Reaction mechanism in a copper flash smelting furnace

Oxygen pressures in the Toyo copper flash smelting shaft have been measured by means of the following galvanic cell: Fe, FeO/ZrO₂ + MgO/O in molten particles. The measured oxygen pressures were normalized to 1523 K with respect to the reaction 4FeO(l) + O₂(g) = 4FeO_1.5(1). The normalized oxygen pressure and gas composition profiles along the vertical direction from the reaction shaft roof to the settler showed the following reaction mechanism. (1) Most of the oxygen contained in reaction air is consumed in the upper zone of the reaction shaft by sup-plemental fuel and some easily combustible copper concentrate particles which become oxidized excessively; and (2) the excessively oxidized concentrate particles, which may contain metallic copper, are reduced by contact with the remainder of the concentrate particles while they fall through the reaction shaft.     

Evaluation of nickel flash smelting through piloting and simulation

An extensive study of the nickel flash smelting process has been undertaken. It is aimed at the optimization of the burner design to improve the smelting performance and to increase the throughput of the rebuilt furnace. A design-based mathematical model was developed to simulate the operation of the four burners and the reaction shaft of the flash furnace at Western Mining Corporation Ltd.’s Kalgoorlie Nickel Smelter. A modified single burner version of the model was validated against data obtained from the pilot plant at the Pyrometallurgical Research Centre (PRC) of the Sumitomo Metal Mining Co.’s Toyo Smelter. The approach taken involved experimental measurements of key process parameters in the pilot plant and detailed numerical simulation of the fluid flow, heat transfer, and combustion in the entire burner-shaft complex. Several burner designs have been tested experimentally at the pilot plant and theoretically through computer simulation. The main outcome of the study was the development of an experimentally validated mathematical model of the flash smelter providing a new powerful design tool. The insight gained about the process from the application of this tool led to the design of a more efficient nickel flash smelting process.     

Measurements of oxygen pressure in a copper flash smelting furnace by an EMF method

Oxygen pressures in a copper flash smelting furnace were measured by means of the following galvanic cell: Fe, FeO/ZrO₂ + MgO/barO in slag or matte. Measured oxygen pressures were normalized to 1523 K with respect to the reaction: 4 FeO(l) + O₂(g) = 4 FeO_1.5(l). Vertical and horizontal variations of normalized oxygen pressures in the reaction shaft and in the settler were studied. The equilibrium relation between normalized oxygen pressure and the ratio of ferric to ferrous oxide content in the furnace slag was confirmed, and the activity coefficient ratio of these oxides was determined.     

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...