Pyrometallurgy of copper pdf

Paul Queneau, U. Queneau and B. Kalling, U. Renzoni, U. Curlook, C. Queneau, U. Queneau, and J. Warner, U. Queneau and C. Warner and P.

Paul Queneau, C. Illis, and J. Queneau, S. Townshend, R. Thoburn and P. Blanco, T. Antonioni, C. Landolt, and G. Antonioni, J. Blanco, C. Landolt, and W. Dutton, J. Edwards, and R. CAS Google Scholar. Bell, J. Blanco, H. Davies, and P. Fritz, S. Marcuson, R. Cowx, and J. Diaz, C. Luraschi, and C. Newman New York: Pergamon Press, , pp. Davies, and R. Marcuson, C.

Diaz, and H. Diaz, S. Marcuson, H. Hydrocyclone Hydrocyclone has been extensively used for closed circuit grinding and….

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Bauxite processing plant Our Solutions. Copper ore beneficiation plant Our Solutions. Gypsum mining equipment Our Solutions. He is the author or co-author of a book on the thermodynamic properties of copper-slag systems, about 50 technical papers and 15 patents of invention, and co-editor of numerous international conference proceedings, including several of the COPPER—COBRE series of conferences. Carlos Landolt graduated from the University of Chile as a mining engineer and continued his studies at Pennsylvania State University where he obtained an MSc in metallurgy and PhD in materials sciences.

Retired from Inco since , he is now an adjunct professor in the School of Engineering of Laurentian University where he teaches operations management, process management and productivity and is involved in the development of distance education programs in operations management. He has also organized several TMS-sponsored conferences and symposia on nickel and copper processing and been co-editor of several volumes of proceedings.

Dr Landolt is the author or co-author of more than 30 papers and patents in process metallurgy and productivity. Heffernan chair in materials processing. After receiving an undergraduate science degree from Oslo University in , he obtained a PhD in metallurgy from the University of Toronto in He worked, from to , in Switzerland as a research engineer for Swiss Aluminium Ltd and, from to , at the metallurgical technology centre of Falconbridge Ltd, in Falconbridge, Canada.

He is a former chairman of the non-ferrous pyrometallurgy committee of the Metallurgical Society of CIM. Smelting and converting of complex copper concentrates 14 In each of these processes, the individual operations, including both oxidizing including the use of tonnage oxygen and reducing steps, are carried out in a batch-wise manner producing a metal-rich phase and a slag. Boliden tested the processes at Lulea on a 5 -mt vessel. The Boliden TBRC converter slag plant, 11 reportedly due to start up in late , will take all the converter slag about , mtpy produced in the Peirce-Smith converters.

The slag is reduced with addition of coal and concentrates to produce a zinc-fuming low copper slag with most of the zinc and antimony, and a copper matte with most of the nickel and some lead.

The process is expected to increase flexibility and the capacity of the copper smelter, improve the elimination of magnetite from the electric furnace and provide better management of heavy metals. It will produce a low-sulfur bullion.

A slag similar to that in the dust treatment plant is produced. Patent l5 assigned to Kennecott Copper Corporation claims the use of a rotary furnace for the pyrometallurgical recovery of copper from slag using a cyclic, two-stage cleaning process.

The TBRC treatment of the so-called complex copper concentrates is the latest Boliden application 14 and a full scale plant is reportedly under construction for a mid-I start-up. In a multi-step operation, chalcopyritic concentrates are first autogenously smelted to a primary matte. If required, enhanced volatilization of elements such as Bi, Sb and As can be achieved by rotating the vessel with the burner set at a controlled oxygen potential.

The subsequent converting to white metal and blister copper is carried out in the normal manner. Offgases are spray-water cooled, cleaned in an electrostatic precipitator and dual-alkali scrubber followed by mercury removal by condensation. The Tennant Creek Smelter in Northern Territory, Australia equipped with an Outokumpu flash furnace and a TBRC for converting high grade matte, closed down in , reportedlyl7 due to difficulties with the matte converting step mouth buildup, sticky slags, extended blowing times and high fuel and refractory consumption.

An improvement in differential flotation techniques to lower bismuth level in copper concentrates from 2. The TBRC vessel offers a high intensity smelting unit and has the flexibility to carry out sequential oxidizing and reduction reactions in the same vessel. It appears admirably suited to small plants, although it is not alone in this category. For special TBRC applications such as the nickel refinery at Sudbury'" or for the enhanced volatilization technique of Boliden,14 some vessel rotation is required to provide good mixing but it is difficult to see the merits of the high rpm vessels for normal copper smelting processes.

One improvement in the top blown vessel would be the achievement of the required mixing without the need for a furnace mechanism to withstand both the rotation at rpm and high temperatures. A pilot study of the application of the oxygen flash smelting technique to small installations was described by Inco at the th AIME Annual Meeting.

The Inco study was to determine the feasibility of using this smelting technique in a smaller vessel such as a converter. The tests were done in a top blown rotary converter which Inco considered most suitable. High smelting rates of up to 5. The observed distribution of minor elements when producing high grade matte was as one would expect.

Slags were normal for the matte grades produced and milling results were satisfactory. The Inco study included an investigation of the reaction rate in the jet of the oxygen concentrate burner, by sampling at different distances from the nozzle. The smelting reactions appeared to be essentially complete and the products molten at a distance of about 2 m from the burner, corresponding to a reaction time of J. The , mtpy Cu smelter at Sar Cheshmeh, Iran, based on reverberatory smelting, is slated for a startup.

GO The startup of the new electric furnace at Anaconda was described by Senne. The Anaconda furnace is the second of the new, large electric furnaces recently installed in the U.

The large electric furnace in copper smelting has had some operating difficulties and equipment failures but it should be regarded as a reasonably well established process. It is considered unlikely that many more large electric furnaces for smelting copper sulfide concentrates will be built unless cheap power is available.

No serious hydrometallurgical competitors to copper pyrometallurgy emerged, however, the Cyprus CI Leach-CI precipitation-H2 reduce process which was announced 28 could be interesting for small plants while the recently presented Sherritt-Cominco copper process seems overly complex.

The Noranda Process can produce high grade mattes of any copper content as required. Conventional converting of high grade matte markedly shortens tuyere brick life. The capacity of a converter is determined by the total blowing rate, which, for a given size vessel is limited mainly by the onset of operating problems such as excess splashing. Continued intensification of the Peirce-Smith converter is limited, although larger vessels-up to 5. The first successful converter for coppel by Manhes in France36 had horizontal tuyeres, which, although in use at the time for Bessemer steel converters, were being displaced by vertical tuyeres.

Horizontal tuyeres in non-ferrous metallurgical vessels have prevailed. It is possible now that the need for intensification and new process engineering might make the bottom-blown copper converter a reality. Such a vesse would have a higher specific capacity and would probably operate with less splashing at comparable specific air rates to the side-blown unit.

In the bottom-blow copper converter one may see higher pressures which give a more stable jer 7 and may eliminate punching Milling of slags from the N orand a Continuous Smelting Process at Noranda, Quebec, Canada, was described by Godbehere and Brooks38 and a patent for the slow cooling of slags was issued.

Flon, Canada, was described by McDonald and Williams. Texasgulf will also use this anode casting method at their new refinery in Northern Ontario. Hazelett is working with the Olen refinery in Belgium to continuously cast full thickness 38 mm anodes.

Continuously cast rod is expected to take a larger share of the wire bar market. An interesting pilot study of a new continuous copper refining process was! The hearth has three adjoining sections-smelting, oxidation with tonnage oxygen and reduction for the impurity removal and poling processes.

The pilot blister refining tests showed excellent elimination of Sn and Pb as would be expected but relatively poor elimination, at about the 0. The process would not seem to have a clear advantage over existing anode refining poling processes, however, in the special case where a copper feed such as scrap or a black copper requires refining, the KHD approach may well find application. Pulling and Garner published papers on secondary copper smelting. In this context, the papers by Warringron 47 on the marketing of copper scrap and Manzone and Opie 48 on the secondary copper operation at United States Metals Refining Company at Carteret, New Jersey, are of interest.

NICKEL The early days of nickel metallurgy in Norway and Germany saw nickel matte smelting being adopted for the sulfidic ores with the processes for the new and mysterious metal being borrowed from copper. Centuries of copper smelting technology were thus effectively applied to nickel.

Matte smelting methods continued to dominate nickel metallurgy for more than seventy years with special techniques being developed to separate the copper from the nickel, an aspect of continuing metallurgical importance.

Matte smelting techniques were used for the first oxide process in New Caledonia in and essentially these operations smelted the charge with the addition of gypsum as a source of sulfur, and lime flux. The subsequent matte was treated in a way similar to that for sulfidic material. Thus with more and more nickel being derived from lateritic ores, significant process metallurgy efforts are being devoted to methods of extraction, whether this be pyrometallurgical or hydrometallurgical, with much development work devoted to the latter.

These ores are moist, low grade, not readily amenable to concentration by mineral dressing techniques and the energy requirement is an important consideration.

The oxide deposits of essentially hydrous nickel-magnesium silicates and nickeliferous iron laterites typically contain virtually no sulfur, copper, group V -A metals or precious metals and occasionally some cobalt and therefore refining presents a different metallurgical picture compared to that for sulfide-based processes where several economic by-products are common. As the entire nickel ore is metallurgically processed, the new generation of large lateritic nickel plants is characterized by massive unit processes, whether these are kilns, smelting furnaces or hydro metallurgical operations.

In oxide nickel metallurgy, the two important new projects-Soroako in Indonesia and Lake Izabel in Eastern Guatemala-use the pryometallurgical route.