镍闪速熔炼黏渣产生的影响及控制研究

镍闪速熔炼过程中,由于闪速熔炼为强氧化熔炼过程,反应物在反应塔空间内氧化时,生成大量金属氧化物,后期通过硫化置换反应、造渣反应从而达到低镍锍与炉渣分离的目的,当炉渣中含有大量高价态金属氧化物或反应塔反应不完全时,导致贫化区低镍锍与炉渣分离差,黏渣层厚度大,或出现炉渣与低镍锍完全分离不清,导致渣中有价金属损失增大,同时低镍锍排放困难,对炉窑安全运行产生风险,因此,控制黏渣层的厚度对闪速炉的安全运行、渣含有价金属指标控制有重要意义。     

降低反射炉渣含镍的生产实践

通过研究32m^2反射炉炉渣渣型及渣含镍的主要原因,改进处理环节工艺方法,控制了Ni3S2转入炉渣中的倾向,降低了渣含镍,提高了金属镍的直收率,降低了加工成本,取得了良好的效率。     

降低矿热电炉渣含镍途径的探讨

由于一般镍精矿的品位较低,在矿热电炉熔炼过程中的产渣率较大,因而损失于炉渣中的镍量也较多。因此,降低渣含镍,减少渣中金属损失,对于提高冶炼回收率是十分重要的。本文试图在对我厂过去大量生产数据进行统计、整理、分析的基础上,就降低矿热电炉渣含镍问题,提出一些粗浅的看法。     

12.5 MVA镍铁电炉渣降镍途径探讨

由于一般红土镍矿的品位较低,在矿热电炉熔炼过程中的产渣率较大,因而损失于炉渣中的镍量也较多。因此降低渣含镍、减少渣中金属损失,对于提高镍铁冶炼回收率十分重要。     

金川闪速炉的设计探讨

新型镍闪速炉是根据高镁镍精矿闪速熔炼工艺特点而进行设计，闪速熔炼与渣贫化在同一熔池内完成，可改善炉渣和冰镍的冶金性能，降低能耗，简化操作，同时在控制技术和水冷技术方面作了较大的可进使新的闪速炉的设计成为可能。     

金川公司钴的回收

金川铜镍硫化精矿含钴0.16%。在现有的电炉熔炼、转炉吹炼过程中,钻有30%进入高冰镍,70%进入转炉渣。目前,转炉渣返回电炉熔炼,钴在电炉与转炉渣之间循环,大部分钻最终进入电炉渣中,使电炉渣含钴高达0.06%,造成钴大量损失,全厂钴的冶炼回收率还不到30%。     

高Al2O3物料对镍电炉渣粘度的影响

论文对Al2O3高达69．46％的含镍物料电炉处理时对炉渣性能的影响进行了研究。研究表明：吉林镍业公司冶炼厂电炉渣1340℃时黏度为0．538P．s；电炉渣在不添加任何其它试剂的情况下，渣中Al2O3含量不宜高于9％；加入添加剂后，炉渣黏度降低，当在配料中加入20％此种含镍物料时，添加剂加入量7％为宜，此时炉渣黏度为0．74P．s（1340℃）。     

金川闪速炉的设计探讨

新型镍闪速炉是根据高镁镍精矿闪速熔炼工艺特点而进行设计的，闪速熔炼与渣贫化在同一熔池内完成，可改善炉渣和冰镍的冶金性能，降低能耗，简化操作。同时在控制技术和水冷技术方面作了较大的改进使新型闪速炉的设计成为可能。     

用FeCl_3溶液浸出从铜转炉渣和熔炼炉渣中回收有价金属

本文报道了用FeCl_3溶液浸出从铜转炉渣和熔炼炉渣中回收有价金属铜、钴、镍的研究。试料取自印度Ghatsila铜冶炼厂,转炉渣中含Cu4.03%、Ni1.99%、Co0.48%;熔炼炉渣中含Cu1.76%、Ni0.23%、Co0.19%。试验时,研究了搅拌、浸出时间与温度、FeCl_3浓度、固/液及粒度等各参数之间的影响。在最佳条件下,转炉渣中铜、钴、镍的提取率分别为92%、24%、28%;而熔炼炉渣中铜、钴、镍的提取率分别为54%,44%,71%。     

金昌冶炼厂电炉渣含铜高的原因分析及对策

分析了奥斯麦特炉熔炼过程中电炉渣含铜高的原因,提出相应对策来降低渣中含铜量。     

镍火法熔炼高钙低硅渣提取铁的研究

镍火法冶炼的高硅酸铁渣在综合利用中还原提取铁比较困难,通过在镍熔炼渣中适当增加CaO含量、减少SiO2含量以改善后续还原提取铁的热力学条件.在对所确定的新渣型对镍锍进行分离试验后,对熔炼终渣进行物相分析和还原提取铁试验,探讨了原渣和高钙低硅新渣型还原提取铁的不同.研究结果表明,高钙低硅新渣型终渣中铁主要以Ca(Fe,Mg) Si2O6以及MgFe2O4形式存在,50％以上的Fe以MgFe2O4的形式存在,其磁性以及还原性都比原渣中的(Fe,Mg)2SiO4要好,有利于其还原.与原渣的还原性相比,在试验条件下,当wCaO/wSiO2为0.80时,其还原率由48.53％提高到了57.45％.     

Ausmelt炉镍熔炼合理渣型的研究

金川集团公司沉降电炉弃渣有价金属含量高且熔化温度高。采用SEM-EDS与XRD确定了镍和铜在渣中的主要损失形式为夹杂或悬浮。测定了以Ausmelt熔炼渣为基础的半合成渣的熔化温度,研究了Fe/SiO2及CaO含量对半合成渣熔化温度的影响。结果表明,当Fe/SiO2=0.9～1.0且CaO含量为6%～10%时,渣的熔化温度明显降低,为Ausmelt炉镍熔炼工艺参数的优化提供参考。     

镍闪速炉合理渣型的研究

针对金川镍精矿含镁较高的特点，通过对人工合成渣物理化学性质的测定，研究了Ｆｅ／ＳｉＯ２比值及氧化镁含量对炉渣性质的影响，提出了适应高镁质矿熔炼的合理渣型，为金川镍闪速炉生产选用最佳操作参数提供了参考。     

A thermodynamic model of nickel smelting and direct high-grade nickel matte smelting processes: Part I. Model development and validation

A thermodynamic model has been developed to predict the distribution behavior of Ni, Cu, Co, Fe, S, As, Sb, and Bi in the Outokumpu flash-smelting process, the Outokumpu direct high-grade matte smelting process, and the INCO flash-smelting process. In this model, as many as 16 elements (Ni, Cu, Co, Fe, As, Sb, Bi, S, O, Al, Ca, Mg, Si, N, C, and H) are considered, and two nickel sulfide species are used to allow for modeling of sulfur-deficient mattes. The compositions of the matte, slag, and gaseous phases in equilibrium are calculated using Gibbs free energies of formation and the activity coefficients of the components derived from the experimental data. The model predictions are compared with the known industrial data from the Kalgoorlie Nickel Smelter (Kalgoorlie, Australia), the Outokumpu Harjavalta Nickel Smelter (Harjavalta, Finland), the INCO Metals Company (Sudbury, Canada), and from a number of experimental data. An excellent agreement is obtained. It was found that the distribution behaviors of Ni, Co, Cu, Fe, S, As, Sb, and Bi in the nickel smelting furnace depend on process parameters such as the smelting temperature, matte grade, and partial pressure of oxygen in the process.     

Corrosion behavior of high alumina and low silicon CaO Al2O3 slags on corundum/calcium hexaaluminate based castables

Due to the corrosion of CaO-Al2O3 based slags on refractory materials is related to the safe smelting of low-density and high-strength steel with high aluminum, the reaction experiment of calcium hexaaluminate castables with high-alumina and low-silicon CaO-Al2O3 based slag was carried out by introducing calcium hexaaluminate into corundum castables, and it was compared with that of alumina magnesia castable. The experimental results agreed with that of thermodynamic simulation and show that corundum calcium hexaaluminate castable has excellent slag resistance. Because the corundum calcium hexaaluminate castable reacted with the CaO Al2O3 based slag and produced high melting point phase CA2, which consumed a large amount of CaO in the slag and increased the viscosity of the slag, and CA2 filled the pores and blocked the penetration of slag. The wear mechanism of the calcium hexaaluminate castable is slag infiltration due to the higher porosity. Therefore, the combination of corundum aggregates and calcium hexaaluminate matrix is expected to be a candidate refractory material for ladle lining of low density and high strength steel smelting.     

高铝低硅CaO-Al2O3系熔渣对刚玉/六铝酸钙质浇注料的作用行为

摘要：由于高铝低硅CaO-Al2O3系熔渣对耐火材料的侵蚀损毁影响高铝含量低密度高强钢的安全冶炼生产,为此通过在刚玉质浇注料中引入六铝酸钙,开展六铝酸钙质浇注料与高铝低硅CaO-Al2O3系熔渣反应实验,并与铝镁浇注料进行对比研究了其作用行为。实验结果表明：刚玉 六铝酸钙浇注料具有优异抗渣性能。这主要是由于熔渣中大量的CaO被消耗,间接提高了熔渣黏度,并与刚玉 六铝酸钙浇注料反应生成的高熔点相CA2填充了气孔,阻挡了熔渣的渗透,实验结果与热力学模拟计算结果相吻合。六铝酸钙浇注料自身气孔率高,熔渣主要以渗透形式对六铝酸钙耐火材料造成破坏。因此,将刚玉骨料与六铝酸钙基质组合是有望成为低密度高强钢冶炼用钢包内衬候选耐火材料。     

转炉冶炼高铬铁水工艺研究与实践

高炉炼铁加入红土镍矿具有较高的降成本优势,但其中的铬元素进入铁水中,在转炉冶炼过程时出现了化渣困难、脱磷率低、铬回收率低等难题,制约着转炉生产顺行。对转炉冶炼高铬铁水存在问题的分析与生产实践、工艺研究,确定了铁水最佳铬含量为0.18%~0.25%。合理控制转炉终渣成分,Cr2O3含量控制在2%左右,解决了制约转炉吹炼的难题;依据转炉吹炼终点残余铬含量的不同,同步优化了相关运行规定及工艺制度,有效发挥了残余元素的价值,降低了钢中的Si、Mn、V等合金元素含量。     

Phase equilibrium and minor-element distribution between Ni3S2-FeS matte and calcium ferrite slag under high partial pressures of SO2

Calcium ferrite slag has been successfully used in the copper smelting process, but no attempt has been made to use it in the nickel smelting process. The phase equilibrium and the distribution of minor elements between the Ni₃S₂-FeS matte and the CaO-FeO_x-based slag (containing about 2 wt pct MgO) in a magnesia crucible were investigated at 1523 K under controlled partial pressures of S₂, O₂, and SO₂ of 10.1, 50.7, and 101.3 kPa, respectively. The results were compared with those for the iron-silicate-based slag, and the following conclusions were obtained: (1) there is no significant difference in the solubility of nickel between both slags in the high-matte-grade range, (2) the dissolution of cobalt in the calcium ferrite slag is clearly smaller than that in the iron silicate slag, (3) detrimental arsenic, antimony, and bismuth are preferentially collected and fixed in the calcium ferrite slag rather than in the iron silicate slag, and (4) it is considered, with regard to technical feasibility, that the use of the calcium ferrite slag in a converting process of the Bessemer matte will have a prominent future for the nickel converting stage.     

Investigation of the sedimentation of FeNi fine grains entrained in ERF slag

Nickel losses in the slag generated at Larco electric reduction furnaces (ERF) during smelting of Greek laterites account for about 20% of the total nickel of the feed. The recovery of the nickel contained in the slag as well as in its magnetic concentrate was studied under different methods. The experimental results have shown that a nickel recovery in the range of 75-90% is possible by allowing the slag to settle. Washing by low carbon steel can be performed during the final stages of the settling process as it improves the finally attained nickel recovery up to 94.4%. The simultaneous carbon reduction and settling process do not favour the Ni- recovery as the produced carbon monoxide and dioxide cause boiling of the bath which promotes the flotation of the metallic grains. In all cases a reoxidation of nickel was observed after 20min approximately. Settling of the ferronickel grains was described by a mathematical model. The model's results are in good agreement to the experimental ones for the initial 20min of the process. A modified model was elaborated combining the settling of the metallic grains with the nickel reoxidation reaction. This model describes with adequate accuracy the whole Ni- recovery process. The developed model can be proven helpful in the design of a slag cleaning step for metal recovery utilizing a slag settling furnace operating on line to the ERF.     

Slag Melting Characteristic of Slag Forming and Slag Splashing for BOF Less Slag Smelting

 The slag melting characteristic of slag forming and slag splashing for 300 t BOF less slag process is researched by combining the methods of the slag chemical composition, the melting point determination and the petrographic analysis. The results show that the melting point of final slag for less slag smelting is 20 ℃ lower than that for conventional smelting. According to results of the petrographic analysis, the C3S (3CaO·SiO2) and C2S (2CaO·SiO2) content for less slag smelting are lower than those for conventional smelting, while the RO (FeO, MgO, MnO, etc) phase and C4AF (4CaO·Al2O3·Fe2O3) phase are higher than those for conventional smelting. According to results of the chemical analysis, the (CaO) content and slag basicity for less slag smelting are higher than those for conventional smelting, while (FeO) and (MgO) content in slag for less slag smelting are almost equal to those for conventional smelting. The reason why slag melting point for less slag smelting is lower than that for conventional smelting is that the quantity of added fluorite for less slag smelting is more than that for conventional smelting. According to the analysis results the slag melting point is determined by the C3S, C2S, RO phase and C4AF content. According to the results of slag melting characteristic before and after slag splashing for less slag smelting, the present adjusting slag process has little effect. It is important to adjust the composition of BOF final slag. The (FeO) content in slag is to be reduced at the slag splashing and adjusting slag process for less slag smelting.