓保留在窑渣中,导致镓的回收流程长且回收率低,湿法处理浸出渣存在镓和铁分离的难题,至今未得到有效解决.氧压浸出炼锌工艺中,镓主要富集在锌粉置换渣里,锌粉置换渣采用酸性浸出和萃取工艺分离富集镓,最终制备金属镓,镓的综合回收率达到71%.通过对火法和湿法炼锌中镓回收工艺进行分析,对镓回收工艺中存在的关键问题和分离技术进行了总结,提出萃取分离、乳状液膜和树脂吸附有望成为锌冶炼过程中回收镓的绿色高效短流程关键技术.

铅锌冶炼重金属重污染土壤稳定化研究

针对部分铅锌冶炼场地遭受严重重金属污染的问题,采用基于铁的稳定化材料FeCl_(3)+CaCl_(2)+NaOH+Ca(OH)_(2),FeCl_(3)+CaCl_(2)+NaOH+Ca(OH)_(2)+Na_(2)S及FeCl_(3)+Na_(2)HPO_(4)进行修复。根据TCLP浸出法评估效果,选出最佳组合为FeCl_(3)+Na_(2)HP0_(4),该组合在3个场地中使Pd浸出浓度分别下降96%,63%,61%,显著减少重金属迁移。研究突显了合适材料的选择对有效土壤稳定化的重要性。

典型钢铁冶炼场地重金属污染空间分布特征及风险评价

以上海某关停钢铁冶炼厂为研究对象,结合专业判断布点法与系统布点法布设83个土壤点位,采集表、中、深层共249个土壤样品,分析As、Pb、Cd、Ni、Hg、Cu这6种重金属的分布特征、污染状况、潜在生态风险及健康风险。结果表明,As、Pb出现部分样品超标,Cd、Pb为强变异,其他重金属变异程度中等;重金属平均含量在垂向上呈现自上而下逐渐降低的趋势,且最高值均分布在表层,累积区域主要为扒渣厂房、钢渣处理区和废钢配料间;地累积指数评价结果显示,Cd和Pb的污染相对较为严重,重污染及以上的样品比例分别为8.43%、3.61%。潜在生态风险评价结果显示,场地整体的生态风险较高,Cd为主要贡献因子,较强风险及以上的样品占比高达51.81%;人体健康风险评价结果显示,Pb、As和Cd可能对人体产生一定的健康风险,因此有必要开展土壤的风险管控或修复以保证场地的再开发利用。

As和MgO的加入对铜冶炼渣中砷玻璃化的影响

研究FeO−SiO_(2)−Fe_(2)O_(3)−B_(2)O_(3)−CaO−Al_(2)O_(3)−(MgO)体系铜冶炼渣中砷(As)的玻璃化。通过XRD、SEM、FTIR和XPS分析手段系统地研究As玻璃化机制。结果表明,As与铁硅酸盐炉渣表现出良好的相容性。FTIR和XPS分析结果表明,As可以部分替代硅形成Si—O—As结构,从而提高熔体的聚合度。[BO_(3)]^(3−)结构单元随着As含量的增加而趋于减少,而加入MgO后则观察到相反的行为。此外,MgO增加了熔体的非桥氧数量(NBO)。TCLP、SPLP和pH依赖性测试结果表明,As的浸出毒性随着As含量的增加而增加,但随着MgO的加入而降低。DSC分析结果表明,As和MgO的加入均可以改善含As玻璃的热稳定性。

黄河流域典型铅锌冶炼企业重金属废水管控与碳排放协同研究

黄河流域作为国家生态安全的重要屏障,重金属污染一直以来备受关注.为提升重金属重点排放源铅锌冶炼行业废水排放管控水平,本文聚焦黄河流域中上游典型地区某铅锌冶炼企业,研究了不同产污环节排放废水中重点重金属排放特征及达标情况,并从行业绿色低碳发展方面测算了不同冶炼工艺流程碳排放强度、不同产污环节排放废水处理过程碳排放强度.结果表明:(1)采用氧化法+硫化钠除汞+石灰中和+生物制剂法+除铊稳定剂的组合处理工艺,污酸废水中总铅、总镉、总汞和总砷的排放浓度均可稳定达到《铅、锌工业污染物排放标准》(GB 25466-2010)特别排放限值要求,以处理后各重金属日最大检出浓度的90%分位数作为参比浓度,该处理工艺对总铅、总镉、总汞的去除率分别为98.2%、99.8%、99.9%.(2)铅锌冶炼企业污酸车间地面冲洗水应全部纳入污酸车间污水处理系统进行集中处理,避免铅、镉、汞、铊等重金属废水稀释排放,长期汇入黄河干流富集造成潜在环境风险.(3)锌冶炼过程重金属主要富存于固相颗粒和液相颗粒中,污酸废水(废气洗涤制酸废水)中总铅、总镉、总汞、总砷产污系数分别为4.83、4.33、7.02、0.01 g/t(以产品计),较实际流向废气中相应重金属产污系数低10^(3)量级.(4)鉴于污酸废水处理碳排放强度约为一般性生产废水的7.93倍,建议加强评估并推广应用2022年《国家先进污染防治技术目录(水污染防治领域)》提出的有色冶炼烟气洗涤污酸废水治理与资源化利用技术,研究提出基于资源化利用途径的污酸废水排放控制要求.(5)湿法炼锌工艺碳排放强度为3.08 t/t(冶炼1 t锌的CO_(2)排放量),相对属于绿色低碳冶炼工艺.研究显示,黄河流域中上游部分典型铅锌冶炼企业已采用相对绿色低碳冶炼工艺,鉴于黄河流域的国家战略定位,需进一步提升末端重金属废水风险管控和减污降碳协同治理力度,引领沿黄冶炼产业高质量发展.

西南某铅锌冶炼废渣堆放场地周边土壤重金属污染特征与风险评价

为探究西南某铅锌废堆渣场地及其周围土壤中重金属空间分布特征和生态风险,以西南某废弃铅锌冶炼废渣堆放场地为研究目标,通过检测其土壤中As、Pb、Zn、Cd、Cr、Cu、Hg、Ni共8种元素,概括其空间分布特征,分析重金属存在形态对其迁移与渗透的影响,并采用多个污染评价方法对该废渣堆放场的重金属状况进行污染风险评估。结果表明:堆渣场地重金属元素分布与地表径流方向一致,且向深层土壤渗透;As、Cd、Cu已很难再以离子形态随地表径流进一步迁移,而Pb、Zn目前仍具有较大的离子迁移性能,仍会进一步向周边及深层土壤扩散;按照综合污染指数评价上层堆渣区属于重污染,污染元素主要来源于As;同时As、Cd含量表现出极强的生态毒性,使该区域存在很强的生态风险。研究结果为该区域土壤的进一步修复提供了理论依据和参考。

我国重有色金属冶炼技术过去、现在和未来发展杂谈

1949年至今,我国重有色金属冶炼技术大体历经三个发展阶段,即中华人民共和国成立后依靠苏联援助艰难起步、改革开放后引进国外技术带动高速发展、进入新世纪自主创新取得多项突破。展望未来,要进一步提高行业的集中度,加强应用基础研究,加大数字智能技术研究。

铜火法冶炼废水处理实践

阐述了铜冶炼火法工艺发展状况,剖析了铜冶炼过程产生废水的主要环节,并对废水处理工艺及原理进行了梳理,分析了某铜冶炼企业废水产生节点、产生特点和组成成分;针对现有的废水处理技术和资源化利用提出了合理的建议。特别阐述了阳谷祥光铜业自主研发的旋浮铜冶炼技术、粗铜自氧化还原精炼技术、平行流电解技术,“硫化+石膏+中和”工艺和废水深度处理联合工艺特点,对采用火法冶炼工艺的铜冶炼企业的废水处理及资源化利用具有借鉴意义。

“王国文明”时期江淮地区冶铜业发展阶段研究

文章通过对近年来江淮地区夏商周时期聚落和矿冶遗址考古资料和相关历史文献的梳理研究,认为“王国文明”时期江淮地区冶铜业的发展可分为三个阶段:夏王朝时期铜基冶金的建立、商王朝时期冶铜术的垄断和周王朝时期冶铜术的扩散。淮夷至少在西周时期已经掌握了冶铜术,历史上所谓“江南金锡”“吴越金锡”和“南金”应不仅指长江以南所出,还应包括整个江淮地区的铜产品。江淮地区既有广泛的铜矿开采和青铜冶铸活动,就不仅仅是东南金锡入贡或交易的一条通道。如果冶铜术经由欧亚大陆传播至中原地区,江淮地区冶铜术应由中原王朝主导,经由中原地区传入。