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.

Optimization of low-temperature alkaline smelting process of crushed metal enrichment originated from waste printed circuit boards

A novel low-temperature alkaline smelting process is proposed to convert and separate amphoteric metals in crushed metal enrichment originated from waste printed circuit boards. The central composite design was used to optimize the operating parameters,in which mass ratio of Na OH-to-CME, smelting temperature and smelting time were chosen as the variables, and the conversions of amphoteric metals tin, lead, aluminum and zinc were response parameters. Second-order polynomial models of high significance and3 D response surface plots were constructed to show the relationship between the responses and the variables. Optimum area of80%-85% Pb conversion and over 95% Sn conversion was obtained by the overlaid contours at mass ratio of Na OH-to-CME of4.5-5.0, smelting temperature of 653-723 K, smelting time of 90-120 min. The models were validated experimentally in the optimum area, and the results demonstrate that these models are reliable and accurate in predicting the smelting process.

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.

FUZZY ADAPTIVE CONTROL MODEL FOR PROCESS IN NICKEL MATTE SMELTING FURNACE

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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.

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.

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。

富氧侧吹熔池熔炼生产金属化镍阳极工艺研究

反射炉熔炼二次镍精矿生产镍阳极板工艺,存在燃料的热利用率低、燃料消耗量大,炉体耐火材料使用寿命短、阳极板脆弱易碎、残极率高,熔炼运行成本高、现场操作环境恶劣等问题。本文通过对富氧侧吹熔池熔炼二次镍精矿生产金属化镍阳极板的工艺研究,得到金属化镍锍产品(Ni+Cu≥76%,Fe<3%,S 16%~20%),最佳工艺参数为:在反应温度为1450~1600℃,富氧浓度65%~75%,连续进料速率为100 kg/h条件下,氧料比10~45 Nm^(3)/t,还原剂率为0.5%~1%。随着氧料比增加,镍锍的品位逐渐增加,且铁、硫含量逐渐降低,相应的熔渣含镍逐渐升高。富氧侧吹熔池熔炼生产金属化镍阳极板具备工艺可行性,实现二次镍精矿短流程的“熔化、除铁、降硫”的目的,可产出合格的金属化镍阳极板,明显提高镍阳极板成材率,大幅提高热利用率、提高生产效率和产能,并降低了生产成本。

红土镍矿侧吹还原造锍熔炼试验研究

基于新能源汽车的快速发展以及三元动力电池的高镍化发展对镍原料需求旺盛的大背景,提出红土镍矿侧吹造锍熔炼生产低镍锍工艺的研究。本文对石膏的热分解行为进行了系统的热力学研究,分析碳硫比、反应温度对CaS转化率的影响,进行石膏选择性还原硫化红土镍矿基础试验,并在此基础上进行富氧侧吹硫化红土镍矿扩大试验,总结石膏选择性还原硫化红土镍矿和富氧侧吹硫化红土镍矿的反应机制。结果表明,脱硫石膏短流程直接还原硫化红土镍矿生产低镍锍工艺可行,该工艺采用工业固废脱硫石膏作为硫化剂,可全组分利用石膏渣中的Ca、S元素,达到“固废绿色循环、资源化利用”的目的,且镍回收率大于90%,钴回收率在87%以上,硫利用率大于75%,铁回收率低于60%,可满足红土镍矿镍、钴、铁的选择性还原硫化富集回收目的。

铜造锍熔炼过程重金属烟尘特性及结瘤控制技术进展

造锍熔炼作为火法炼铜的核心工序之一,其处理过程产生携带有大量含Cu、Pb、Zn、As等有害重金属烟尘及高SO_(2)浓度的高温烟气。工业上,受烟气系统各部位温度场和气氛改变的影响,烟尘性质会逐渐变化,并在重力和静电场作用下与烟气逐步分离。部分高温烟尘会粘附于上升烟道和余热锅炉内壁或换热管上,形成坚硬的结瘤物,造成锅炉换热效率降低、气流通道口截面减小等问题,增加了有害重金属烟尘的环境污染风险及连续化生产成本。因此,研究铜冶炼过程烟尘排放特性及粘结行为,开发新型烟尘结瘤控制技术成为行业关注的焦点。本文综述了不同铜冶炼工艺中烟气处理系统各个阶段的烟尘及结瘤物物性特征,归纳解析其成分、物相变化规律及结瘤形成机理,对比分析了工业上现有结瘤控制技术现状,并做出评述及提出相关建议。

铂族金属火法冶炼技术研究进展

全球铂族金属资源高度集中,我国铂族金属资源匮乏,随着我国对海外铂族金属矿产的开发,实现对铂族金属资源的高效回收利用有着重要意义。本文对目前铂族金属的火法冶炼机理、工艺进行了综述,以期为今后铂族金属矿火法冶炼技术相关研究提供借鉴和参考。同时指出,对于浮选后的铂族金属精矿,电炉+转炉工艺仍然是主要的火法冶炼方法,工艺流程包括干燥、电炉熔炼制备低镍锍(低冰镍)、转炉吹炼制备高镍锍(高冰镍)等。未来铂族金属矿火法熔炼技术的研究可重点关注铂族金属矿物的强化熔炼、熔池熔炼等高效熔炼方法,低镍锍吹炼可重点关注连续吹炼(底吹、多枪顶吹)替代PS转炉吹炼的可行性。

铜复杂资源造锍熔炼过程中MgO对铜锍和二氧化硅饱和铁硅渣相平衡的影响

采用高温平衡实验及电子探针微区分析方法研究铜复杂资源中MgO对造锍熔炼平衡体系铜锍及熔炼渣成分(FeO_(x)-SiO_(2)-MgO)的影响。结果表明,在1300℃、p(SO_(2))=10kPa熔炼条件下,增加熔炼渣中MgO含量可降低渣中FeO的活度,进而降低渣中氧分压(p(O_(2)))、减少铜在渣中化学溶解损失量;同时,渣中FeO活度降低可促进铜锍中FeS氧化进渣,提高铜锍品位。在高硅渣型中,过量MgO易在渣中形成固相夹杂颗粒(Mg_(2)SiO_(4)-Fe_(2)SiO_(4)),导致渣黏度升高、增加渣中铜损失。当熔炼温度由1200℃升至1300℃及p(O_(2))为10-6kPa时,FeO_(x)-SiO_(2)-MgO渣中MgO的最大溶解量由3%增至8%(质量分数);渣中MgO含量增加时,可通过添加SiO_(2)熔剂调整渣型、升高熔炼温度,进而降低渣中固相析出物含量,改善熔渣性质。

氧化镍和硫化铜矿联合熔炼炉渣的黏度

测定氧化镍和硫化铜矿联合冶炼熔渣的黏度。制备的模拟熔渣与实际熔渣的成分和结构相似,并限制研究的熔渣的成分范围,含铁熔渣的成分(质量分数)为:8.9%CaO、11.8%MgO、12.5%Al_(2)O_(3)、47.4%SiO_(2)、13.3%FeO和5.0%Fe_(2)O_(3);无铁熔渣是将含铁熔渣中的氧化铁去除得到,其成分(质量分数)为:12.5%CaO、16.0%MgO、9.4%Al_(2)O_(3)和58.3%SiO_(2)。由振动法测试的含铁熔渣(1550~1300℃)和无铁熔渣(1550~1400℃)的黏度实验值分别为0.31~2.33 Pa·s和1.28~4.55 Pa·s。由Kalmanovitch-Frank模型预测的含铁熔渣的黏度值与实验值存在偏差。通过Weimann-Frenkel-Urbain方程对实验数据进行回归分析,提出可预测所考虑温度范围内的初级熔渣黏度的原始经验模型。当碱度从0.7(含铁熔渣)降低到0.6(无铁熔渣),黏性流动活化能从204 kJ/mol增加到236kJ/mol。为了保持最佳熔渣黏度,氧化镍和硫化铜矿联合冶炼的温度应不低于1400℃。

低品位铜镍电镀污泥还原硫化熔炼低冰镍

通过热力学分析,揭示了铜镍电镀污泥还原硫化熔炼低冰镍过程中主要金属的物相演变规律,分析了还原硫化熔炼过程的主要影响因素。经热力学理论计算可知,电镀污泥铜和镍品位分别为6%和4%时,采用硫石膏作为硫化剂,硫实际用量为理论用量的2.0倍,熔炼气氛P(CO)/[P(CO)+P(CO_(2))]=50%,预期产出低冰镍的品位(Cu+Ni)为57.2%,渣中铜和镍品位均低于0.2%,铜和镍直收率分别可达99.89%和96.59%,固硫率77.20%。铜镍污泥高温硫化熔炼低冰镍工业应用结果表明,与常规湿法回收工艺相比,该工艺金属回收率更高,过程绿色低碳,具有显著的技术优势。