底吹连续炼铜工艺构想

一、前言 目前,全世界的火法炼铜工艺都分为两段,第一段是造锍熔炼,由铜精矿炼成含铜40%～75%的铜锍(或称冰铜),第二段是将此铜锍炼成粗铜.     

砷铅高杂铜锍富氧强化吹炼机理研究及工艺优化

砷铜锍(Cu₃As)、铅铜锍(Cu₂S、PbS)是粗铅精炼除铜渣熔炼副产物,属于毒性危险废物。本文提出富氧底吹强化吹炼法处理砷铜锍、铅铜锍,富集回收Cu和分离脱除Pb、As。通过热力学计算,阐明了Cu、Pb、As吹炼反应机理及元素物相演变规律,确定吹炼优化条件,并开展工业生产。结果表明：1250℃下,砷铜锍、铅铜锍富氧底吹强化吹炼经氧化、还原两阶段产出粗铜、吹炼渣及烟气。粗铜中Cu、As含量(质量分数)分别为93.94%、3.85%;原料中60.42%Cu富集至粗铜,27.43%Cu损失于吹炼渣;Pb在吹炼渣、烟气的分配率分别达到82.77%、17.22%;As在烟气和吹炼渣的分配率达89.46%。砷铜锍、铅铜锍富氧底吹强化吹炼实现了Cu向粗铜中定向富集,并将Pb、As脱除至吹炼渣和烟气,可用于含砷复杂资源高效处理。     

富氧侧吹熔池熔炼粗铜的生产工艺及其专用设备

该发明公开了一种富氧侧吹熔池熔炼粗铜的生产工艺及其专用设备,包括铜精矿熔炼、炉渣贫化、铜锍吹炼步骤,即将含铜物料、石英石、石灰石,粉煤加入熔池炉内,鼓入高压富氧空气,形成的铜锍,     

氧气底吹炼铜机理（英文）

氧气底吹炉是一种类似诺兰达炉的卧式旋转反应器,但富氧空气从炉体底部喷入熔体。通过分析底吹熔炼特性,提出了氧气底吹炼铜机理。在机理模型中,底吹炉内由上到下分成7个功能层,分别是烟气层、矿料分解过渡层、渣层、造渣过渡层、造锍过渡层、弱氧化层和强氧化层;沿轴线方向分成3个功能区,分别是反应区、分离过渡区、液相澄清区。模型中所有的层和区分别具有不同的作用。氧气底吹熔炼过程处于非稳态的近似多相平衡状态,且炉内不同空间位点的氧势、硫势呈梯度变化;通过合理控制不同层、区的氧势、硫势,可进一步提高氧气底吹炉的熔炼能力。     

底吹连续炼铜工艺构想

一，前言 目前，全世界的火法炼铜工艺都分为两段，第一段是造锍熔炼，由铜精矿炼成含铜40％～75％的铜锍（或称冰铜），第二段是将此铜锍炼成粗铜。     

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（英文）

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-SiO₂-MgO)的影响。结果表明，在1300℃、p(SO₂)=10 k Pa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(O₂))、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Fe S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(Mg₂SiO₄-Fe₂SiO₄)，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(O₂)为10^-6 k Pa时，FeO_x-SiO₂-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SiO₂熔剂调整渣型、升高熔炼温度，进而降低渣...     

氧气底吹铜熔炼工艺分析及过程优化

通过分析氧气底吹铜熔炼渣及铜锍,结合冶金过程原理,研究渣-铜锍间多组元含量的映射关系及熔炼过程优化。结果表明:铜锍中Cu、S、Fe含量之间呈现出较强的相关性;渣中Cu、SiO_2、Fe含量及渣型铁硅比m_(Fe)/m_(SiO_2)相互之间也呈现出一定的相关性;铜锍中Cu、Fe、S含量对渣中S含量的映射关系较为明显;基于铜锍中S、Cu含量和渣中S含量,或基于渣型铁硅比m_(Fe)/m_(SiO_2)和铜锍品位都可对渣中Cu含量进行预测,后者的准确度较高,说明铜锍品位和渣型对渣中Cu含量有较大影响。     

氧气底吹炼铜多组元造锍行为及组元含量的映射关系

通过分析氧气底吹炼铜过程产生的高品位铜锍中Cu、Fe、S、Si O2等组元含量变化趋势,结合冶金过程原理,研究上述各组元造锍行为及组元含量间的映射关系。结果表明:Cu、Fe、S、Si O2等组元在铜锍中的造锍行为具有相互关联性,其中Cu、Fe、S相互之间的关联性较强,Cu-Fe、Cu-S、Fe-S含量之间线性相关系数R2分别为0.96、0.89、0.79,但Si O2与Cu、Fe、S之间的关联性较弱。构造了Cu、Fe、S组元含量复合映射模型,该复合模型预测精确度高于单因素模型的预测精确度,可为生产过程中高品位铜锍多组元含量的精细调控,及熔炼-吹炼过程热量精确分配提供指导。     

造锍熔炼富集含砷难处理金矿中金的研究

在含砷难处理金矿中添加氧化铜造锍熔炼,将金和银富集在铜锍中。通过单因素实验法研究了造锍熔炼过程中主要元素的行为,得到造锍熔炼的最佳条件为:质量比m(CaO)/m(SiO2)=0.5、m(FeO)/m(SiO2)=2.0,物料中铜的总含量为5%,熔炼温度为1300℃,保温时间为60 min,此时金银在铜锍中得到有效富集。金在锍相中的品位为78.3 g/t,回收率可达到99.98%;锍相中铜的回收率为98.64%;渣相中砷和硫含量都很低。物相分析表明铜锍相中的铜和铁主要是以CuFeS2、FeS、Cu2S和Cu存在,对金具有富集作用。     

铜闪速吹炼过程杂质元素分配行为的热力学分析

利用已开发的铜闪速吹炼过程多相平衡热力学数学模型,计算某典型铜闪速吹炼生产工况,验证模型热力学分析的可行性,进而考察粗铜含硫(C_(SCu))、渣中钙铁比(R_(CaFe))、富氧浓度(C_O,体积分数)、吹炼温度(T)对杂质元素在吹炼产物中分配行为的影响。结果表明:提高C_(SCu)、T或降低R_(CaFe)、C_O将导致杂质在粗铜中分配率升高、而入渣率降低、有害杂质挥发率升高。在铜锍量和成分一定条件下,吹炼过程宜在"低粗铜含硫与吹炼温度"和"高渣中钙铁比与富氧浓度"条件下进行。综合考虑粗铜质量和渣含铜,C_(SCu)、R_(CaFe)和T建议分别控制在0.20%、0.4和1526 K左右,而C_O应根据制氧成本和炉内反应状况适当控制。     

Direct Production of Copper

The use of commercially pure oxygen in flash smelting a typical chalcopyrite concentrate or a low grade comminuted matte directly to copper produces a large excess of heat. The heat balance is controlled by adjusting the calorific value of the solid feed. A portion of the sulfide material is roasted to produce a calcine which is blended with unroasted material, and the blend is then autogeneously smelted with oxygen and flux directly to copper. Either iron silicate or iron calcareous slags are produced, both being subject to a slag cleaning treatment. Practically all of the sulfur is contained in a continuous stream of SO₂ gas, most of which is strong enough for liquefaction. A particularly attractive feature of these technologies is that no radically new metallurgical equipment needs to be developed. The oxygen smelting can be carried out not only in the Inco type flash furnace but in other suitable smelters such as cyclone furnaces. Another major advantage stems from abolishion of the ever-troublesome converter aisle, which is replaced with continuous roasting of a fraction of the copper sulfide feed.     

氧气底吹铜熔池熔炼过程的机理及产物的微观分析

对氧气底吹熔炼过程气体喷吹行为、造锍熔炼化学反应机理及熔炼炉内热工作状态进行理论分析及水模型实验和取样分析验证。结果表明,氧气底吹气流能使熔体形成均匀的扩散区,实现熔体的搅拌,在气体连续相区和液体连续相区,气液、液液之间的相互作用强烈,为炉内化学反应及传热传质提供了良好的动力学条件;氧气底吹熔炼过程在零配煤的情况下能达到自热熔炼,在节能减排方面,该工艺具有很强的优势;获得了铜渣、冰铜和蘑菇头中各组分的形貌,确定了铜渣、冰铜和蘑菇头的物相组成,渣样主要由冰铜相、磁铁矿相、铁橄榄石相和玻璃体相组成,熔炼内的氧势和硫势分布有利于反应的进行,能有效抑制Fe3O4的形成以及降低渣含铜。     

Thermodynamic Consideration for Oxygen Pressure in a Copper Flash Smelting Furnace at Toyo Smelter

JOM - Based on the emf measurements of the galvanic cell (Fe, MgO/O in slag or matte) and the equilibrium calculations, the oxygen pressure in a copper flash smelting furnace at Toyo smelter is...     

Numerical analysis on fluid flow and heat transfer in the smelting furnace of mitsubishi process for Cu refining

To understand complex behavior in the smelting furnace of Mitsubishi continuous process for copper refining, comprehensive 3-D numerical simulation and field experiment were performed. The numerical simulation results showed that strong and complex velocity fields of gas, matte and slag were generated in the furnace and large amounts of matte and slag were splashed into the gas area. Temperature measurements at the lance during field operation revealed that wide range of temperature variation appeared depending on the injection condition of concentrates. Numerical simulation results provided good agreements with experiments results and showed that the chemical reaction induces temperature increase during gas injection period. On the other hand, lance temperature is decreasing because of cold concentrates during gas and particles injection period. From the FFT analysis results, the fluctuations of matte and slag volume fraction near the lance induce temperature fluctuations of the lance. Through these experimental and simulation results, it was revealed that the lances in the smelting furnace were exposed to severe conditions such as high temperature, repeated large temperature change and cyclic change of large temperature gradient across the thickness.     

闪速熔炼在中国的进展与研究--冷风技术及"非接触冶金"

从环境保护角度阐述了世界铜、镍闪速熔炼的发展与现状,讨论了"冷风节能"及其工业应用技术.介绍了中国在"闪速炉扩产"、"闪速冶金事故监控"、"水套新材料"、"闪速炉连续炼铜"等方面的研究成果.为根本解决强化冶金对炉衬的腐蚀,提出了"非接触冶金"的思路,描述了中心旋涡柱闪速熔炼方法,并介绍了旋涡喷嘴基本设计及计算机仿真实验.     

Copper smelting mechanism in oxygen bottom-blown furnace

The SKS furnace is a horizontal cylindrical reactor similar to a Noranda furnace, however, the oxygen enriched air is blown into the furnace from the bottom. Mechanism model of the SKS process was developed by analyzing the smelting characteristics deeply. In our model, the furnace section from top to bottom is divided into seven functional layers, i.e., gas layer, mineral decomposition transitioning layer, slag layer, slag formation transitioning layer, matte formation transitioning layer, weak oxidizing layer and strong oxidizing layer. The furnace along the length direction is divided into three functional regions, that is, reaction region, separation transitioning region and liquid phase separation and settling region. These layers or regions play different roles in the model in describing the mechanism of the smelting process. The SKS smelting is at a multiphase non-steady equilibrium state, and the oxygen and sulfur potentials change gradually in the length and cross directions. The smelting capacity of the SKS process could be raised through reasonably controlling the potential values in different layers and regions.     

Mass balance calculations in copper flash smelting by means of genetic algorithms

This paper presents mass balance calculations using genetic algorithms for copper smelting in an Outokumpu flash furnace. Based on the elemental composition of the copper concentrates being fed to the reactor, the mineralogical composition of the concentrate mixture is adjusted by means of genetic algorithms. The macroscopic mass balance equations for the species entering and leaving the furnace are solved and the compositions and flow rates of matte, slag, and the off-gas stream are computed. Good agreement between the predicted and plant data was obtained in terms of matte and slag flow rates, matte grade, and copper, iron, magnetite, and silica contents in the slag. Predictions are more suitable and faster to obtain with this method than a conventional method in which the mineralogical composition of the feed is not adjusted. Future applications of the formulation are discussed. For more information, contact V.M. Sanchez-Corrales, Universidad de Sonora, Departamento de Ingeniería Química y Metalurgia, Blvd. Luis Encinas y Rosales, Hermosillo, Sonora, 83000, Mexico; +662-259-2105; fax +662-259-2105; e-mail vsanchez@guaymas.uson.mx.     

EFFECTS OF TEMPERATURE ON DISTRIBUTION BEHAVIORS OF MINOR ELEMENTS IN COPPER FLASH SMELTING──COMPUTER SIMULATION

ＥＦＦＥＣＴＳＯＦＴＥＭＰＥＲＡＴＵＲＥＯＮＤＩＳＴＲＩＢＵＴＩＯＮＢＥＨＡＶＩＯＲＳＯＦＭＩＮＯＲＥＬＥＭＥＮＴＳＩＮＣＯＰＰＥＲＦＬＡＳＨＳＭＥＬＴＩＮＧ──ＣＯＭＰＵＴＥＲＳＩＭＵＬＡＴＩＯＮ￥ＴａｎＰｅｎｇｆｕ；ＺｈａｎｇＣｈｕａｎｆｕ（Ｄｅ...     

Top-blown injection smelting and converting: The Mitsubishi process

The Mitsubishi process is a continuous copper smelting and converting process comprising three steps—smelting of raw materials by injection, separation of slag and matte, and direct converting of high-grade matte. Since commercial operation began in 1974, the hearth productivity has been doubled, and several other improvements have been made, including higher-grade matte smelting and the treatment of various secondary materials. Because the Mitsubishi process is superior to the conventional process, it was decided to construct a larger unit of the Mitsubishi furnaces to replace the two existing smelter lines. This article discusses various technical considerations.     

铜闪速炉沉淀池渣中锍液滴沉降机理及其影响因素

通过分析沉淀池内锍液滴的沉降机理,导出了渣中最大锍液滴直径的计算公式。根据闪速炉的实际生产条件,计算出渣中最大锍液滴直径的理论值为0.063 mm,并用矿相显微镜对沉淀池出口处的渣样进行了观察,渣中最大锍颗粒粒径为0.06 mm,两者结果一致。由此证明了沉降机理分析的正确性。在此基础上,进一步分析渣中锍夹带损失影响因素。结果表明:增大熔体中离散态分布的锍液滴直径是降低渣中铜夹带损失的重要措施;其次是升高渣温度有助于渣中锍的沉降;减小渣层厚度等措施对降低渣中铜夹带损失作用不大。