Pyrometallurgy

SYMPOSIUM: 03 PYROMETALLURGY

CODE AUTHOR TITLE ABSTRACT

PY01 James Edwards COMING OF AGE - 21 YEARS COMERCIAL

OPERATION OF COPPER ISASMELT IM AT MONT ISA

PY02 Kim Fagerlund SMELTING - INTEGRATED, SUSTAINABLE PLANT

SOLUTION

PY03 Dean Gregurek WEAR PHENOMENA OF BASIC BRICK LININGS IN

COPPER INDUSTRY

PY04 Dean Gregurek CORROSION TESTING METHODS FOR NEWLY

DEVELOPED REFRACTORY PRODUCTS

PY05 N. Brogden ELECTROMAGNETIC LEVEL PROFILE

MEASUREMENT SYSTEM TESTED BY AGELLIS

GROUP AB ON KENNECOTT COPPER FLASH

SMELTERS IS DESIGNED TO ENHANCE PROCESS

CONTROL DECISION MAKING AND IMPROVE

OPERATOR SAFETY

PY06 Klaus Gamweger FIELD REPORTS OF THE NEW INNOVATIVE GAS

PURGING SYSTEM FOR STATIONARY AND TILTING

COPPER ANODE FURNACES

PY07 F. Alvear SMELTING OF KAZAKHSTAN CONCENTRATES AT

UST-KAMENOGORSK USING A COPPER ISASMELT™

FURNACE

PY08 Angelika Ressler DESTRUCTIVE AND NONDESTRUCTIVE TESTING

METHODS FOR THE CHARACTERIZATION OF

MGOCR2O3-BASED REFRACTORY BRICKS

PY09 Chiharu Tokoro SULFULIZATION AND SLOW-COOLING FOR

MOLYBDENUM RECOVERY FROM COPPER

SMELTING SLAG

PY10 Gavin Swayn DESIGN AND COMMISSIONING OF THE OUTOTEC®

AUSMELT TSL COPPER SMELTER AT DNMC

PY11 Cristian

Martinez

General Maintenance of Electric Furnace

PY12 Grf Alvear XSTRATA TECHNOLOGY`S APPROACH FOR THE

PROCESSING OF COPPER BEARING MATERIALS

PY13 G. Richter CALETONES SMELTER; ENVIRONMENTAL AND

COMPETITIVENESS CHALLENGES

PY14 Maximo Leon ON THE INTERACTION BETWEEN REVERTS MEAN

PARTICLE SIZE AND FLASH FURNACE REACTION

SHAFT HEIGHT: A SENSITIVITY ANALYSIS

Pyrometallurgy

PY15 Taufiq Hidayat A THERMODYNAMIC OPTIMIZATION OF THE

"CU2O"-CONTAINING SLAG SYSTEM AND ITS

APPLICATIONS IN HIGH-TEMPERATURE COPPER

MAKING PROCESSES

PY16 Carl Justav Berg OPTIMUM DRYING SOLUTION FOR COPPER

CONCENTRATE

PY17 Per G.

Brännström

ENVIRONMENTAL IMPROVEMENTS FOR PS

CONVERTERS WITH OUTOTEC'S CONVERTER HOOD

TECHNOLOGY FOR PRIMARY AND SECONDARY GAS

CAPTURE

PY18 G. Richter INCREASE AVAILABILITY SMELTER PLANT

PY19 G. Richter INCREASE SULFUR CAPTURE - OPERATIONAL

MANAGEMENT

PY20 G. Richter INSTALLATION OF DILUTED OPXYGEN

COMBUSTION TECHNOLOGY IN A COPPER ANODE

REFINING FURNACE AT CODELCO EL TENIENTE

PLANT

PY21 Boajun Zhao FEATURES OF THE BOTTOM BLOWN OXYGEN

COPPER SMELTING TECHNOLOGY

PY22 Baojun Zhao VISCOSITY MEASUREMENTS FOR COPPER

SMELTING SLAGS

PY24 Alejandro

Molina

AVA (ANÁLISIS VÍA VISIÓN ARTIFICIAL)} SYSTEM

PY25 Alejandro

Molina

THE SYSTEM FOR OPERATIONAL CONTROL OF

EMISSIONS (SCOE+)

PY26 F. Jimenez SPECIATION OF COPPER IN FLASH, CONVERTER AND

SLAG CLEANING FURNACE SLAGS

PY27 Milorad ?irkovi? SYNERGY OF ENERGY RESOURCES OF COPPER

PYROMETALLURGY IN RTB BOR-SERBIA

PY28 S. Pietrzyk VISCOSITY OF COPPER SLAGS FROM THE PROCESS

OF DECOPPERING IN AN ELECTRIC FURNACE

PY29 J. Font OPTIMAL CONFIGURATION OF VOLTAGE AND

CURRENT INTENSITY IN AN ELECTRIC FURNACE

FOR SLAG CLEANING

PY30 B. T. Chambers SULPHATION ROASTING OF ENARGITE

CONCENTRATE

PY31 A. Warczok COPPER RECOVERY FROM THE SMELTING SLAG IN

A ELECTRIC FURNACE

PY33 Peter Björklund RECENT EXPRIENCES FROM IMPLEMENTING

DYNAMIC PROCESS CONTROL AND MONITORING IN

THE FLASH SMELTING PROCESS

PY34 S. B. Breyner THERMAL SHOCK RESISTANT ALUMINA-CHROMIA

REFRACTORY MATERIALS FOR THE COPPER

Pyrometallurgy

INDUSTRY

PY35 Zhi Sun LIQUIDUS TEMPERATURES, MAJOR AND MINOR

ELEMENTS EQUILIBRIUM PARTITIONING IN COPPER

SMELTING SLAG / MATTE /GAS SYSTEMS

PY36 Zhi Sun QUASI-CHEMICAL VISCOSITY MODEL FOR COPPER-

CONTAINING MULTI-COMPONENT LIQUID SLAGS

PY37 Czernecki Jozef MEANS OF REMOVING LEAD AND ARSENIC DURING

THE COPPER PRODUCTION CYCLE IN UPGRADED

TECHNOLOGY OF KGHM POLSKA MIED? SA

PY38 Zhou Jun FLASH SMELTING AND FLASH CONVERTING

PROCESS AND COMMISSIONING AT JINGUAN

COPPER

PY39 Vaajamo Lina AN EXTENSIVE SLAG DATABASE: LEAD-ING THE

WAY

PY40 Ata Fallah-

Mehrjardi

INVESTIGATION OF THE BATH-DEPOSIT INTERFACE

OF FREEZE-LININGS IN COPPER SLAGS

PY41 Sergio Carrasco ADVANCED PILOT PLANT ROASTING TESTS GIVE

NECESSARY KNOWLEDGE FOR DESIGN OF A LARGE

ROASTER PLANT AT MMH

PY42 Evgueni Jak INTEGRATED EXPERIMENTAL AND MODELLING

RESEARCH ON COPPER SLAGS PHYSICO-CHEMICAL

PROPERTIES IN SUPPORT OF OPTIMISATION OF

COPPER MAKING PROCESSES

PY43 E. Jak CALCIUM FERRITE SLAG PHASE CHEMISTRY

CONTROL USED IN CONTINUOUS FLASH

CONVERTING

PY44 Katsunori

Yamaguchi

DISTRIBUTION RATIOS OF PLATINUM AND

PALLADIUM BETWEEN IRON OXIDE SLAGS AND

MOLTEN COPPER AT 1573 K

PY45 Hiromichi Inada IMPROVEMENT OF CIRCULATED WATER COOLING

SYSTEM FOR COPPER SLAG GRANULATION AND

EFFECTIVE USE OF BLEEDING-OFF WATER

PY46 S. Sasai DEVELOPMENT OF SIDE-BLOWING OXY-FUEL

CONCENTRATE BURNER IN FLASH SMELTING

PROCESS AT SUMITOMO TOYO SMELTER

PY47 Jun-Ichi STUDY ON LIQUIDUS TEMPERATURE AND

VISCOSITY OF COPPER SMELTING SLAG

PY50 Masanori

Yoshida

THE ESTABLISHMENT OF AN OPTIMUM OPERATION

AFTER THE INTRODUCTION OF THE O-SR PROCESS

AT ONAHAMA SMELTER & REFINERY

PY51 R. König HIGH EFFICIENT SLAG CLEANING - LATEST RESULTS

FROM PILOT SCALE OPERATION

Pyrometallurgy

PY52 N. Cardona OPTIMIZING CONVERTER AISLE OPERATION AT

ATLANTIC COPPER SMELTER, HUELVA, SPAIN

PY53 Javad Khosravi APPLICATION OF EXERGY ANALYSIS IN COPPER

SMELTING PRODUCTION

PY54 Baojun Zhao PHASE EQUILIBRIA STUDIES FOR COPPER

SMELTIMG/ CONVERTING SLAGS

PY55 Ata Fallah-

Mehrjardi

INVESTIGATION OF FREEZE-LINING FORMED IN AN

INDUSTRIAL COPPER CONVERTING CALCIUM

FERRITE SLAGS

PY56 V.R. Parra-

Sanchez

CHEMICAL COMPOSITION AND DUST GENERATION

OF COPPER CONCENTRATE PARTICLES OXIDIZED

UNDER SUSPENSION-SMELTING CONDITIONS

PY57 V.R. Parra-

Sanchez

EVOLUTION OF SIZE DISTRIBUTION OF COPPER

CONCENTRATE PARTICLES OXIDIZED UNDER

SUSPENSION-SMELTING CONDITIONS

PY59 I. Wilkomirsky CONTINUOUS CONVERTING OF COPPER MATTE IN A

MOLETEN - LAYER REACTOR

PY60 I. Wilkomirsky PHYSICO - CHEMISTRY OF NEUTRAL ROASTING OF

HIGH ARSENIC COPPER CONCENTRATES

PY61 I. Wilkomirsky RECOVERY OF COPPER, MOLYBDENUM, ZINC AND

IRON (HEMATITE) FROM COPPER SMELTER SLAGS

PY62 Claudio Queirolo NEW SLAG FLOTATION PLANT POTRERILLOS

SMELTER

PY63 Mark Coleman REFINEMENT OF FLASH FURNACE AND CODELCO

TENIENTE REACTOR MATERIAL FEED SYSTEMS TO

UTILISE CALCINED CONCENTRATES

PY64 Xiaohong Hao DEVELOPMENT AND APPLICATION OF OXYGEN

BOTTOM-BLOWING CU SMELTING TECHNOLOGY

PY65 Bing Li DEVELOPMENT OF THE CONTINUOUS BOTTOM-

BLOWING MATTE CONVERTING PROCESS

PY66 Mike Santaluce AN INTEGRATED LIFECYCLE APPROACH TO

FURNACE REBUILDS

PY67 P.J. Mackey COPPER SMELTING TECHNOLOGIES IN 2013 AND

BEYOND

PY68 Alfredo Martinez USE OF WASTE HEAT BOILERS TO SAVE RESOURCES

PY69 Antoine Allanore DIRECT SULFIDES ELECTROLYSIS: A SUSTAINABLE

PROCESS FOR COPPER RECOVERY?

PY70 L. Scheunis THE EFFECT OF IN SITU PHASE FORMATION ON THE

INFILTRATION BEHAVIOR AND CHEMICAL

DEGRADATION OF MAGNESIA-CHROMITE BRICKS IN

CONTACT WITH A SYNTHETIC NON-FERROUS SLAG

Pyrometallurgy

PY71 Marcin

Kacperski

OPTIMIZATION OF TECHNOLOGY FOR

CONCENTRATE SMELTING IN FLASH FURNACE

WITH CHARGE CHANGES

PY73 Patricio

Hernandez N.

MECHANICAL SYSTEM FOR REVERTS CHARGING

INTO PEIRCE-SMITH CONVERTERS

PY74 Alberto

Fernandez

EMISSIONS REDUCTION AND PROCESS

IMPROVEMENTS ACHIEVED WITH THE NEW ANODE

FURNACE OFF-GAS SYSTEM AT ASARCO HAYDEN

PY75 Matt Russell TECHNOLOGY DEVELOPMENTS FOR SMELTER OFF-

GAS HEAT RECOVERY

PY76 A.J.Rigby THE USE OF CHROME-ALUMINA REFRACTORIES IN

THE HIGH WEAR AREAS OF ANODE REFINING

VESSLS

PY77 L. Voisin IMPURITY BEHAVIOUR DURING THE CONTINUOUS

CONVERTING OF COPPER MATTE IN A PACKED BED

REACTOR

PY78 L. Voisin - J.

Diaz

OXIDATION KINETIC OF COPPER MATTE DURING

THE CONTINUOUS CONVERTING PROCESS IN A

PACKED BED REACTOR

PY79 L. Voisin - F.

Mansilla

KINETIC AND MODELING OF CONTINUOUS COPPER

REFINING IN A PACKED BED REACTOR DURING THE

REDUCTION STAGE

PY80 L. Voisin - G.

Damm

PHASE RELATIONS AND MINOR ELEMENT

DISTRIBUTION IN CU-FE-PB-AS SYSTEM SATURATED

WITH CARBON AT 1473 K

PY81 L. Voisin - K.

Mühlenbrock

PHASE RELATIONS AND MINOR ELEMENT

DISTRIBUTION IN CU-FE-PB-SB SYSTEM SATURATED

WITH CARBON AT 1473 K

PY82 L. Voisin - E.

Marambio

THERMO-FLUID-DYNAMICS MODELING FOR

CONTINUOUS CONVERTING PROCESS OF COPPER

MATTE IN PACKED BED REACTOR

PY83 L. Voisin CHARACTERIZATION AND FROTH FLOTATION OF

SMELTING FURNACE COPPER SLAG

PY85 Chang-Buhm

Kim

MAXIMIZATION OF HEAT RECOVERY BY

PRODUCING LOW PRESSURE STEAM

PY86 Jonkion Font COPPER DISSOLUTION IN THE FEOX-SIO2 BASE SLAG

OF THE FLASH SMELTING FURNACE AND THE

TENIENTE CONVERTER AT THE CHUQUICAMATA

SMELTER

PY87 Kozhakhmetov S IMPROVEMENTS IN THE VANYUKOV SMELTING

TECHNOLOGY

PY88 J. Font - J.

Ahumada

CHUQUICAMATA SMELTER: PRESENT AND FUTURE

Pyrometallurgy

PY89 Yan Jie LATEST DEVELOPMENT OF OXYGEN BOTTOM-

BLOWING COPPER SMELTING TECHNOLOGY

PY90 Li Feng DEVELOPMENT OF COPPER/GOLD SULFIDE

CONCENTRATES PYROMETALLURGICAL PROCESS

PY91 Zhixiang Cui INDUSTRIAL TEST DEVELOPMENT OF CONTINUOUS

BOTTOM BLOWN OXYGEN COPPER SMELTING

PROCESS

PY92 Zhixiang Cui NEW DEVELOPMENT OF BOTTOM BLOWN OXYGEN

SMELTING TECHNOLOGY IN DONGYING FANGYUAN

NONFERROUS METALS CO. LTD

PY93 Eduardo

Balladares

COPPER SMELTING FLUE DUST CHARACTERIZATION

AS A KEY ISSUE IN THEIR TREATMENT

PY95 L. A. Campos DESIGN OF A HEAT RECOVERY COOLING CHAMBER

SYSTEM FOR COPPER SMELTERS

PY96 L.B. Tsymbulov COMPARATIVE ANALYSIS OF

PYROMETALLURGICAL METHODS FOR PROCESSING

OF SULFIDE COPPER CONCENTRATION FROM

UDOCAN DEPOSIT

PY97 L.B. Tsymbulov OPTIMAL SLAG COMPOSITION FOR PROCESSING OF

COPPER NICKEL MATTES AND CONCENTRATES IN A

VANIUKOV TWO-ZONE CONVERTER THAT

PRODUCES BLISTER COPPER

PY98 P.Coursol ARSENIC REMOVAL FROM BLISTER COPPER USING

MOLTEN SODIUM AND CALCIUM SULPHATES

PY99 M. Rosales ON THE POSSIBILITY OF USING HIGH OXYGEN

ENRICHMENT IN TENIENTE CONVERTERS

PY101 G. Wastavino COPPER CONTENT IN FLASH FURNACE SLAG

CHUQUICAMATA SMELTER, USING OLIVINE-TYPE

SLAG

PY103 Enrique Herrera CONTROLLING SO3 FORMATION IN THE OFF-GASES

PROCESS FROM THE ISASMELTTM FURNACE AT

SOUTHERN PERU ILO SMELTER

PY104 Stefan

Konetschnik

SERVICE LIVE INCREASE OF TSL LANCES USING

IONIC LIQUID COOLING TECHNOLOGY

PY105 Arsenio (Jun)

Enriquez

AN UPDATE ON KENNECOTT UTAH COPPER'S USE OF

PRAXAIR'S COHERENT JET TECHNOLOGY IN ANODE

REFINING - DEVELOPMENTS SINCE 2010

PY106 Alessandro

Navarra

AUTOMATIC SCHEDULING OF ALTONORTE

OPERATIONS USING GREEDY ALGORITHMS

PY134 Gert Erasmus A NOVEL METHOD FOR QUANTIFYING SMELTER SO2

FUGITIVE EMISSIONS USING AN OPEN PATH

FOURIER TRANSFORMS INFRARED (FTIR) ANALYSER

Pyrometallurgy

PY135 Thomas Zabev -

Pascal Coursol

OBSERVATIONS ON THE REDUCTIVE PYRO DE-

ARSENIFICATION OF ENARGITE

PY136 Y. Prevost FORTY YEARS OF OPERATION OF THE NORANDA

REACTOR PROCESS

PY137 A.Warczok PHENOMENOLOGY OF COPPER MATTE CONTINUOUS

CONVERTING IN A PACKED BED

PY138 L. Diaz A MASS TRANSFER MODEL FOR MOLTEN COPPER

DEOXIDATION

PY139 M. Gous DUST EXPLOSIONS AT THE CHAGRES SMELTER DUE

TO SPONTANEOUS SELF-HEATING OF DRIED COPPER

CONCENTRATES

PY140 Chunlin Chen THERMODYNAMICS DATABASE OF SULPHIDE

SMELTING SYSTEM AND ITS APPLICATIONS TO

RECYCLING CU-PB-FE-S MATERIALS

PY141 Evelien De

Wilde

CHARACTERIZATION METHODOLOGY FOR CU-

DROPLET LOSSES IN SLAGS

PY142 G. Wastavino COPPER LOSSES CONTROL IN FLASH SMELTING

SLAG AT CHUQUICAMATA SMELTER

PY143 Bhavin Desai CONTROL STRATEGY FOR REDUCING COPPER LOSS

FROM MITSUBISHI PROCESS

PY144 M. U. Jastrzebski IN PURSUIT OF IMPROVED FLASH-SMELTING

BURNER PERFORMANCE

PY145 Songlin Zhou APPLICATION OF ROTATION-SUSPENSION

SMELTING PROCESS AND PULSE CYCLONE BURNER

IN XIANGGUANG COPPER

PY146 Afshin Sadri APPLICATION OF SPECIALIZED NON-DESTRUCTIVE

TESTING (NDT) FOR OPERATING COPPER PROCESS

VESSELS

PY147 G. Richter DEVELOPMENT PLAN CALETONES SMELTER

PY148 Joel Kapusta THE SAVARD-LEE SHROUDED INJECTOR: A REVIEW

OF ITS ADOPTION AND ADAPTATION FROM

FERROUS TO NON-FERROUS PYROMETALLURGY

PY149 Michael Reed DEBOTTLENECKING AND OPTIMISATION OF COPPER

SMELTERS LEVERAGING SIMULATION

Pyrometallurgy

PY01

COMING OF AGE - 21 YEARS COMMERCIAL OPERATION OF COPPER

ISASMELT™ AT MOUNT ISA

JS Edwards

Principal Metallurgist, Xstrata Technology, Level 10, 160 Ann St, Brisbane, Queensland,

Australia, 4000

P Telford

General Manager, Mount Isa Mines, Mount Isa, Queensland, Australia, 4825

L Yunus

Senior Metallurgist, Mount Isa Mines, Mount Isa, Queensland, Australia, 4825

ABSTRACT

Development of a new smelting technology, such as ISASMELT™, requires a

significant investment of time as well as resources and capital. In the case of the copper

ISASMELT™ process developed in Mount Isa the commissioning of the commercial

furnace in 1992 was the culmination of 14 years of bench, pilot and demonstration scale

testwork. The demonstration plant was operated from 1987 to 1992, initially at a feed rate

of 12 t/h of concentrate increasing to a maximum of 50 t/h during trials performed to reduce

the scale-up factor between demonstration plant and commercial plant.

The commercial scale copper ISASMELT™ furnace in Mount Isa was

commissioned in August 1992 with a capacity rated at 180 000 tonnes per year of copper

anode. In 2013 the copper ISASMELT™ has been operating for 21 years which is a

Coming of Age birthday in Australia. After two major smelter upgrades in 21 years the

original furnace is still in service and routinely treats in excess of 1 000 000 tonnes per

annum of copper containing feed and has a demonstrated campaign life, using uncooled

refractory, approaching 4 years.

Pyrometallurgy

PY02

OUTOTEC® SMELTING – INTEGRATED, SUSTAINABLE PLANT SOLUTIONS

Fagerlund, K

ABSTRACT

Outotec has a very unique and exceptional combination of different types of

smelting process technologies together with the state-of-art products and continuous

development in our research laboratories and pilot-plants. World’s leading smelting

technologies are all now within the Outotec family: Outotec® Flash Smelting, Kennecott-

Outotec Flash Converting, Direct Blister Flash Smelting, Ausmelt TSL, Kaldo, Troff,

Electric Furnace, Fire-refining and Anode Casting. Outotec is not only able to evaluate the

available various complex raw materials but also to provide the best available solution for

the specific project. This paper will provide examples how to cross-utilize and apply know-

how, expertise from different technologies and products in an innovative way to provide

sustainable solutions for copper industry.

In addition, social responsibility and increasing governmental regulatory

requirements brings new demands to the copper producers, thus environmental approvals

for the new and existing smelting plants have become increasingly more difficult to

acquire.

This paper will provide an examples how to combine overall process knowledge

together with modern tools to enable reliable and effective data for decision making,

especially while discussing with different authorities, stake-holders and investors. Selection

of best-available-technologies with proven references can ensure the long operational life-

time of the smelters. Also, modernization and upgrade investments of the operational plants

can be better justified by taking into consideration not only the economical but also

environmental aspects. Examples will be provided where safety, campaign life, furnace

integrity all contribute into the plant life-cycle, where Outotec new cooling solutions can

provide considerable improvements and can be flexibly applied in the operating plants and

also in wide variety of different applications.

Pyrometallurgy

PY03

WEAR PHENOMENA OF BASIC BRICK LININGS IN THE COPPER INDUSTRY

D. Gregurek, C. Majcenovic

RHI AG; TC Leoben; Magnesitstrasse 2; Leoben, A-8700, Austria

A. Spanring, M. Kirschen

RHI AG; Wienerbergerstrasse 9, Vienna, A-1100, Austria

ABSTRACT

In the non ferrous metals industry particulary in the copper smelting furnaces the

refractory lining made of magnesia-chromite bricks is exposed to several stresses rather

complex in their interaction. These can be classified as chemical, thermal and mechanical

stresses occurring as a single wear factor or in combination.

The chemical factors include corrosion caused by acidic slag and gaseous SO2

diffusion, redox effects and in particular cases hydration. In most of the non-ferrous

metallurgical processes the chemo-thermal load by Fe-silicatic slags of fayalithic type is a

common wear mechanism of the magnesia-chromite bricks. Nevertheless the extraordinary

massive SiO2-supply caused by changes in the processing and the uncontrolled addition of

silica sand results in a severe formation of forsterite respectively in a volume expansion due

to “forsterite bursting”. Increased temperature level respectively changes in the temperature

during the furnace operation as well as the copper metal infiltration into the brick

microstructure are further wear factors on thermal side. The hot erosion is the dominant

mechanical factor. Therefore understanding of wear mechanisms through “post mortem

investigation” and praxis field trials are highly important to ensure product

recommendation for industrial application.

Pyrometallurgy

PY04

CORROSION TESTING METHODS FOR NEWLY DEVELOPED REFRACTORY

PRODUCTS

D. Gregurek, A. Ressler, V. Reiter,

RHI AG, TC Leoben, Magnesitstrasse 2, Leoben, A-8700, Austria

A. Franzkowiak, A. Spanring

RHI AG, Wienerbergerstrasse 9, Vienna, A-1100, Austria

ABSTRACT

The processing routes in the base metals industry, especially copper smelting,

converting and fire-refining, have recently undergone significant changes in terms of slag

chemistry, temperatures, redox and more frequently deviating raw material compositions

(blended low-grade fractions) in the primary smelter feed. All these parameters

significantly influence the performance of already well-approved refractory linings.

Decreased brick lifetimes associated with process changes - also confirmed by the results of

post mortem studies - were a clear signal for RHI AG to focus on the development of high

grade refractory bricks for chemically stressed areas. In order to determine the most

suitable refractory grades and to improve the performance in specific furnace areas, special

test methods were selected.

The practical test facilities, including an induction furnace, rotary kiln and cup test,

at RHI’s Technology Center use process slags, for example of a fayalithic and Ca-ferritic

type, and enable the best possible understanding of brick wear on a pilot scale. A complete

mineralogical investigation including thermo-chemical calculations with FactSage were

performed to determine the highest influencing wear parameters. Optimized and engineered

Pyrometallurgy

lining solutions for the copper industry can be provided based on the acquired knowledge

from test results in combination with praxis trials.

Pyrometallurgy

PY05

ELECTROMAGNETIC LEVEL PROFILE MEASUREMENT SYSTEM TESTED

BY AGELLIS GROUP AB ON KENNECOTT COPPER FLASH SMELTERS IS

DESIGNED TO ENHANCE PROCESS CONTROL DECISION MAKING AND

IMPROVE OPERATOR SAFETY.

N. Brogden, JP. Nilsson, P. Bloemer, A. Lyons AGELLIS Group AB, Tellusgatan 15, 224 57 Lund, Sweden

R. Kaur, David Krippner,

KUC, Magna Plant, Salt lake City, Utah, USA

ABSTRACT

Reliable and accurate furnace level information for blister, matte and slag during

smelting processes is invaluable for decision making and process optimization, while

obtaining such information safely is a necessity.

Agellis Group AB had previously identified inherent problems with gauging levels

accurately in furnaces. We had successfully installed our EMLI ELP systems on

Submerged Arc and other electric furnaces in order to solve measurement problems.

In Flash Furnaces the problems appeared to be the same, with sounding bars operated from

the furnace roof area being used to take measurements. As a result operators can be at risk

and the results are often inaccurate. It was therefore decided to test the ELP system on a

flash smelter.

This paper shows how the Agellis EMLI-ELP system was successfully trialled at

Kennecott Utah Copper (KUC) on both their Flash Smelting (FSF) and Flash Converting

(FCF) furnaces. The results were used to compare the accuracy and reliability of

Kennecott’s current measuring methods with that of the Agellis system.

Finally the paper will discuss the potential production/safety improvements,

maintenance savings and data integration attainable through application of the Agellis

EMLI- ELP measurement system.

Pyrometallurgy

PY06

FIELD REPORTS OF THE NEW INNOVATIVE GAS PURGING SYSTEM FOR

STATIONARY AND TILTING COPPER ANODE FURNACES

Klaus Gamweger

ABSTRACT

The use of gas purging plugs in the copper industry is a widely used practice. They

provide substantial improvements especially in anode refining furnaces, where savings in

process time and energy are obtained as well as refractory wear and buildups inside the

furnace are minimized. The newly developed system enables purging plugs to be

implemented in both stationary and tilting furnaces is in operation in vessels on three

continents.

An additional advantage in these furnaces above all other benefits is the

significantly improved melting rate. This innovative and patented gas purging system

consists of a purging plug cooling device and a slidable, cooled piping system. It provides

compensation for any thermal expansion in the furnace lining and minimizes the risk of

undesirable copper infiltration.

Economics and Markets

PY07

SMELTING OF KAZAKHSTAN CONCENTRATES AT UST-KAMENOGORSK

USING A COPPER ISASMELT™ FURNACE

G.R.F. Alvear F.1, A.S. Burrows

2 and A.T. Tynybaev

3

1Xstrata Technology;

Level 10, 700 West Pender St. Vancouver, Canada 2Xstrata Technology;

Level 10, 160 Ann St.; Brisbane, QLD 4000, Australia 3Kazzinc Ltd;

1 Promyshlennaya St., 070002 Ust-Kamenogorsk, Republic of Kazakhstan

ABSTRACT

In July 2011 a new Copper ISASMELT™ Furnace was commissioned at the Ust-

Kamenogorsk Metallurgical Complex, in Ust-Kamenogorsk, Kazakhstan. It was part of a

greenfields smelter project, situated inside an existing metallurgical complex. The entire

copper stream was new, from feed blending through to cathode strapping. Within 14

months it was sustainably achieving its design production capacity.

For the project to be brought to successful fruition, numerous challenges had to be

met: new technology had to be brought into the Republic of Kazakhstan and the local

operating team had to become competent to operate it; the complex polymetallic

concentrates of the East Kazakhstan region had to be smelted without compromising the

production rate or product quality; and the copper production stream had to be integrated

into the overall metallurgical complex to derive greatest benefit from the polymetallic

nature of the raw materials.

Economics and Markets

This paper describes how the Copper ISASMELT™ Furnace fitted into this

strategy, and how the coordinated actions of Kazzinc and Xstrata Technology personnel

brought this project to fruition.

Pyrometallurgy

PY08

DESTRUCTIVE AND NONDESTRUCTIVE TESTING METHODS FOR THE

CHARACTERIZATION OF MGO-CR2O3-BASED REFRACTORY BRICKS

A. Ressler, C. Manhart and R. Neuboeck

RHI AG

Technology Center Leoben

Magnesitstrasse 2

A-8700 Leoben, Austria

Angelika.ressler@rhi-ag.com

A. Franzkowiak

RHI AG

Wienerbergstrasse 9

A-1100 Vienna, Austria

ABSTRACT

In the nonferrous metal industry and particularly in the copper production

magnesia-chromite refractory bricks are widely applied since decades. Being characterized

by high refractoriness and good resistance to slag corrosion these bricks are used in

chemically high stressed areas.

While the frequently determined physical properties (e.g. density, open porosity,

cold crushing strength – measured at room temperature) are adequate for quality

management and selection purposes, but they are insufficient for conclusions about the

behavior of the brick after installation at application temperature (from 1200°C up to

1750°C). Especially the characterization at operation conditions support the understanding

of main wear mechanisms. This paper provides information concerning investigated

properties, which have a high impact on the lining performance, such as thermal shock

resistance, modulus of elasticity and hot modulus of rupture.

The results of destructive and non destructive measurement methods are compared

for specific magnesia and magnesia-chromite brick qualities. The correlation of all tested

properties at room and different application temperatures enhance the decisions for lining

concepts in different applications for our customers in the copper and other nonferrous

metals industry.

Pyrometallurgy

PY09

SULFULIZATION AND SLOW-COOLING FOR MOLYBDENUM RECOVERY

FROM COPPER SMELTING SLAG

CHIHARU TOKORO

Waseda University, Tokyo, Japan, tokoro@waseda.jp

SHUNSUKE SUDO

Waseda University, Tokyo, Japan, s-sudo@fuji.waseda.jp

TAKAHIKO OKURA The University of Tokyo, Tokyo, Japan, okura@iis.u-tokyo.ac.jp

ABSTRACT

Sulfurization and slow-cooling process was investigated for selective recovery of

molybdenum (Mo) from the copper smelting slag. To get slag samples containing 0.2 to

4.0 % of Mo, MoO3 reagent was added to a water cooled slag and heated at 1300 ºC for 1

hour in Ar atmosphere. After cooled and ground under 125 m, sample was mixed with

FeS2 (pyrite) to be 2 or 5 of S/Mo molar ratio. This mixture was heated at 1300 ºC for 1

hour in Ar atmosphere and slowly cooled at up to 18 ºC/min.

XRD patterns of the slow cooled slag containing 2.0 or 4.0 wt.% of Mo showed

Mo was sulfurized as MoS2 crystal. XANES spectra at Mo K edge showed 95.83 % of Mo

was sulfurized as MoS2 when S/Mo molar ratio was 5 and Mo content in slag was 4.0 wt.%.

According to the observation using SEM-EDS, maximum particle diameter of MoS2 was

150 m which is enough grain size for several physical separations. 16.7 wt.% of Mo

concentrate was obtained by flotation after ground under 125 m with PAX and MIBC at

pH 6.6.

Pyrometallurgy

PY10

DESIGN AND COMMISSIONING OF THE OUTOTEC® AUSMELT TSL COPPER

SMELTER AT DNMC

LIU Chuanzhuan, WAN Jun, CHEN Baizhi

Daye Non-Ferrous Metallurgical Company, People’s Republic of China

Gavin Swayn, Jacob Wood, Alexander Glinin

Outotec, Level 2, 2 Brandon Park Drive, Wheelers Hill, Victoria, Australia

ABSTRACT

The largest commercial copper smelter using Outotec® Ausmelt TSL Technology has

been successfully commissioned and put into operation at Daye Non-Ferrous Metallurgical

Company Ltd operations in Huangshi City, Hubei Province, China. The plant was

commissioned from November 2010 to January 2011 after three years of design and

construction works.

The process treats low grade copper sulphide concentrates to produce a matte

containing 55% copper and a low copper bearing slag. The molten matte and slag flow

continuously from the TSL furnace via an underflow weir to a specifically designed electric

settling furnace for matte/slag separation. The paper provides details of the start-up and

increase in production to 200kt/a contained copper capacity processing rates in line with

oxygen availability, achieved in the first 3 to 6 months of operation.

Pyrometallurgy

PY11

GENERAL MAINTENANCE OF ELECTRIC CLEANING FURNACE SLAG

C. Herrera, C. Martínez, B. Medel, M. Lara G., W. Díaz, M. Correa.

Hernán Videla Lira Smelter

Empresa Nacional de Minería

Copiapó, Chile

ABSTRACT

The Hernán Videla Lira Smelter operates an electric slag cleaning furnaceto treat

the slag of the Teniente Converter. This furnace was supplied by DEMAG and was

commissioned in September 2001, with a treatment capacity of 800 t/d of liquid slag and

150 t/d of reverts, with a copper content in the end slag of maximum 0,85%. The furnace

dimensions are 10 meters of outer diameter and 5,2 meters high. Its electric power reaches

11 MVA.

Since its last general maintenance (GM), 4 years ago, a new GM was scheduled to be

performed since January the 8th

2013, which mainly includes the replacement of the walls

refractory lining, the floor skewback and refractory dome. Additionally, there placement of

the open circuit water distribution system, the cooling rings of the slippers of the electrodes

N°1 and N°2, and a full service of 22 of the 24 hydraulic heads of the electrodes

displacement system.

The dome refractory and cooling rings replacements were works scheduled for the first

time since the commissioning of the furnace.

The detailed programming and efficient coordination of the activities involved, allowed a

repair time of 29 days, 1 day less than considered in the original program. The activities

carried out during the GM were recorded in an audio visual file which will be presented at

this Conference.

Pyrometallurgy

PY12

XSTRATA TECHNOLOGY’S APPROACH FOR THE PROCESSING OF

COPPER BEARING MATERIALS

G.R.F. Alvear F.

Xstrata Technology;

Level 10, 700 West Pender St. Vancouver, Canada

S. Nikolic A. S. Burrows, M. Hourn

Xstrata Technology;

Level 10, 160 Ann.; Brisbane, QLD 4000, Australia

J. C. Salas M.

Xstrata Technology;

Alcántara 200, Of. 1202, Las Condes, Santiago, Chile

ABSTRACT

The processing of copper bearing materials is becoming more challenging due to the

increase in their mineralogical and compositional complexity.

Smelting of polymetallic concentrates is becoming more common and this trend has

led to the requirement that smelters modify their operating strategies to remain cost

competitive, whilst meeting ever more stringent environmental regulations. In addition,

when considering the processing of secondary materials, a key aspect in the recycling of

electronic scrap is the diverse range of elements that may require recovery.

The increased complexity of these primary and secondary raw materials requires the

use ofadvanced technologies to maximise the recovery of the targeted metals whilst

maintaining sustainable operating practices.

Xstrata has developed at its operations a number of processes, including

ISASMELT™ the Albion Process, and IsaKidd™ technologies that, both individually and

when combined, provide a competitive solution for the sustainable production of copper

Pyrometallurgy

PY13

CALETONES SMELTER: ENVIRONMENTAL AND COMPETITIVENESS

CHALLENGES

G. Richter P., J. Bobadilla M. and F. Hernández A.

Caletones Smelter - Codelco-Chile - Division El Teniente

ABSTRACT

In the nineties decade the environmental variable started to impact in a sensible way

the Caletones Smelter business due to the necessity to commit the introduced standards and

the Decontamination Plan agreed in 1998 with the governmental authorities.

During that period several technical and management modifications were

introduced in the smelter, being the most noticeable the construction of the sulfuric acid

plants 1 and 2 in 1995 and 1999 respectively, and the adoption of a new operation

philosophy of progressive subordination of the copper production to the environmental

control. The operation paradigm change implemented in an almost centenary smelter has

been a complex process of continuous improvement not exempt of difficulties.

However the net result had been favorable, noticed that Caletones Smelter is

accomplishing the environmental standards currently in force in Chile and attaining also

competitive results that permitted to successfully overcome recent periods of depressed and

volatile treatment charges.

Most recently in 2011, as result of several operational improvements introduced in

the gas handling and treatment systems, SO2 capture that until 2010 was less than 88%, was

increased to 94%, ensuring the environmental results attained.

Pyrometallurgy

Even though the human en financial efforts done in the recent past, the

environmental performance achieved is not being enough to fulfill the most strict emission

standards that the governmental authorities are designing to be applied to the Chilean

copper smelters.

This paper describes the actions that allow the present environmental results and the

proposal of improvement that Caletones Smelter is developing to accomplish the future

environmental standards and maintain it as a sustainable smelter.

Pyrometallurgy

PY14

ON THE INTERACTION BETWEEN REVERTS MEAN PARTICLE SIZE AND

FLASH FURNACE REACTION SHAFT HEIGHT: A SENSITIVITY ANALYSIS

Maximo Leon, Javier Larrondo, Tom Gonzales

ABSTRACT

The dimensions of a Flash Furnace (FF) are critical in determining the

characteristics of its cooling system. In particular, the thermal loads on cooling blocks

located at the base of the Reaction Shaft (RS) are strongly dependent on the heat generated

by the reactions taking place inside the furnace. In the typical FF process, low sulfur feed-

materials are added to reduce the temperatures that arise from these reactions.

The current paper provides a sensitivity analysis of the size of the RS for several

mean particle sizes of reverts. The objective is to develop a correlation between the

minimum Reaction Shaft size and revert particle size. Computational Fluid Dynamics

(CFD) is used to compare the heat absorbed by reverts with that absorbed by the cooling

system. The indicated minimum size is determined with the design parameters of the

cooling system.

In general, a non linear interaction between the size of the furnace and the mean

particle size of reverts has been found. However, a more precise indication of a

recommended FF size needs to be studied in detail within a range of FF shaft sizes.

Pyrometallurgy

PY15

A THERMODYNAMIC OPTIMIZATION OF THE “Cu2O”-CONTAINING SLAG

SYSTEM AND ITS APPLICATIONS IN HIGH-TEMPERATURE COPPER

MAKING PROCESSES

Taufiq Hidayat, Evgueni Jak

PYROSEARCH, the University of Queensland, Brisbane, Queensland, Australia

Denis Shishin, Sergei A. Decterov

Centre de Recherche en Calcul Thermochimique (CRCT), École Polytechnique, Montréal,

Québec, Canada

ABSTRACT

Improvements to industrial copper production can be made through informed

decisions on the selection of slag compositions, fluxing strategies, and operating conditions

for a given feed and product requirement. This can be facilitated through thermodynamic

modelling in which phase equilibria, partitioning of major and minor elements between

phases, activities, vapour pressure, and other thermodynamic properties of the relevant

systems can be accurately predicted over a wide range of process conditions. The Al-Ca-

Cu-Fe-Mg-Si-O-S system is of importance for copper smelting, converting, and slag-

cleaning processes. New experimental data of the systems for various compositions and

conditions relevant to copper production process have been generated and improvement of

the existing chemical thermodynamic FactSageTM

database for the cuprous oxide-

containing system has been carried out as part of the overall integrated research program on

complex copper-containing slag-matte-metal-solids system. All cuprous oxide-containing

binaries, ternaries, and multi-components systems are optimized simultaneously to obtain one

self-consistent set of model parameters for Gibbs energies of stoichiometric phases, solid

solutions, and liquid solution as functions of temperature and composition. Details of the

recent optimization of the thermodynamic database and examples of industrial application

of the database for the high-temperature copper making processes are presented.

Pyrometallurgy

PY16

OPTIMUM DRYING SOLUTION FOR COPPER CONCENTRATE

Mr. Jyri Talja, Dr. Shaolong Chen, Mr. Hannu Mansikkaviita, Dr. Carl-Gustav Berg

Kumera Corporation

Kumerankatu 2

11100 Riihimäki, Finland

ABSTRACT

Non-ferrous metal concentrates contain typically 7-12 % water when received at the

smelter. Removal of this water prior to smelting is always economically feasible because

unnecessary heating of vapour can thus be eliminated resulting in major savings and reduc-

tion in CO2 emission.

Energy efficiency of drying can be significantly increased by selection of modern

drying technology. Consequently, CO2 emission, SO2 emission and NOx emission will be

all eliminated.

Replacement of conventional devices with indirect steam dryers brings, in addition

to significant reduction in emission, additional savings due to improved energy efficiency.

Direct energy savings count for 900-1,300 MJ/tH2O, which depending on the concentrate

feed rate, its moisture content and price of energy is worth 1-3 MEUR every year. Further-

more, other operational expenses can also be cut by another 1-3 MEUR resulting in com-

bined 2-6 MEUR direct savings annually in operational expenses. Furthermore, availability

can exceed 99 %.

Sustainability is the key issue today in process industry. Kumera Steam Dryer is al-

ready recognized as a symbol of the energy saving and emission-free equipment with very

high availability for non-ferrous metallurgical industry world-wide. Latest improvements of

the Kumera steam dryer are discussed in greater detail.

Pyrometallurgy

PY17

ENVIRONMENTAL IMPROVEMENTS FOR PS CONVERTERS WITH

OUTOTEC’S CONVERTER HOOD TECHNOLOGY FOR PRIMARY AND

SECONDARY GAS CAPTURE

Per G. Brännström & Lennart M. Hedlund

Outotec

ABSTRACT

The paper describes the improvements that Outotec has made on the design on

converter hoods in order to improve operational performance and environmental situation

in the converter aisle.

Most smelters have changed their primary smelting technology. Reverberatory

furnaces have been replaced by more environmentally friendly and energy-efficient

furnaces like Outotec FSF or TSL. When the environmental performance has been

improved for the primary smelting furnace, the focus turns toward the acid plant (if single

absorption) and later the converter aisle.

Outotec`s Converter Hood Technology assures that processing of copper matte will

be done more sustainable and environmentally acceptable. Sulphur and dust capture above

95 percent is no problem to reach with Outotec`s water cooled primary converter hoods.

Outotec`s converter hoods for primary gas capture are designed for low false air inlet and

high production.

After changing the primary hoods, the next step in the environmental efforts, is

implementation of a secondary gas system to collect fugitive gas and dust. Fugitive gas

comes from rolling the PS-converter in and out, ladles handling etc. With Outotec`s

knowhow and technology the converter aisle will become a more environmentally friendly

unit with high production.

Pyrometallurgy

PY18

INCREASE AVAILABILITY SMELTER PLANT

G. Richter P.

General Manager - Codelco-Chile

J. Berrios O.

Maintenance Superintendent - Codelco-Chile

ABSTRACT

Caletones Smelter has a nominal capacity of 1.4 Mton smelting copper concentrate, for

this purpose, would have a significant asset, namely:

Three Concentrate Drying Plants

Two Smelting Reactors, Teniente Converters

Four Peirce Smith Converters

Four Slag Cleaning Furnaces

Five Anode Refining Furnace

Two Casting Wheels

Two Acid Plant

Two Effluent Treatment Plants

Two Oxygen Plant

In order to increase the use of smelter complex, intensive work is done in the main

equipment.

This work consisted of defining operating models, use of materials and different

maintenance strategies, the results to date are:

Pyrometallurgy

Bases Present

Smelting Reactors: 1.5 years 3 years

Acid Plants: 1 year 2 years

Slag Cleaning Furnaces: 7 months 2 years

This paper describes the actions, which allowed achieving these results and

increasing the smelting capacity of concentrate.

Pyrometallurgy

PY19

INCREASE SULFUR CAPTURE – OPERATIONAL MANAGEMENT

G. Richter P.

General Manager - Codelco-Chile

J. Bobadilla M.

Operation Superintendent - Codelco-Chile

ABSTRACT

Caletones Smelter has a nominal melting capacity of 1,4 Mt/y copper concentrated,

the concentrate is fed entirely from the mining complex of mine – pant of El Teniente

Division.

Until 2010 sulfur capture reached 85%, re presenting a sulfur dioxide (SO2)

emission of 130 kt/y. This low capture put at risk the future fulfillment of sulfur emission

limits voluntarily committed environmental authorities, commitment established the

following schedule

:

Year 2011 2012 2013 2014

Sulfur dioxide emission (SO2)

(kt/y) 140 130 120 100

In order to meet the timetable for reducing emissions in 2011, modifications were

made to the scheme operating and maintenance and modifications to the gas handling

system. Changes made it possible to increase the capture of sulfur to 92.9% in 2011 and

94% by 2012, sulfur dioxide emissions were around 60 kt/y.

Pyrometallurgy

This paper describes the actions that allowed these results and anticipate achieving

compliance contracted emission reduction.

Pyrometallurgy

PY20

INSTALLATION OF DILUTED OXYGEN COMBUSTION TECHNOLOGY IN A

COPPER ANODE REFINING FURNACE AT CODELCO EL TENIENTE PLANT

G. Richter P., C. Carrasco O., F. Condore R.

Codelco Chile División El Teniente

A. Tasca

White Martins Gases Industriais Ltda

F. Kaiser

Praxair Chile Ltda.

ABSTRACT

The combustion system in #2 Anode Refining furnace at CODELCO (Corporación

Nacional del Cobre) El Teniente’s plant in Chile was retrofitted to an advanced oxy-fuel

technology called DOC (Dilute Oxygen Combustion). Praxair® DOC technology uses

separate high momentum fuel and oxygen jets to generate strong in-furnace gas

recirculation.

This technique produces low peak temperature flame, substantially improves

temperature uniformity, generates ultra low NOx emission rates and reduces carbon

emissions. DOC technology has been developed and commercially demonstrated in several

types of industrial melting and heating furnaces meeting the industry needs for increased

productivity and lower operating costs with minimal capital expense and low maintenance.

This paper presents the results achieved regarding fuel savings, and reduction in operating

cost.

Pyrometallurgy

PY21

FEATURES OF THE BOTTOM BLOWN OXYGEN COPPER SMELTING

TECHNOLOGY

Baojun Zhao

School of Chemical Engineering, The University of Queensland, Brisbane, Australia

Zhixiang Cui, Zhi Wang

Dongying Fangyuan Nonferrous Metals Co., Ltd, Dongying City, China

Email: baojun@uq.edu.au

ABSTRACT

The first commercial scale bottom blown oxygen copper smelting furnace has been

installed and operated at Dongying Fangyuan Nonferrous Metals Co., Ltd. for 4 years. This

is the first modern copper smelting technology developed in China with the advantages of

1) high oxygen enrichment, which results in high productivity, low off-gas volume and

negative pressure inside the furnace;

2) high Fe/SiO2 ratio in the slag, which not only reduce the direct cost of the flux (SiO2)

but also reduce the slag volume and therefore the heat loss associated with the slag and

workload of the slag cleaning;

3) high grade matte (over 70 wt% Cu) and low Cu content (2-3 wt%) in the smelting slag

which significantly increase the direct recovery of the smelting process;

4) autothermal operation. When normal concentrate is treated in the bottom blown oxygen

furnace no extra fuel is required due to a) low temperature operation (1160-1180 oC); b)

high Fe/SiO2 ratio results in low slag volume for less heat loss; c) high concentration

oxygen reduces the heat loss associated with the off-gas; d) high heat efficiency as a

result of submerge combustion.

Pyrometallurgy

The details of these advantages and their influences on the operations are discussed.

Economics and Markets

PY22

VISCOSITY MEASUREMENTS FOR COPPER SMELTING SLAGS

Baojun Zhao

School of Chemical Engineering, University of Queensland, Brisbane, Australia

ABSTRACT

Phase equilibria of silicate slags relevant to the copper smelting/converting

operations have been systemically investigated in the temperature range 1.200 to 1.300 oC

and oxygen partial pressures between 10-5

and 10-9

atm. The experimental procedures

include high temperature equilibration, quenching and accurate measurements of phase

compositions using electron probe X-ray microanalysis (EPMA). The effects of CaO,

Al2O3, MgO and PO2 on the phase equilibria of the fayalite slags have been systematically

investigated.

It was found that spinel and silica are major primary phases in the composition

range related to copper smelting/converting slags. In addition, olivine, diopside and

pyroxene also appear at certain conditions. The presence ofup to 20 wt% CaO, and up to 10

wt% MgO and Al2O3 in the slag increases the spinel liquidus and decreases the silica

liquidus. Liquidus temperatures in silica primary phase field are not sensitive to PO2;

Liquidus temperatures in spinel primary phase field increase significantly with increasing

PO2.

Pyrometallurgy

PY24

AVA (ANÁLISIS VÍA VISIÓN ARTIFICIAL)} SYSTEM

Alejandro Molina Olave

E-MAS Ingeniería S.A.

ABSTRACT

We present an artificial vision system to analyze the concentration of copper in the

white metal or matte, that is based on the measurement of some color tones of a sample

obtained from the liquid discharge of the copper concentrate’s melting furnace .

Empirically we have obtained a mathematical relationship that allows relating the color

intensity of a sample of white metal with its concentration of copper, which is the base of

the patent no. 47.109 “Integrated system for the determination of copper in a sample of

white metal and associated method”.

This technology strengthens the eyesight of the operators to determine the quality of

the product by some distinguishing and quantifiable physical characteristic. Here, we

propose to capture an image of the sample using a diffuse lighting system for further

digital processing with an algorithm that quantifies and correlates the color intensity with

the copper composition. This method requires no sample preparation room (avoiding the

production of contaminant, noise, dust and solids waste that usually take place in this

facilities) after the analisys, .

This technological innovation analyzes quickly, with precision and accuracy matte

grade and allows the operator to opportunely correct the input variables for control.

Pyrometallurgy

PY25

THE SYSTEM FOR OPERATIONAL CONTROL OF EMISSIONS (SCOE+)

Alejandro Molina Olave

E-MAS Ingeniería S.A.

ABSTRACT

The System for Operational Control of Emissions (SCOE+) uses mathematical

modeling of mass and energy balances, thermodynamic equilibrium and empirical

correlations to simulate steady state all daily unit operations of a copper concentrate smelter

in stationary state. SCOE+ integrates in its simulations all the reactions that take part during

the following processes: drying, smelting, conversion and refining, flotation , and acid

plant, and allows to configure any particular foundry.

The interface user-server is friendly and just requires a basic knowledge of

managing windows and pop-up menus. The user configures each unit operation and also

stablishes its own strategy for handling with the recycle material. The result report includes

the following outputs: flows of supplies and products, overall balances, particular mass

balances (for copper, sulfur, arsenic, etc.), flows of emissions of contaminants and

performance indicators (KPI). These outputs can be exported and integrated with other

applications/softwares, allowing to look for optimal points of production in a sustainable

way.

SCOE+ is an innovative solution that gives daily support on the analysis of

operations, evaluation of strategies for the mitigation of polutants, and it also stands as a

help to look for sustainable points of production without investments, using information

about concentrates mix, matte grade, handling of recycles and fuels..

Pyrometallurgy

PY26

SPECIATION OF COPPER IN FLASH, CONVERTER AND SLAG CLEANING

FURNACE SLAGS.

J.C. Fernández-Caliani

Department of Geology, University of Huelva, Spain

F. Jiménez, G. Ríos, J. Martínez

Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold), Huelva, Spain

ABSTRACT

Research on slags involved in smelting-converting-refining operations to produce

blister copper at the Atlantic Copper smelter, in Huelva (Spain), has been carried out by

quantitative electron microprobe analysis, X-ray diffraction and digital imaging techniques.

The results showed that mechanically entrapped matte particles are the dominant

copper losses in the slags. The largest proportion of Cu-bearing particles is present in the

magnetite-rich converter slags, due to the negative effect of viscosity on coalescence and

precipitation of copper matte during conversion.

The mechanical entrapment of copper matte by slags from both the flash and

electric furnaces resulted in copper losses mostly occurring as tiny particles with a

stoichiometric composition similar to that of bornite. The Cu-bearing particle distribution

has been analysed and the effect on settling time in the slag cleaning furnace calculated.

Pyrometallurgy

PY27

SYNERGY OF ENERGY RESOURCES OF COPPER PYROMETALLURGY IN

RTB BOR-SERBIA

Milorad ĆIRKOVIĆ, Vlastimir TRUJIĆ, Mile BUGARIN

Mining and Metallurgy Institute Bor, Zeleni bulevar 35, Bor, Serbia

E-mail: milorad.cirkovic@irmbor.co.rs

MILANČE MITOVSKI

RTB-BOR Group, Djordja Vajferta 20, Bor, Serbia

Aleksandra MITOVSKI

University of Belgrade, Tehnical Faculty, Bor, Serbia

ABSTRACT

Copper production is a big consumer of energy consisting of almost all fossil fuels,

including also electricity. This work presents a comparison of the specific energy

consumption of many metallurgical copper producers in the world, with the installed

different technological processes, in relation to the production of copper in RTB Bor

(Serbia). An important place is dedicated to the quantitative participation of energy fuels in

the production of copper. In addition to this, an analysis of cost structure for energy fuels

was shown in the production process of copper. This work particularly emphasizes the

aspect of use the secondary (waste) heat energy as a prerequisite to improve the energy

efficiency and economy of pyrometallurgical copper production. Using the waste heat of

pyrometallurgical process, m the protection of workin and life environment is improved

Selection and development of new metallurgical processes in order to achieve the

best economic effects is achieved selecting the optimum technology, on one side, and

selection of energy system with the best performances with the full utilization the

secondary heat energy of the process. Concretization of this aspect also relates to the

modernization of the Copper Smelter in RTB Bor installing the new technology for

smelting of copper concentrates.

Pyrometallurgy

PY28

VISCOSITY OF COPPER SLAGS FROM THE PROCESS OF DECOPPERING

IN AN ELECTRIC FURNACE

S. Pietrzyk, J. Kowalczyk, W. Mroz

AGH-University of Science and Technology, Faculty of Non-ferrous Metals,

Department of Physical Chemistry and Metallurgy of Non-ferrous Metals, Krakow, Poland

ABSTRACT

One of the stages of copper production process based on direct-to-blister flash

furnace is decoppering of a slag containing considerable amounts of copper (12-15 wt%).

At the GLOGOW Copper Smelter this stage is performed under reducing conditions in an

electric slag-cleaning furnace with the addition of coke and limestone. During the

implementation of a process, there are changes of the viscosity of the slag subjected to

decoppering.

In this work, viscosity of the industrial flash smelting slags with different degree of

reduction and variable contents of the oxides were investigated in the temperature range

from 1200 to -13500C. The viscosity was measured by the rotating cylinder method.

The increase of CaO and Cu2O contents leads to decrease in the viscosity as long as the

slags remain fully liquid. However, upon reaching the liquidus temperature, a sharp inverse

in viscosity is observed. This is clearly illustrated by change in the slope of the viscosity

logarithm vs the temperature. The activation energy above the critical temperature have

been determined.

Pyrometallurgy

PY29

OPTIMAL CONFIGURATION OF VOLTAGE AND CURRENT INTENSITY IN

AN ELECTRIC FURNACE FOR SLAG CLEANING

J. Font and V. Montenegro

Instituto De Innovacion En Mineria Y Metalurgia

Ahumada 357, Piso 7.

Santiago, Chile

A.Warczok

Universidad De Chile

Departamento Ingenieria deMinas

Av. Tupper 2069

Santiago, Chile awarczok@bell.net

A. Moyano

Codelco Norte

Calama, Chile

ABSTRACT

The three phases, rounded electric furnace is the most typical unit used for a slag

cleaning. The configuration voltage/current depends on the slag electric conductivity, the

depth of electrodes immersion in the slag and the properties of the transformer,

Based on analysis of industrial parameters of the electric furnace in CODELCO

NORTE Smelter the optimal voltage/current intensity has been determined for various

criteria, such as unitary energy consumption, unitary coke and electrode consumptions, and

copper recovery.

CFD and heat transfer modeling allowed for determination of a slag motion and its

impact on the rate of magnetite reduction, coalescence of copper matte inclusions for

various depth of electrodes immersion and voltage.

The increase of the electrodes immersion in a slag did not result in the increase of

the slag motion, leading to the increase of cod and the decrease of energy efficiency.

Pyrometallurgy

PY30

SULPHATION ROASTING OF AN ENARGITE CONCENTRATE

B. Chambers, C. Pickles and J. Peacey

Robert M. Buchan Department of Mining

Queen’s University

Kingston, Ontario

Canada K7L 3N6

John.Peacey@queensu.ca

ABSTRACT

Due to the increasing difficulty of finding conventional copper and gold ore bodies, the

processing of complex ores, such as those containing enargite, is being explored. A

sulphation roast, weak-acid leach, electrowinning process flowsheet was studied as a

possible new treatment method for copper concentrates containing significant amounts of

enargite. The sulphation roasting of an enargite concentrate was investigated in the

laboratory in order to determine the behaviour of arsenic as a function of roasting

conditions. Diagnostic leaching tests were then used to estimate the probable arsenic,

copper and iron phases in the resulting calcine. Based on the estimated heat and mass

balances, the economics of a sulphation roast-leach-electrowinning process was compared

to that for the conventional partial dearsenizing roast and sale of calcine to copper smelters.

Pyrometallurgy

PY31

COPPER RECOVERY FROM THE SMELTING SLAG IN AN ELECTRIC

FURNACE

A.Warczok

Universidad De Chile

Departamento Ingenieria deMinas

Av. Tupper 2069

Santiago, Chile

awarczok@bell.net

J. Font, V. Montenegro and C.Pizarro

Instituto De Innovacion En Mineria Y Metalurgia

Ahumada 357, Piso 7.

Santiago, Chile

A. Moyano

Codelco Norte

Calama, Chile

ABSTRACT

The mechanisms of a slag reduction and removal of copper matte inclusions in an

electric furnace for slag cleaning have been analyzed and discussed on the basis of CFD

modeling, rate of magnetite reduction controlled by its transfer in the slag, and gravitational

coalescence of copper matte and metallic copper inclusions. The results were confronted

with the results of slag cleaning in CODELCO NORTE Smelter.

Slag properties, particularly its viscosity and related temperature, were analyzed on

the background of matte inclusions size distribution, and their settling and gravitational

coalescence.

The recycling of highly oxidized slags from matte converting into Teniente

Converter as a smelting unit was pointed out as one of the important factor affecting the

decrease of copper recovery.

Pyrometallurgy

PY33

RECENT EXPERIENCES FROM IMPLEMENTING DYNAMIC PROCESS

CONTROL AND MONITORING IN THE FLASH SMELTING PROCESS

Peter Björklund, Tiina Ranki, Elli Miettinen

Outotec Oyj, Espoo, Finland

ABSTRACT

This paper will discuss recent advances and challenges in implementing control and

monitoring of the Flash Smelting –process and possibilities to utilize these in improving not

only the process itself but also the safety and work environment for the smelter personnel.

To achieve these targets Outotec has developed advanced Expert Systems integrated with

the Automation system and these were successfully started up in the Paranapanema Smelter

in 2012.

As raw-materials become more complex operating tools need to follow this trend.

The Outotec Process Advisor is a predictive dynamic online process control model for

calculating the optimal operating parameters in real time taking into account all relevant

raw-material elements and the actual furnace situation. Together with the Outotec Proscon

automation system, these form a complete platform for smelter operation.

A rising trend is also the need to focus on plant safety in a smelter. The highest risk

rankings are often related to close proximity of molten metal. Through accurate and user-

friendly individual element heat flux monitoring these risks can be caught and reacted on in

time and the furnace integrity improved, meaning a safer plant and a longer campaign life.

The Outotec Sentinel system provides such a complete monitoring system.

Pyrometallurgy

PY34

THERMAL SHOCK RESISTANT ALUMINA-CHROMIA REFRACTORY

MATERIALS FOR THE COPPER INDUSTRY.

S. B. Breyner, K. Santowski

RHI AG, TC Leoben, Magnesitstrasse 2, Leoben, A-8700, Austria

T. Prietl

RHI AG, Wienerbergstrasse 9, Vienna, A-1100, Austria

ASBTRACT

Conventional alumina-chromia materials are characterized by a high resistance to

acidic slags due to the formation of a Al2O3-Cr2O3 solid solution during brick firing.

Typical application areas for such products are glass tanks, waste incinerators or copper

smelting furnaces. In other areas, where not only corrosion by chemothermal load but also

thermal shock is predominating, these products suffer from discontinuous spalling and

exhibit poor refractory service life.

Research and development efforts were therefore shifted in favour of increased

thermal shock resistance of shaped alumina-chromia products. Laboratory slag testing and

physical testing indicated that the material properties are on a sufficiently high level to

conduct field experiments at customers. First test results in a tyuere zone of a Peirce-Smith

converter demonstrated that the material properties of the new alumina-chromia products

meet both the corrosion and thermal shock resistance required for this application. This was

particularly evident from the fact that the postmortem sample had a residual thickness of

47% after a standard operation cycle of 11 weeks.

Pyrometallurgy

PY35

LIQUIDUS TEMPERATURES, MAJOR AND MINOR ELEMENTS

EQUILIBRIUM PARTITIONING IN COPPER SMELTING SLAG / MATTE /GAS

SYSTEMS

Zhi Sun, Evgueni Jak

PYROSEARCH, The University of Queensland, Brisbane, QLD, 4072, Australia

ABSTRACT

Phase-equilibria data make it possible to identify the likely outcomes of reactions

and the limits to reactor performance. Although repeated studies have been carried out

over the past several decades, significant gaps and uncertainties still remain for the copper

slag/matte/gas systems so that the description of liquidus-temperatures, major and minor

elements equilibrium partitioning require further improvements.

Experimental procedures involving high-temperature-equilibration and quenching

followed by electron-probe X-ray microanalysis, developed at PYROSEARCH, have

resolved a number of experimental difficulties associated with high temperature phase-

equilibria determination in these systems. Systematic investigations are carried out in the

multi-component Cu-Fe-Si-S-O system with addition of impurities, such as CaO, Al2O3,

MgO, and minor elements, such as Bi, Sn, at controlled oxygen and sulphur partial

pressures and temperatures in the range of interest to copper smelting operations.

New experimental data have been obtained for the slag/matte/gas equilibria.

Tridymite/spinel liquidus, copper and sulphur solubilities in slag, Bi and Sn partitioning

between slag and matte for the range of matte grades from 20 to 70 wt.% Cu have been

measured. These data resolve previous discrepancies in values previously reported in

literature, and provide better characterisation of the complex chemistry, which is vital for

the process optimisation of copper production.

Pyrometallurgy

PY36

QUASI-CHEMICAL VISCOSITY MODEL FOR COPPER-CONTAINING MULTI-

COMPONENT LIQUID SLAGS

Zhi Sun, Evgueni Jak

PYROSEARCH, The University of Queensland, St Lucia, Brisbane, QLD 4072 Australia

Masanori Suzuki Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, 565-0871

Osaka, Japan

ABSTRACT

Slag viscosity is one of the key properties particularly important for good metal

recovery and overall productivity in pyrometallurgical copper-making processes. The

quasi-chemical viscosity (QCV) model has been developed and recently modified to allow

the viscosities of multi-component fully-liquid oxide slags to be predicted within

experimental uncertainties over wide ranges of compositions and temperatures.

This model takes into account the complex internal slag structure providing

advantages in accurate predictions of multi-component liquid slag viscosities, especially in

slags having high SiO2 concentrations. The present research extends the QCV model to the

SiO2 - Al2O3 - CaO - MgO - ‘FeO’ - Fe2O3 – “Cu2O” multi-component liquid slags directly

relevant to various copper smelting and converting operations by incorporating new

experimental data and new optimised thermodynamic model of copper-containing oxide

slags. Critical analysis of the available experimental viscosity measurements and their

uncertainties, as well as analysis of common trends, has enabled the model parameters to be

developed so as to give reliable viscosity predictions. Examples of the applications of the

model will be presented for conditions where the control of viscosity of the multi-

component complex slag systems is important for the copper smelting and converting

operations.

Pyrometallurgy

PY37

MEANS OF REMOVING LEAD AND ARSENIC DURING THE COPPER

PRODUCTION CYCLE IN UPGRADED TECHNOLOGY OF KGHM POLSKA

MIEDZ SA

Czernecki Józef, Ph.D, Prof. IMN

Miczkowski Zdzisław, Dr Eng.

Krawiec Grzegorz, MSc.Eng.

Institute of Non-ferrous Metals, Gliwice

Byszyński Leszek MSc.Eng

Gostyński Zbigniew MScEng

KGHM Polska Miedź S.A. Lubin

ABSTRACT

The copper content in chalcocite-bornite concentrates produced by KGHM Polska

Miedź SA is similar to that in chalcopyrite concentrates (20 - 30% by wt.). However, the

concentration of sulfur and iron is much lower, respectively by 9 - 12 and 3 - 6% by wt.

Furthermore, a characteristic of Polish concentrates is the presence of carbon (6 - 9% by

wt.) and impurities: lead (1.5 - 3.0% by wt.) and arsenic (0.05 - 0.4% by wt.).

Due to the low sulfur and iron content and the presence of organic carbon, two types

of technology were chosen for the melting of the kinds of concentrates encountered in

Poland: the shaft smelting process (Głogów I and Legnica) and the one-stage flash smelting

process (Głogów II). In both processes the organic carbon constitutes a fuel to provide the

desired temperature of the products.

The smelters in which the shaft process is used are characterized by a high degree of

elimination of Pb and As in the copper production cycle when, in the first two

pyrometallurgical operations (concentrates melting, copper matte converting) stable sulfide

phases occur.

Pyrometallurgy

A different situation occurs in the one-stage flash smelting process, where the

sulfides are oxidized quickly to the metals.

The beginning of the process of pyrometallurgy modernization by KGHM Polska

Miedź SA, involving replacement of the shaft furnaces at Głogów I and Legnica with a

single flash smelting furnace, required solutions to such problems as how to remove major

contaminants such as lead and arsenic from the copper production cycle.

In this paper the behavior of lead and arsenic is presented, as well as the current

means of removing these contaminants from the copper production cycle, when there are

two technologies, i.e. the process of shaft furnace smelting and the one-stage flash smelting

process.

To deal with the situation after the upgrade, when KGHM Polish Copper SA will

operate two flash smelting furnaces for the production of copper blister directly from

concentrates, solutions are being developed to enable the elimination of Pb and As to the

degree necessary to ensure that the concentration levels of these metals in the semi-finished

products are maintained at the required level.

Pyrometallurgy

PY38

FLASH SMELTING AND FLASH CONVERTING PROCESS AND

COMMISSIONING AT JINGUAN COPPER

Zhou Jun, Sun Laisheng,

Tongling Nonferrous Metals Group Co., Ltd

Tongling, Anhui, China

244100

zhouj@jgty.net, zhouj@tlys.cn

ABSTRACT

Tongling Nonferrous Metals Group, the leading copper producer in China, started up a

green-field copper smelter and refinery in December 2012. The new copper smelter employs

Outotec flash smelting and Outotec-Kennecott flash converting process with a design

capacity of 400,000tpa primary copper. It is the third flash converting plant in the world, and

also the biggest copper smelter in terms of concentrate throughput. This paper presents

process, facilities, commissioning, operation and environment control of the new smelter.

Pyrometallurgy

PY39

AN EXTENSIVE SLAG DATABASE: LEAD-ING THE WAY

Vaajamo Iina, Taskinen Pekka, Gisby John

ABSTRACT

Industrial processes at high temperatures are complex in nature involving many

types of compounds, substances and solution phases. Due to this complexity it is sometimes

impossible to investigate a specific problem experimentally or even understand in-depth the

problem in question without input from reliable models. The MTDATA software package

from UK’s national measurement institute NPL (National Physical Laboratory) and the

thermodynamic databases developed by NPL and its co-operators are used to understand

these problems faced by industry. This work gives insight into the development of a lead-

based database built as a part of NPL’s extensive MTOX (metal-oxide-sulphide) database.

The database development work has required a critical literature review, new

equilibration experiments providing information of the mutual solubilities of the elements,

and optimization of interaction parameters for the lead-containing systems. A direct-to-

blister copper slag cleaning process in an electric furnace has been simulated as an

illustrative application of the MTOX database.

Pyrometallurgy

PY40

INVESTIGATION OF THE BATH-DEPOSIT INTERFACE OF FREEZE-LININGS

IN COPPER SLAGS

Ata Fallah-Mehrjardi, Peter C. Hayes, Evgueni Jak

Pyrosearch, The University Of Queensland, Brisbane,

Australia

ABSTRACT

Freeze-lining technology is actively employed to protect reactor’s walls from

chemically- aggressive molten slags. To date, the design of freeze-linings for

pyrometallurgical reactors has been solely based on the assumption that the interface

between the deposit and bath at steady stage is at the liquidus temperature of the

bulk liquid bath. However, there is increasing evidence that the interface temperature

between stagnant deposit and molten bath at steady state may be below the liquidus of

the bulk liquid. This finding strongly influences the way bath chemistry effects should be

taken into account in freeze-lining designs. In order to investigate fundamental

processes involved in the formation and stability of the freeze- lining deposits,

experimental laboratory studies have been undertaken in the Cu-Fe-Si-Al-O slag system

at equilibrium with metallic copper using an air-cooled “cold finger” probe technique; the

probe is submerged into the synthetic slag bath heated in an induction furnace and stirred

by rotation of a crucible.

The effects of bath agitation on the microstructure, morphology of phases and

formation of various layers across the freeze-lining deposit were studied at steady-state

conditions in this study. It appears that the changes in the fluid flow characteristics

strongly affect the deposit microstructures, the formation of the sealing solids layer and,

thus, the interface temperature between freeze-lining deposit and the liquid bath. The

results demonstrate that the mass transfer and crystallisation / dissolution processes in

the area adjacent to the deposit interface are crucial factors that determine the

Pyrometallurgy

microstructures and temperatures of the interface layer of the deposits. Systematic

laboratory study provides firm scientific basis to assist in the freeze-lining design that can

result in significant energy savings and therefore reduction of CO2 emissions by

optimisation of process temperature and flux additions.

Pyrometallurgy

PY41

ADVANCED PILOT PLANT ROASTING TESTS GIVE NECESSARY

KNOWLEDGE FOR DESIGN OF A LARGE ROASTER PLANT AT MMH

Sergio Carrasco, Mr Daniel Deutsch,

Codelco-VP

Gunnar Berg, Dr Åke Holmstrom, Mr Lars Hedstrom,

Outotec

ABSTRACT

The MMH roaster project has a long history and it is now about 20 years

since the initial plans of a roaster for the MMH concentrate came up.

The first contacts were made between Codelco and Outotec. (At the time

named Boliden Contech.) Outotec had the knowledge of arsenic removal from copper and

gold concentrates by fluidized bed roasting and Codelco had a new huge copper deposit,

called MMH, located in between the Calama city and the Chuquicamata copper smelter.

The arsenic bearing mineral at MMH is mainly enargite (Cu3AsS4) so is not

possible to eliminate the arsenic by selective flotation. Partial roasting is one possible

method to clean the concentrate from arsenic and thereby produce a suitable raw material

for the copper smelter.

Outotec had already before the MMH project run pilot plant tests in a

fluidized bed roaster on behalf of Codelco to remove arsenic from the arsenic rich

Chuquicamata concentrate to produce a low arsenic containing calcine. The tests were

successful and showed that the roasting process was an efficient way of separating arsenic

from the copper rich raw material before it is treated in the copper smelter.

All concentrates containing arsenic are unique and the process design of a

roaster plant must be based on relevant design data. The process data was collected during

several tests in fluidized bed pilot plants. Most tests were made in the fluidized bed pilot

plant of Outotec in Sweden and others were carried out in Chile (Concepción University).

Pyrometallurgy

The influence on calcine quality by critical process parameters like e.g.

roasting temperature, silica bed, feed composition and the temperature of gas cleaning

equipment was studied and the outcome of the tests have had direct influence on the design

of the full scale plant at Calama.

The ability to run pilot plant tests is essential during development of the

roasting process. During the long history of roasting in Outotec, the roasting group, formed

out of former Lurgi and Boliden Contech, has to date delivered 285 fluid bed plants. The

Outotec roaster reference list includes a variety of processes and concepts: from high

trough-put circulating fluid bed rosters for ore (Newmont Gold Roaster) to small two-stage

stationary bed rosters for concentrate (Tongguan Smelting). Outotec can deliver the

complete process chain for the pyrometallurgical plant, e.g.: roaster; dust-gas separation;

calcine cooling; gas cleaning; water treatment; sulphuric acid. Outotec can also provide

required technology for many beneficiation and the hydrometallurgical processes, which

are connected to our roasters. In the MMH project, Codelco has chosen Outotec as

supplier on EPC basis for roaster, gas cleaning sulphuric acid and effluent treatment.

This presentation summarizes the pilot plants experiences made during tests

both in Sweden and in Chile and describes how important knowledge has been collected by

the cooperative work of Codelco and Outotec.

Pyrometallurgy

PY42

INTEGRATED EXPERIMENTAL AND MODELLING RESEARCH ON COPPER

SLAGS PHYSICO-CHEMICAL PROPERTIES IN SUPPORT OF OPTIMISATION

OF COPPER MAKING PROCESSES

Evgueni Jak and Peter Hayes

Pyrosearch, The University Of Queensland, Brisbane, 4072, Australia.

E.Jak@uq.edu.au

ABSTRACT

Copper smelter operations around the world are under sustained pressure to reduce

costs and increase output. Through the provision of reliable data on fundamental properties

of the chemical systems the opportunities for improvements of industrial copper production

can be identified. Experimental and modelling studies on phase equilibria,

thermodynamics and viscosities of copper slag/matte/metal/gas systems have been

combined into an integrated research program undertaken at PYROSEARCH.

Experimental phase equilibria studies involve high temperature equilibration in controlled

gas atmospheres, rapid quenching and direct measurement of compositions of equilibrium

phases with electron probe X-ray microanalysis (EPMA). Thermodynamic modelling is

undertaken using the computer package FactSage in conjunction with advanced models

used for complex solution phases. Slag viscosities are characterised through systematic

modelling supported by experiments. Progressive development of these research

methodologies has brought significant advances in characterisation of these complex

systems.

The new data and models can now be applied to assist in improvements of the

processes. The effects of changes to chemistry and process conditions within the smelting

reactor can be examined. Examples of multivariate analysis of trends in a range of

conditions relevant to a typical copper smelter operation parameters are provided. These

examples examine the potential impact of impurity elements on slag properties, fluxing

requirements, metal losses, fuel requirements and operating temperature. These

demonstrate the potential of the theoretical, laboratory and plant-based studies, to improve

smelter performance.

Pyrometallurgy

1

PY43

CALCIUM FERRITE SLAG PHASE CHEMISTRY CONTROL USED IN

CONTINUOUS FLASH CONVERTING

E. Jak,

Pyrosearch, The University of Queensland, Brisbane, Australia, e.jak@uq.edu.au

C. Nexhip , D. P. George-Kennedy

Rio Tinto -Kennecott Utah Copper LLC, Magna, Utah, USA

ABSTRACT

Calcium ferrite slags with Cu2O, "Fe2O3" and CaO as major components are used in

the continuous flash copper-converting process developed at Rio Tinto -Kennecott Utah

Copper LLC (KUC). A number of other impurities including SiO2 , S, MgO, Al2O3, As and

other are also present in the slag. Knowledge of phase equilibria in this slag system is im-

portant for optimal control of the furnace performance including melting temperatures and

deposit control.

Extensive investigations have been undertaken a) to characterise the phase chemis-

try of deposits taken from various parts of the smelter in parallel with b) comprehensive

laboratory-based liquidus and sub-liquidus phase equilibria studies in the multi-component

system using synthetic slag samples. Major findings related to the phase chemistry control

of the Ca-ferrite slags, constitution and possible mechanisms of deposits formation in the

converter, including protective freeze-lining, will be summarised. The role of major and, in

particular, minor elements including SiO2, S, and As will be discussed. The combination of

systematic collaborative research into the plant deposits and fundamental phase equilibria

studies provided better understanding of the melting and solidification behaviour of the

complex Ca-ferrite slags.

Pyrometallurgy

PY44

DISTRIBUTION RATIOS OF PLATINUM AND PALLADIUM BETWEEN IRON

OXIDE SLAGS AND MOLTEN COPPER AT 1573 K

Katsunori Yamaguchi

Iwate University

ABSTRACT

Copper scrap containing PGM is treated with a copper smelting process, and copper

and PGM are recovered. As a fundamental study of the oxidation process, measurement of

the distribution ratios of iron, platinum and palladium between the FeOx-CaO slag and

molten copper was carried out in the range of log pO2 between 9 and -5 at 1573 K

Distribution ratios of iron, platinum and palladium are increasing with oxygen partial

pressure. Based on the distnb~ ution ratios, the recovery of platinum and palladium is

calculated under the oxygen potential, log yo2 between `9 and -5 at 1573 K using the

FeOx-CaO slag.

Pyrometallurgy

PY45

IMPROVEMENT OF COPPER SLAG GRANULATION SYSTEM WITH CLOSED

WATER CIRCULATION AND IMPURITIES BLEED--OFF CIRCUIT

Hiromichi Inada, Hiroyuki Wakasa

Tamano Smelter & Refinery

Bibi Kyodo Smelting Co., Ltd

Tatsuya Wada

Saganoseki Smelter & Refinery

Pan Pacific Copper Co., Ltd.

ABSTRACT

In Tamano smelter, seawater had been used as the granulation measure of flash

smelting furnace slag. Since some amount of heavy metals, such as As and Pb, tended to

elute from slag to the granulation water, Tarn&no tried to reduce the heavy metals emission

via discharging seawater by converting the granulation system to the closed water

circulation. 'I_amano smelter locates at the area where the industrial water supply is not

abundant. Therefore, the indirect water cooling system was applied to minimize the

evaporation loss. To avoid the impurities condensation in the circulating water, impurities

bleed-off circuit was developed and adopted to the system. The system has started its

operation in April 2012, and achieved almost zero emission of impurities derived from slag

granulation. This paper describes the design concept of the system and its cuxTent

operational performance.

Pyrometallurgy

PY46

DEVELOPMENT OF SIDE-BLOWING OXY-FUEL CONCENTRATE BURNER IN

FLASH SMELTING PROCESS AT SUMITOMO TOYS SMELTER

S, Sasai, K. Nagai, K. Kawanaka and K. Yarnamoto

Toyo Smelter & Refme Non-ferrous Metals Division

Sumitomo MetaI Mining Co., Ltd,

DISH 145-I, FunLtya, Saijo, Ehime 793-0005

JAPAN

ABSTRACT

Sumitomo Metal Mining Toyo Smelter and Refillery has achieved concentrate

feeding rate of Flash smelting furnace up to 4,000 TPD by developing the Surnitomo type

concentrate burner, lo misc the performance of concentrate burner more, Sumitomo original

smelting process, "Side-blowillg Oxy-fuel concentrate burner in Flash Smelting process"

(S.O.F) which had been developed by using pilot plant in 1980s at Niihama Research

Laboratories, was applied to commercial plant. In S.O.F process, parts of reaction air are

blown from the side nonles of flash furnace reaction shaft.

In commercial plant, several tests had been carried out and the longest test was

continued successfully for one month without serious trouble. S.O.F process also showed

very high performance such as low dusting rate. This paper describes the details of those

technical development referring test operation results.

Pyrometallurgy

PY47

STUDY ON LIQUIDUS TEMPERATURE AND VISCOSITY OF COPPER

SMELTING SLAG

Jun`ichi TAKAHASHI

Sumitomo Metal g Co., Ltd.

Niihama Research Laboratories

Process Metallurgy Group

Manager of Pyrometallnrgy' Section

ABSTRACT:

Limited data are available on the phase chemistry of the copper smelting slag

system used in the copper smelting and slag cleaning processes. The measurement of

liquidus temperature of silicate slag systems relevant to copper smelting was carried out at

controlled oxygen partial pressures in equilibrium with metallic copper by the procedures,

which involve equilibration of mixtures, rapid quenching of resulting phases, and

measurement of phase compositions using electron probe X`ray microanalyses (EPMA),

developed at the Pyrometallurgy Research Centre (PYROSEARCH), the University of

Queensland. The measurement or viscosities was also carried out by using the rotating

cylinder viscometer techniques which developed at the Kyushu University from 1423K to

1573K at oxygen partial pressure of 10.9 atm as a function of CaO% A1203%, and Fe/SiO2

weight ratio.

The increase of CaO% decreases liquidus temperature. The increases of FeiSiO2

and A1203% increase liquidus temperature. The decreases of viscosity were obtained with

the increase of CaO% and the increase of Fe/SiO2 without relation to the liquidus

Pyrometallurgy

PY50

THE ESTABLISHMENT OF AN OPTIMUM OPERATION AFTER THE

INTRODUCTION OF THE O-SR PROCESS AT ONAHAMA SMELTER &

REFINERY

Masanori Yoshida

Manager of Production Division

Onafiama Smelter & Refinery

Onahama Smelting and Refinery

Tetsuro Sakai

Managing Director & General Manager

Onahafna Smelter & Refinery

Onahama Smelting and Refinery Co, Ltd

ABSTRACT

The "O-SR" Process, which is an innovative combination of a newly installed

Mitsubishi-Process S-furnace with the existing reverberatory furnaces (RFs) followed by

PS-converters (PSC), has been operated since December 2007. The project of the O-SR

process had aimed to increase the treatment of copper concentrates in the S-furnace while

enhancing the treatment of combustible wastes such as shredder residue (SR) and

successively corresponded the intention. The original facilities of the O-SR process have

recently modified to establish an optimum operation, as follows:

Launder between the S-furnace and RFs was redesigned to increase the availability

at S-furnace @ A new coal combustion system and a compact hot-blast stove were adopted

for RFs. The operation of PSCs including the number of working converters was cllanged

to treat high grade matte. As a results, the operation cost and carbon footprint due to the

consumption of fossil fuel have decreased dramatically.

Pyrometallurgy

PY51

HIGH EFFICIENT SLAG CLEANING – LATEST RESULTS FROM PILOT

SCALE OPERATION

R. König, R.Degel, L. Rose (SMS Siemag),

J. Schmidl, A. Specht, H. Kadereit (Aurubis AG)

ABSTRACT

During the last 25 years sustainability has become one of the major issues for our

growing society. The fast development of the emerging countries and the still high level of

consumption in the industrialized states require the further development of existing

production processes. The future challenge for the copper industry is to treat more complex

ores on the one hand and increasing the yield by reducing the copper losses and to remain

the iron-silicate-by-product marketable on the other hand.

By applying a magnetic field to a slag crossing a DC field stirring is improved and

thereby the settling of entrained copper droplets is fostered. Based on this theoretical

background and the results of an intensive parameter study by CFD-simulation the results

were subsequently verified in a 2-4 t/h pilot plant. During 10 test trials, each one week, in

the pilot plant it was the aim to generate reliable results for an approximation of the

economic feasibility of the new process. The results confirmed that a significant reduction

of the Cu-content in the resulting iron-silicate-product depending on the incoming copper-

slag content is feasible and economical interesting. Hence, the basics for the design of an

industrial furnace were determined.

Pyrometallurgy

PY52

OPTIMIZING CONVERTER AISLE OPERATION AT ATLANTIC COPPER

SMELTER, HUELVA, SPAIN

Nubia Cardona V. Kingston Process Metallurgy

759 Progress Avenue Kingston, ON, Canada K7M6N6

nubia.cardona@kpm.ca

A. Martin, F. Jiménez and G.Rios Atlantic Copper

Av. Francisco Montenegro s/n

21001, Huelva, Spain

Philip Mackey P.J. Mackey Technology Inc.

Pascal Coursol Barrick Gold Corp. 3700-161 Bay Street

Toronto, ON, Canada, M5J 2S1

ABSTRACT

With the aim of reducing copper losses in slag and to further optimize converters

performance, the Atlantic Copper smelter (Huelva smelter) performed a project leading to

optimisation of its converter aisle practices. This study consisted of a review of the current

converter aisle operation, a full mapping of the slag chemistry and a modeling of the

converter cycle through a new “blow-by blow” approach. The modelling approach and

main variables influencing overall performance, slag chemistry and copper losses are

discussed in this paper. The impact of operational practices such as blowing rate and

blowing time, oxygen enrichment, fluxing, reverts and scrap copper addition, copper slag

recirculation and slag skimming practices are discussed in the context of overall heat and

mass balance for the Peirce Smith converters. Activities performed at the plant, leading to

marked improvements in the converter aisle performance and slag quality are also

discussed.

Pyrometallurgy

PY53

APPLICATION OF EXERGY ANALYSIS IN COPPER SMELTING

PRODUCTION

Javad Khosravi1, Mark A. Rosen

2

1 WorleyParsons Minerals and Metals, 2645 Skymark Avenue, Mississauga, Ontario,

Canada 2

Faculty of Engineering and Applied Science, University of Ontario Institute of

Technology, Oshawa, Canada

Email of corresponding author: javad.khosravi@worleyparsons.com

ABSTRACT

Exergy analysis has received lots of attention in recent years due to its application in

the waste heat management in various industries. However, the exergy analysis still is not a

common tool for metallurgical industries to use as useful and accurate method of energy

measurement. This paper intends to briefly review the exergy concept and its applicability

in energy management of metallurgical processes. Two case studies were analyzed: exergy

analysis of a copper smelter at different matte grade production. In another study the

impacts of copper concentrate grade on exergy of copper production were analyzed.

Pyrometallurgy

PY54

PHASE EQUILIBRIA STUDIES FOR COPPER SMELTING/CONVERTING

SLAGS

Baojun Zhao

School of Chemical Engineering

The University of Queensland, Brisbane, Australia baojun@uq.edu.au

ABSTRACT

Phase equilibria of silicate slags relevant to the copper smelting/converting operations

have been systemically investigated in the temperature range 1200 to 1300 oC and oxygen

partial pressures between 10-5

and 10-9

atm. The experimental procedures include high

temperature equilibration, quenching and accurate measurements of phase compositions

using electron probe X-ray microanalysis (EPMA). The effects of CaO, Al2O3, MgO and

Po2 on the phase equilibria of the fayalite slags have been systematically investigated.

It was found that spinel and tridymite (SiO2) are major primary phases in the

composition range related to copper smelting/converting slags. In addition, olivine,

diopside and pyroxene may also appear at certain conditions. The presence of up to 20 wt%

CaO, up to 10 wt% MgO and 10 wt% Al2O3 in the slag increases the spinel liquidus and

decreases the tridymite liquidus. Liquidus temperatures in tridymite primary phase field are

not sensitive to Po2; Liquidus temperatures in spinel primary phase field increase

significantly with increasing Po2. Addition of the same weight of Al2O3 or MgO in slag

shows the same effect on the liquidus temperatures in spinel and tridymite primary phase

fields. The trends in the effects of Al2O3 or MgO on liquidus temperatura are similar for

both copper smelting and converting slags.

Pyrometallurgy

PY55

INVESTIGATION OF FREEZE-LINING FORMED IN AN INDUSTRIAL COPPER

CONVERTING CALCIUM-FERRITE SLAG.

ATA FALLAH-MEHRJARDI , PETER C. HAYES, EVGUENI JAK

PYROSEARCH, The University of Queensland, Brisbane, Australia

JANI JANSSON2, PEKKA TASKINEN2

Thermodynamics and Modelling Group, Aalto University, Finland

ABSTRACT

Pyrometallurgical coppermaking processes are operated under intensive conditions

such as high process temperatures and vigorously agitated bath to accelerate kinetics of

reactions and to achieve high smelters throughput. Slag freeze-lining reactor wall protection

is a widely used technology in coppermaking processes, such as, flash smelting and

converting reactors to mitigate and resist the effects of thermal and chemical attack by

aggressive slags. In this laboratory-based study, water-cooled probe “cold finger” technique

has been used to investigate the behaviour of the calcium ferrite slags in equilibrium with

metallic copper; the slag composition reflects that used in the industrial copper flash

converting furnace of Rio Tinto – Kennecott Utah Copper LLC (KUC). The effects of

probe immersion times on the thickness, stability, and heat transfer characteristics of

freeze-lining deposits have been measured.

It has been shown that under steady-state conditions several different layers are

formed within the deposit starting from the cold probe surface as follows: quenched and

microcrystalline layers; closed crystalline layer with multiphase sub-liquidus material

formed without mass exchange with the bulk liquid; dense primary phase crystals sealing

layer; and the subliquidus boundary layer between stagnant deposit and the agitated liquid

bath. The microstructures of the freeze-lining obtained at steady-state thickness were

compared to sub-solidus equilibrium phase assemblages.

Pyrometallurgy

PY56

CHEMICAL COMPOSITION AND DUST GENERATION OF COPPER

CONCENTRATE PARTICLES OXIDIZED UNDER SUSPENSION-SMELTING

CONDITIONS

V.R. Parra-Sánchez, M. Pérez-Tello, V.M. Sánchez-Corrales, A. Gómez-Álvarez

Department of Chemical Engineering and Metallurgy, University of Sonora

Blvd. Luis Encinas & Rosales. Hermosillo, México 83000

mperezt@iq.uson.mx

R. Parra-Figueroa, E. Balladares-Varela, E. Araneda

Dept. of Metallurgical Engineering, University of Concepcion.

Department of Metallurgical Engineering, University of Concepción

Edmundo Larenas 285 Casilla 160-C Correo 3

Concepción, Chile.

ABSTRACT

The chemical composition and dust formation during the oxidation of copper

concentrate particles under suspension-smelting conditions were investigated. The effects

of initial particle size and oxygen concentration in the process gas on the particle

composition, morphology, and mineralogy of the reacted particles along a laminar-flow

reactor were tested. The chemical composition of the reacted particles was determined by

atomic absorption spectroscopy.

The mineralogy was determined by X-ray diffraction and QEMSCAN® techniques,

the latter of which involves scanning electron microscopy combined with energy-dispersive

X-ray spectroscopy. The experimental data indicated that the smaller the size fraction in the

feed, the higher the extent of oxidation. The QEMSCAN® micrographs in general agree

with a reaction mechanism involving expansion and further fragmentation of the particles

during flight. The extent at which both phenomena occurred was dependent upon the initial

particle size and residence time of the particles in the reactor.

Pyrometallurgy

PY57

EVOLUTION OF SIZE DISTRIBUTION OF COPPER CONCENTRATE

PARTICLES OXIDIZED UNDER SUSPENSION-SMELTING CONDITIONS

V.R. Parra-Sánchez, M. Pérez-Tello and V.M. Sánchez-Corrales

Department of Chemical Engineering and Metallurgy, University of Sonora

Blvd. Luis Encinas & Rosales. Hermosillo, México 83000

mperezt@iq.uson.mx

R. Parra-Figueroa and E. Balladares-Varela

Department of Metallurgical Engineering, University of Concepción

Edmundo Larenas 285 Casilla 160-C Correo 3

Concepción, Chile

ABSTRACT

Experiments were conducted to investigate the effects of the initial particle size and

oxygen concentration in the process gas on the size distribution of copper concentrate

particles oxidized under suspension-smelting conditions. The size distribution was

determined by both QEMSCAN® and laser diffraction techniques from samples of reacted

particles collected along the reactor length of a laminar-flow reactor.

The experimental data indicate that the change in particle size of the particle

population was strongly dependent upon the particle size of the feed material, whereas the

oxygen concentration in the process gas did not play a significant role in the range of 40-70

vol. %. Particle expansion was the predominant phenomenon in the early stages of

oxidation, whereas fragmentation started to occur at further stages of oxidation down the

reactor length. The amount of dust, i.e., particles with size smaller than 20 m, is discussed

as a function of the operating conditions tested in the experiments.

Pyrometallurgy

PY59

CONTINUOUS CONVERTING OF COPPER MATTE TO BLISTER COPPER IN A

HIGH – INTENSITY MOLTEN - LAYER REACTOR.

I. Wilkomirsky, R. Parra, F. Parada & E. Balladares

Dept. Metallurgical Engineering

University of Concepción

Edmundo Larenas 285, Concepción, Chile

iwilkomi@udec.cl

ABSTRACT

Continuous converting of copper matte or white metal into blister copper can be

carried out in a new high - intensity molten layer reactor that operates with dry, -65 mesh

grinded matte or white metal and technical oxygen. The reactor operates at 1500-1600ºC

producing a blister copper with 0.5 – 0.8%S which can be refined in conventional form, and

a slag with less than 8% Cu. The reactor operates continuously with no fugitive emissions,

generating and off gases with over 50% SO2. The phenomenological model of the molten –

layer reactor can predict with good agreement the results obtained in a pilot prototype

reactor.

Pyrometallurgy

PY60

PHYSICO–CHEMISTRY AND KINETICS MECHANISMS OF PARTIAL

ROASTING OF HIGH – ARSENIC COPPER CONCENTRATES

I. Wilkomirsky, R. Parra, F. Parada and E. Balladares

Dept. Metallurgical Engineering

University of Concepción

Edmundo Larenas 285, Concepción, Chile

iwilkomi@udec.cl

ABSTRACT

A physico–chemical/kinetic model is being proposed to explain the formation of

bornite, chalcopyrite and magnetite during partial roasting of high–arsenic copper

concentrates at 700ºC. The mechanism involves solid state-gas and solid–gas reactions

between chalcosite, pyrrhotite and gaseous sulphur, and is thermodynamically consistent

with the experimental results obtained in pilot plant.

Pyrometallurgy

PY61

RECOVERY OF COPPER, MOLYBDENUM, ZINC AND IRON FROM COPPER

SMELTER SLAGS.

I. Wilkomirsky, R. Parra, F. Parada and E. Balladares

Dept. Metallurgica Engineering

University of Concepción, Chile

iwilkomi@udec.cl

J. Smit, M. Acuña and M. P. Merino

ECOMETALES Ltd.

Calama, Chile

ABSTRACT

A new process is being developed which permit to recover up to 98% of copper,

76% molybdenum and 98% zinc from copper smelter slags, generating a solid residue of

red hematite that can be used in paints and ceramics. The process consist of two

consecutive step: an initial total sulphation of the slag at 150-180ºC with sulphuric acid

followed by a thermal decomposition at 700ºC – 750ºC of the sulphated slag to form copper

and zinc sulphates, copper molybdate and hematite. The acid used in the first step of

sulphation is re-synthtetical in the seconds step of thermal decomposition and recirculated

back to the sulphation step. The process is being developed at pilot scale in a plant that will

be commissioned by the end of 2013.

Pyrometallurgy

PY62

NEW SLAG FLOTATION PLANT FOR POTRERILLOS SMELTER

Claudio Queirolo

Projects Manager Salvador Division CODELCO CHILE

ABSTRACT

Potrerillos Smelter, Salvador Division, CODELCO CHILE, replaced its Slag

Cleaning Furnaces by a Slag Flotation Plant to treat the smelter slag, as a way to improve

its metallurgical efficiency and to reduce gases emissions.

The plant has capacity to treat 1.530 t/d of the Teniente Converter slag with 8 to 10

% Cu, produces a 38 % Cu concentrate and a 0,4 % Cu waste. The copper concentrate is

reprocessed in the Teniente Converter.

The project considered pots slag cooling to optimize copper recovery, a SAG mill

followed of ball mill, two flotation stages, thickening and filtering of copper concentrate

and final waste.

After its start up, the smelter has increased its copper recovery from 95,5 % to 97,4

%. And additional ongoing project considering improvements of the reception, storing and

handling of copper concentrates will increase the global copper smelter recovery to 98 %.

Pyrometallurgy

PY63

REFINEMENT OF FLASH FURNACE AND CODELCO TENIENTE REACTOR

MATERIAL FEED SYSTEMS TO UTILISE CALCINED CONCENTRATES

Mark Coleman

ABSTRACT

Clyde Process an established customer-driven solutions provider, utilising its

knowledge, expertise and technologies to transform production processes, operating in the

ferrous and non-ferrous metals industries joined the Schenck Process Group of Darmstadt

Germany bringing the Brand into their focused Process Team.

Clyde Process solutions have delivered transformed operation to many of their

global clients, enabling them to generate sustainable economic benefit and maintain

positions as leaders in their markets.

Clyde Process have been a partner of Codelco for some time and when Codelco

developed its Calcined Concentrate from the new Hales Mine they turned to Clyde to

support their operation of the Flash Furnace and the Codelco Teniente Reactor allowing the

material to be exploited. Homogeneously mixed and delivered such that the existing

furnaces could maintain their performance.

Following process trials, targets were set and Clyde contracted to supply the

transport conveying equipment to deliver the Calcined material from the roaster to the

smelter and then homogeneously mix the materials on the Flash Furnace direct to the day

bin and on line directly to the Lances on the Codelco Teniente Converter with standard

Copper Concentrate and Silica Flux.

This paper reveals the solutions delivered showing the truth of Schenck Process

Solutions claim that ‘we make processes work’

Pyrometallurgy

PY64

DEVELOPMENT AND APPLICATION OF OXYGEN BOTTOM-BLOWING CU

SMELTING TECHNOLOGY

Xiaohong Hao, Zhifang Lu, Kejian Wei, Zhenmin Zhang, Liqiong Hu and Bing Li

China ENFI Engineering Corporation

12 Fuxing Avenue

Haidian District,Beijing 100038P.R.China

haoxh@enfi.com.cn

Zhi Wen , Fuyong Su and Yue Yu

University of Science & Technology Beijing

30 Xueyuan Road

Haidian District, Beijing 100083 P.R.China

wenzhi@me.ustb.edu.cn

ABSTRACT

Oxygen Bottom-blowing Cu Smelting Technology is a modern and clean technology

featured with low capital cost, low comprehensive energy consumption, high metal and

sulfur recovery rate, low operating cost and a good operational environment. The core

equipment of this technology is the bottom-blowing smelting furnace. This paper

summarizes the development history of bottom-blowing Cu smelting technology, and the

structural features and applications of a bottom-blowing smelting furnace. It then compares

it with other bath smelting technologies, coming to the conclusion that oxygen bottom-

blowing smelting furnace could ensure higher smelting strength, longer furnace life and

higher operational efficiency and that this technology has broad development prospect.

Pyrometallurgy

PY65

DEVELOPMENT OF THE CONTINUOUS BOTTOM-BLOWING MATTE

CONVERTING PROCESS

Bing Li, Jimu Jiang, Kejian Wei, Feng Li and Xiaohong Hao

China ENFI Engineering Corporation

12 Fuxing Avenue

Haidian District, Beijing 100038 P.R.China

libing@enfi.com.cn

Chuanfu Zhang

Central South University (CSU)

Changsha, Hunan 410083, PR. China

Chuanfuzhang@csu.edu.cn

ABSTRACT

This Paper describes the continuous bottom-blowing matte converting process, as

well as the pilot plant test conducted for this process from May to June, 2012. The pilot

plant test shows that under three-phase conditions in the bath, sulfur in blister is 0.7%-1.0%,

and Cu in slag is 8-12%; while under two-phase conditions, sulfur in blister is 0.2%, and

Cu in slag is around 20%. During the test, oxygen lance and refractory linings are under

good conditions. Therefore, it can be concluded from the pilot plant test that continuous

bottom-blowing matte converting process has good application prospect. The first plant

adopting this process is under design now and will be put into operation in China in

October 2013.

Pyrometallurgy

PY66

AN INTEGRATED LIFECYCLE APPROACH TO FURNACE REBUILDS

Mike Santaluce

Outotec

1551 Corporate Dr

Burlington, Canada L7L 6M3

mike.santaluce@outotec.com

ABSTRACT

Outotec’s Integrated, Lifecycle Solution to Furnace Rebuild Projects is designed to

provide smelters with reliable furnace rebuild project solutions and asset program lifecycle

services. The concept addresses furnace rebuilds at the project level and at the asset

program level. At the project level, this solution combines Outotec’s proven Smelting

Technology with its expertise in executing furnace rebuild shutdowns to deliver a complete

furnace rebuild project solution to clients which includes design, supply, construction,

commissioning and start-up activities for the furnace. At the asset program level, it delivers

regular audits, process, operating and maintenance support to provide a solution for

lifecycle management of the furnace rebuild program, aimed at maintaining continuity

between individual rebuild projects and improving the overall performance of the furnace

over the smelter lifecycle.

The Integrated, Lifecycle Solution to Furnace Rebuild Projects offers clients a

number of benefits both at the project level and the asset management level, ultimately with

the goal of enhancing the return on investment that copper smelters extract from their

rebuild projects and from the furnace asset itself over the lifecycle of the furnace.

Pyrometallurgy

Ref: 20/10/2013 10:28 AM

PY67

COPPER SMELTING TECHNOLOGIES IN 2013 AND BEYOND

P.J. Mackey

P.J. Mackey Technology Inc., Kirkland, QC, Canada

E Mail: pjmackey@hotmail.com

ABSTRACT

Modern bath and flash smelting technologies dominate world copper smelting

today. In recent years, these technologies have been perfected achieving high unit tonnages

as a result of continuous plant improvements and development work by the technology

owners. Flash smelting is dominated today by the Outokumpu flash technology, while there

are a number of established bath smelting technologies today including: Top Lance

Smelting such the ISASMELTTM

Process, the Noranda and El Teniente Processes and the

Mitsubishi Process.

This paper explores the development cycle of these leading processes and charts

potential future trends, including aspects such as the early role of piloting and process

perfection, energy consumption, environmental design and sustainability, along with capital

and operating costs. Included is a technical evaluation of emerging and new smelting

technologies, typified by the SKS bath smelting process. Looking beyond 2013 and based

on the technical review, the paper attempts to place into perspective the likely niche such

new technologies will have in the suite of the bath and flash technologies of the future.

Pyrometallurgy

PY68

USE OF WASTE HEAT BOILERS TO SAVE RESOURCES

Dipl.-Ing. Alfredo Martínez

Oschatz GmbH

Westendhof 10 - 12

Essen, Germany

martinez.a@oschatz.com

ABSTRACT

Pyro-metallurgical industries are constantly affected by more rigorous

environmental regulations and global lack of necessary resources, like energy and water for

their processes. Plant owners look for new ways to operate their plants in an efficient and

economical way. One possibility is the usage of waste heat boilers (WHB) to recover the

energy potential of their plants. The WHB recovers the waste heat of the process to

generate steam and cools down the gas.

The produced steam can be used for power generation to improve the energy

efficiency of the plant. By cooling down the waste gas, the requirement of additional

cooling systems like water injection is not necessary. Water consumption is reduced.

This work describes some existing furnace technologies and types of WHB which

can be installed in non-ferrous industry plants. The main objectives are to show different

possibilities to save natural resources (fuels, water, etc.) while producing electrical energy

from the steam generated by these WHB.

Furthermore, some mechanisms which improve the efficiency of the waste heat

recovery are described and an example for using the recovered heat to generate electricity is

shown.

Finally, a preview on further developments for this subject is given.

Pyrometallurgy

PY69

DIRECT SULFIDES ELECTROLYSIS:

A SUSTAINABLE PROCESS FOR COPPER RECOVERY?

Antoine Allanore

Massachusetts Institute of Technology

Department of Materials Science & Engineering

77 Massachusetts Avenue, Cambridge, MA 02139 USA

allanore@mit.edu

ABSTRACT

Environmental awareness along with restrictions on investments, are calling for the

development of new approaches for metal extraction. In particular, the notion that an

extraction process necessary involves the emission of hazardous gas or the investment in

capital-intensive post-treatments is to be revisited. Technological trends suggest that an

electricity-based technique is well suited to accommodate these modern challenges [1]. In

the case of sulfides processing, one underexplored approach is the direct electrolysis of the

sulfides [2], leading to the decomposition of the feedstock to metal and elemental sulfur,

e.g.:

Cu2S 2Cu + ½S2 (g)

This concept, in particular if applied at a temperature above the metal melting point,

has the advantage to allow a semi-continuous single step process, as experienced for

aluminium. It also offers to decouple the metal production from the generation of sulfuric

acid. In terms of volume, the generation of S2 is an asset as it can be conveniently disposed

or transported in solid form. This presentation first proposes to review some of the pioneer

concepts. In a second part, a discussion of the electrolyte design challenges that are

currently limiting this approach will be offered, along with new opportunities that are

arising in this field.

[1] A. Allanore, ‘Contribution of Electricity to Materials Processing: Historical and

Current Perspectives’, JOM, vol. 65, issue 2, 131, (2013)

[2] F. Habashi, ‘The Recovery of Elemental Sulfur from Sulfide Ores’, Bureau of

Mines and Geologym Bulletin 51, (1966)

Pyrometallurgy

PY70

THE EFFECT OF IN SITU PHASE FORMATION ON THE INFILTRATION

BEHAVIOR AND CHEMICAL DEGRADATION OF MAGNESIA-CHROMITE

BRICKS IN CONTACT WITH A SYNTHETIC NON-FERROUS SLAG

L. Scheunis1, A. Malfliet

1, M. Campforts

2, P.T. Jones

1, B. Blanpain

1

1Dept. Metallurgy and Materials Engineering, KUL, Leuven, Belgium;

2Umicore R&D, Olen, Belgium

ABSTRACT

To have a robust smelting process it is essential to be able to rely on a long

refractory life. In case of Cu-smelters, life times of 2 and more years can be obtained. In

these processes a fayalite slag is used. However, in processes where a PbO slag is used, the

refractory life time is often lower. A major difference between both slags lies in the

infiltration behavior of the slag; PbO slags can infiltrate the porous lining much deeper,

attacking a larger part of the lining. In order to mitigate this, the possibility of preventing

deep infiltration by sealing off the pores with in-situ formed phases is investigated for a

synthetic non-ferrous PbO-SiO2-MgO slag. The results indicate the formation of forsterite

(Mg2SiO4) throughout the refractory sample by the reaction between the silica present in

the infiltrated liquid and the MgO from the refractory sample. This phase grows with time,

eventually sealing off the pores near the interface with the bath but is unable to prevent

complete infiltration of the refractory. However, once the forsterite seals off the pores, it

prevents contact between the bath and the interior of the brick, ceasing the chemical

corrosion inside the brick.

Pyrometallurgy

PY71

OPTIMIZATION OF TECHNOLOGY FOR CONCENTRATE SMELTING IN

FLASH FURNACE WITH CHARGE CHANGES

Marcin Kacperski, Zbigniew Gostyński, Tomasz Gąbka, Piotr Poks.

KGHM PM, Poland

ABSTRACT

Copper Smelter Glogow (HMG) is a part of mining and metallurgical concern

KGHM PM SA. There are two primary smelters and copper refineries in HMG. The flash

furnace was built 1978 and the process of concentrates blend melting began. Due to the

characteristics of the Polish concentrates (low sulfur content, high organic carbon and lead)

technology of the direct smelting to blister copper was applied. Year by year the technology

was improved both technically and in case cost effectiveness. Recently, lead and organic

carbon content in concentrates increased and forced a change in approach to the

technological process parameters and verification its important parameters. The

presentation / paper describes the technical and technological changes in flash furnace

smelting.

Pyrometallurgy

PY73

MECHANICAL SYSTEM FOR REVERTS CHARGING INTO PEIRCE-SMITH

CONVERTERS

Patricio Hernández Norambuena1

Christian Guibout Cid2

1Ingeniero de Desarrollo Senior, División Ventanas, Codelco Chile 2Ingeniero Jefe de Fundición, División Ventanas, Codelco Chile

ABSTRACT

This system aims to feed reverts during the blowing step of the PSC converting

process at the Ventanas Smelter, thus avoiding direct addition through the converter mouth,

thereby reducing the emission of gases to the atmosphere. This mechanized system which

replaces the normal feeding procedure by tilting the converter and adding reverts through

the gas mouth is part of the Investment Plan that Codelco Ventanas Division is developing

to improve industrial processes in order to reduce gaseous and particulate matter emissions

to the atmosphere.

This system is made up with several auxiliary equipment and control systems,

which allows, in addition to reducing emissions to the atmosphere, to adequately control

the temperature of the conversion process during the blowing operation, as well as to obtain

a more stable flow of gas to the acid plant and not to expose the operator to hazardous work

conditions.

This paper shows in some detail how the system is structured describing its

mechanical and process control components. It also outlines the way the system works and

the results obtained to date.

Pyrometallurgy

PY74

EMISSIONS REDUCTION AND PROCESS IMPROVEMENTS ACHIEVED WITH

THE NEW ANODE FURNACE OFF-GAS SYSTEM AT ASARCO HAYDEN

Alberto Fernandez, Steve Gasser, Kevin McPeak, and Joe Wilhelm

ASARCO Hayden Operations, Hayden, Arizona USA

Mark Rowsell, Matt Russell, and Paykan Safe

GCT, LLC, Irving, Texas USA

ABSTRACT

The ASARCO smelter in Hayden, Arizona operates three anode furnaces to fire-

refine blister copper for casting to anodes. The furnaces use natural gas with steam for

reduction and natural gas burners for temperature control. Previously, anode furnace off-

gas discharged directly to the building with no gas collection, and burner gas consumption

was high.

ASARCO engaged GCT, LLC to provide preliminary and detail engineering and

EPCM services for a new off-gas system to reduce anode furnace emissions. The baghouse-

based system was installed and successfully started up in February 2012. Following startup

of the new off-gas system, ASARCO and GCT worked together to optimize the tuyere and

burner practices in order to improve reduction efficiency and processing time, to reduce gas

consumption and soot formation, and to optimize the off-gas system operation. The process

improvements resulted in significantly reduced natural gas consumption and improved gas

capture performance of the new hoods.

This paper outlines the challenges faced in designing the new off-gas system and

the process improvements and energy savings achieved through the collaborative

optimization effort.

Pyrometallurgy

PY75

TECHNOLOGY DEVELOPMENTS FOR SMELTER OFF-GAS HEAT

RECOVERY

Matt Russell and Paykan Safe

GCT, LLC, Irving, Texas USA

ABSTRACT

Smelter processes generate a significant amount of heat, of which a large percentage

is released with the process off-gas. Therefore off-gas heat recovery is critical to

minimizing energy consumption and reducing operating costs. Metallurgical process off-

gas presents major challenges for heat recovery due to high dust loading, corrosive gases,

and thermal cycling in batch processes. Waste heat boilers have been used for many years

for heat recovery on continuous smelting and converting processes. However, heat recovery

technologies have not been widely adopted on batch processes such as Peirce-Smith

converting and other lower temperature applications.

The design and development of novel heat recovery technologies to smelter

processes can provide produce significant reductions in energy consumption, greenhouse

gas emissions, and operating cost. This paper outlines the challenges faced in recovering

heat in smelter processes and presents recent technology developments for heat recovery

for batch processes and lower temperature applications, including a recent successful

installation of Organic Rankine Cycle (ORC) technology for heat recovery to power

generation on a steel reheat furnace.

Pyrometallurgy

PY76

THE USE OF CHROME-ALUMINA REFRACTORIES IN THE HIGH WEAR

AREAS OF ANODE REFINING VESSLS

A.J.Rigby Harbison-Walker Refractories, Pittsburgh, U.S.A.

ABSTRACT

Refractory lining designs based on products containing direct-bonded or rebonded

fused grain magnesia-chrome have been the industry-wide standard for anode refining

vessels in all primary copper smelters. These linings are usually zoned with the denser

rebonded fused grain material at the severe wear areas at the tuyeres, tapholes, skimming

ports and charges mouths. This zoning aids to improve the lining performance in these

areas but commonly the vessels must be taken out of service every 4-6 months for

maintenance. It has been shown in the past that wear mechanisms leading to severe joint

penetration at the skimming ports and significant spalling of the brick in the tuyere areas

are a result of copper oxide penetration and reaction.

Early trials of alumina-chrome monolithics and bricks containing 30% chromic oxide

have shown remarkable resistance to copper oxide slags. Chemical analysis and

microscopical examination of laboratory test samples and refractory products recovered

from the field illustrate that the matrix of the refractory rich in chromic reacts oxide with

the penetrating copper oxide slag to form a refractory reaction layer that prevents further

ingress of the slag.

This paper will summarize the actual results realized in the anode refining vessels

and develop an over-arching vision of the potential future benefits generally which could

very well accrue additionally in the primary smelting and converting production units

Pyrometallurgy

PY77

IMPURITY BEHAVIOUR DURING THE CONTINUOUS CONVERTING OF

COPPER MATTE IN A PACKED BED REACTOR

L. Voisin and J. Diaz

AMTC-DIMin, University of Chile

Advanced Mining Technology Center-Department of Mining Engineering

Av. Tupper 2007-2069,

Santiago Chile 837-0451

lvoisin@ing.uchile.cl

ABSTRACT

The Chilean mining is facing high and rising levels of arsenic and antimony

contents in copper sulphide ores and therefore their smelters have had to treat complex

concentrates rich in these impurities under stricter environmental regulations.

Concerning the study of the continuous converting of copper matte to Blister in a

packed bed reactor, the distribution of detrimental impurities of As, Sb, Pb and Zn were

investigated by experimental tests at laboratory scale at 1523K in relation to four variables;

matte grade, blast flow rate, oxygen enrichment into the blast and packed bed height.

The results indicated that the removal of impurities towards the slag and gas phases

is strongly dependent on oxygen enrichment and packed bed height. An increase of the

latter, contributes to prolong the residence time of the impurities improving contact with the

blast, while higher oxygen enrichment enhanced their oxidation and subsequent slagging

and volatilization. Compared to the conventional processes, As and Sb removals were

similar, whereas those for Pb and Zn were higher.

The study corresponds to the first reference of impurity behaviour in a packed bed

reactor and indicate a concrete and promising use of this novel technology as a replacement

to the traditional ones.

Pyrometallurgy

PY78

OXIDATION KINETIC OF COPPER MATTE DURING THE CONTINUOUS

CONVERTING PROCESS IN A PACKED BED REACTOR

J. Diaz and L. Voisin

AMTC-DIMin, University of Chile

Advanced Mining Technology Center-Department of Mining Engineering

Av. Tupper 2007-2069,

Santiago Chile 837-0451

lvoisin@ing.uchile.cl

ABSTRACT

The increasingly stringent environmental requirements against the emission of

impurities and fugitive gases and the higher energy costs during the converting of copper

matte have encouraged the development of continuous and cheaper processes.

Thus, a new continuous converting process has been developed based on the

oxidation of copper matte with a countercurrent oxygen-enriched air blast into a packed bed

reactor. In this study, the oxidation kinetic of copper matte was investigated by

experimental tests at laboratory scale in relation to four variables; matte grade, blast flow

rate, oxygen enrichment into the blast and packed bed height.

Copper matte oxidation, in terms of desulfurization, follows a first order kinetic,

where the sulfur content into the Blister copper, [S], depends on the oxygen enrichment,

%O2, and the packed bed height [H]:

10.9H))2.18Hln(%O(

02e[S][S]

Pyrometallurgy

A high oxidation kinetic was observed due to the increasing reaction area produced

by the higher dispersion of copper matte within the reactor, reporting a minimum

standardized desulfurization rate of 5.67x10-3 [mol/g/min], which corresponds to 4 times

of that in the conventional processes, besides, it was determined that the kinetic of the

reaction was controlled by the diffusion of the oxygen contained into the blast.

Pyrometallurgy

PY79

KINETIC AND MODELING OF CONTINUOUS COPPER REFINING IN A

PACKED BED REACTOR DURING THE REDUCTION STAGE

F. Mansilla and L. Voisin

AMTC-DIMin, University of Chile

Advanced Mining Technology Center-Department of Mining Engineering

Av. Tupper 2007-2069,

Santiago Chile 837-0451

lvoisin@ing.uchile.cl

ABSTRACT

A novel technology was proposed by the Department of Mining Engineering of

University of Chile which consists in two cylindrical packed bed furnaces in cascade for

refining molten blister copper. The first furnace, containing a refractory packed bed has the

function of removing the sulfur until 25 [ppm] as SO2 using a countercurrent airflow, while

the second one, containing a coal or coke packed bed reduces the oxygen to around 1500

[ppm] as CO, CO2 and H2O(g). This technology is characterized by increasing the kinetics

of refining, decreasing the amount of fugitive combustion gas emissions and as a result

reduces both investment and operating costs compared with the traditional anodic furnace.

The purpose of the present work was to model this technology at a laboratory scale during

the reduction stage in order to obtain optimum parameters for future industrial furnace

designs.

The experimental tests were carried out in a laboratory scale electric furnace at

1473 K and the oxygen content in anodic copper was measured with a LECO analyzer.

Results allow visualizing the copper flow and oxygen concentration inside the crucible and

mainly confirm that is possible to achieve an anodic copper with oxygen values below 1500

[ppm].

Pyrometallurgy

PY80

PHASE RELATIONS AND MINOR ELEMENT DISTRIBUTION IN

Cu-Fe-Pb-As SYSTEM SATURATED WITH CARBON AT 1473 K

G. Damm and L. Voisin

AMTC-DIMin, University of Chile

Advanced Mining Technology Center-Department of Mining Engineering

Av. Tupper 2007-2069,

Santiago Chile 837-0451

lvoisin@ing.uchile.cl

ABSTRACT

In order to develop a new pyrometallurgical process for eliminating detrimental

arsenic and recovering precious elements of silver, gold and platinum from arsenic-rich

copper-lead scraps the phase relations in the Cu-Fe-Pb-As system saturated with carbon and

the distribution of minor elements between the condensed phases generated during the

equilibrium at high temperature were studied. The investigation was carried out by

performing a series of laboratory scale experiments into an electrical furnace at 1473 K

follows by a quenching method on the final stage.

The samples obtained from the experiments were analyzed by using Inductively

Couple Plasma, ICP and Carbon Infrared Spectrometry, CIS techniques. The results were

discussed on the basis of the activity coefficient of arsenic and distribution parameters for

precious metals in the miscibility gap where three equilibrated alloy phases of lead-rich,

copper-rich and iron-rich coexist. It is expected that by using this phase separation

technique it might be feasible both, to recover some precious elements into the copper-rich

or lead-rich alloy phases and eliminate iron and arsenic into the iron-rich alloy phase,

which can be discarded as a harmless and smaller deposit.

Pyrometallurgy

PY81

PHASE RELATIONS AND MINOR ELEMENT DISTRIBUTION IN

Cu-Fe-Pb-Sb SYSTEM SATURATED WITH CARBON AT 1473 K

K. Mühlenbrock and L. Voisin

AMTC-DIMin, University of Chile

Advanced Mining Technology Center-Department of Mining Engineering

Av. Tupper 2007-2069,

Santiago Chile 837-0451

lvoisin@ing.uchile.cl

ABSTRACT

In order to develop a new pyrometallurgical process for eliminating detrimental

antimony and recovering precious elements of silver, gold and platinum from arsenic-rich

copper-lead scraps the phase relations in the Cu-Fe-Pb-Sb system saturated with carbon and

the distribution of minor elements between the condensed phases generated during the

equilibrium at high temperature were studied. The investigation was carried out by

performing a series of laboratory scale experiments into an electrical furnace at 1473 K

follows by a quenching method on the final stage.

The samples obtained from the experiments were analyzed by using Inductively

Couple Plasma, ICP and Carbon Infrared Spectrometry, CIS techniques. The results were

discussed and compared with those obtained in a previous work related the Cu-Fe-Pb-As-C

system on the basis of the activity coefficient of antimony and distribution parameters for

precious metals in the miscibility gap where three equilibrated alloy phases of lead-rich,

copper-rich and iron-rich coexist. It is expected that by using this phase separation

technique it might be feasible both, to recover some precious elements into the copper-rich

or lead-rich alloy phases and eliminate iron and antimony into the iron-rich alloy phase,

which can be discarded as a harmless and smaller deposit.

Pyrometallurgy

PY82

THERMO-FLUID-DYNAMICS MODELING FOR CONTINUOUS CONVERTING

PROCESS OF COPPER MATTE IN PACKED BED REACTOR

E. Marambio and L. Voisin

AMTC-DIMin, University of Chile

Advanced Mining Technology Center-Department of Mining Engineering

Av. Tupper 2007-2069,

Santiago Chile 837-0451

lvoisin@ing.uchile.cl

ABSTRACT

The conversion of copper matte to Blister, is a traditional and essential stage during

the production process of metallic copper from sulfide concentrates, however, higher

energy costs and environmental standards are becoming increasingly stringent regarding

fugitive gas emissions and impurities disposal, thereby, the development of continuous

processes with lower operational costs have been considered. Thus, the pyrometallurgical

group of University of Chile, ENAMI and Buildtek S.A. have been investigating and

developing a continuous process based on the oxidation of copper matte with a

countercurrent oxygen-enriched air blast into a packed bed reactor. This study considered

the elaboration of the Computational Thermo Fluid Dynamics, CTFD modeling based on

experimental laboratory scale results and the adjustment of transport phenomena equations

related to heat, mass and momentum behavior.

The modeling considers parameters such as oxygen concentration in copper, packed

bed height, diameter of the spherical refractory packed bed, etc., and will be developed and

simulated by using the software COMSOL Multiphysics. It is expected that the modeling

will be able to describe and predict the behavior at a laboratory scale of the proposed novel

technology of continuous converting in packed bed reactor providing the base for the

replacement of the traditional Peirce-Smith Converter.

Pyrometallurgy

PY83

CHARACTERIZATION AND FROTH FLOTATION OF

SMELTING FURNACE COPPER SLAG

L. Voisin, W. Kracht and G. Jeldres

AMTC-DIMin, University of Chile

Advanced Mining Technology Center-Department of Mining Engineering

Av. Tupper 2007-2069,

Santiago Chile 837-0451

lvoisin@ing.uchile.cl

ABSTRACT

During the first stage of the pyrometallurgical production of molten copper a

smelting slag, contains from one to eight percent of both chemical and in trap copper

depending mainly on matte grade, is generated. In Chile, the treatment of this phase to

recover copper is widely performed in an electric or a fuel fired slag-cleaning furnace,

however higher energy costs and environmental problems related to the fugitive gas

emissions and the disposal of complex treated slag have increased, thereby, the study of

froth flotation for smelting complex copper slag with high content of impurities of arsenic

and antimony have been considered. The study considered to stages, the first one related to

the characterization of smelting slag, provided by four of the seven copper smelters located

in Chile, using optical microscopy, XRD, XRF, XPS and ICP techniques, and the second

stage concerning to investigate by experimental test the optimal froth flotation reagents and

conditions to maximize the recovery of copper. The results were compared with the

traditional treatment methods and will be generate a technical-economic assessment which

allows Chilean copper smelters to make the best decision regarding to the treatment of

smelting furnace copper slag.

Pyrometallurgy

PY85

MAXIMIZATION OF HEAT RECOVERY BY PRODUCING LOW PRESSURE

STEAM

Chang-Buhm Kim, Kyoung-Soo Jung, Hyung-Taek Chung

LS-Nikko Copper Inc.

148, Sanam-ro, Onsan-eup, Ulju-gun

Ulsan, 689-892, Korea

cbkim@lsnikko.com

ABSTRACT

All companies are facing global warming issues now. Copper business also cannot be

free from CO2 emission. Before taking into new and renewable energy, LS-Nikko is trying

to maximize waste heat recovery. By installing HRS system and new Waste Heat Boiler,

we have succeeded to reduce CO2 emission about 65,000 tons per year since 2004. From

2011, low pressure steam is generated in flash drum at Sulfuric acid No.1. It heats up

combustion air for flash smelting furnace and anode furnaces. At Plant No.2, modified HRS

preheater can warm up feed water to the waste heat boilers in both acid plant and smelter.

As the result, the CO2 emission has been decreased by 15,000 t/y additionally.

Pyrometallurgy

PY86

COPPER DISSOLUTION IN THE FEOX-SIO2 BASE SLAG OF THE FLASH

SMELTING FURNACE AND THE TENIENTE CONVERTER AT THE

CHUQUICAMATA SMELTER

J. Font, A. Moyano

Codelco Chile, Chuquicamata Smelter & Division

Av. Once Norte 1291, Villa Exótica Calama, Chile

jfont@codelco.cl

K. Itagaki

Emeritus Professor, Tohoku University

Sendai, Japan

ABSTRACT

It is well known that at a given matte grade the solubility of copper in the slag is

independent of pSO2 in both smelting units of the Chuquicamata smelter, namely the Flash

Smelting Furnace (FSF) and the Teniente Converter (TC), and depend mainly on the

oxygen potential or matte grade. The metallic forms of copper content in the same slags

depend indirectly on the oxygen potential by affecting the slags chemical compositions

which influence the slags viscosities. For instance, in the FeOX-SiO2 slag saturated with

SiO2 which is the base slag for both smelting units, the Fe3O4 content in the FSF slag has

lower values than that of the TC slag, and this difference affects directly the total copper

content in the FeOX-SiO2 base slag.

Thus, as an update contribution to the understanding of oxygen-blowing of copper matte

smelting, the copper solubility between the FeOX-SiO2 base slag and the Cu2S-FeS matte

will be discussed in the Flash Smelting Furnace and the Teniente Converter.

Pyrometallurgy

PY87

IMPROVEMENT TECHNOLOGY OF VANYUKOV SMELTING

Kozhakhmetov S., Kvyatkovskiy S., Abisheva Z.,

Bekenov M.,KamirdinovG., Semenova A.

Center of Earth Sciences, Metallurgy and Ore Beneficiation,

Almaty, Republic of Kazakhstan; kvyatkovskiy55@mail.ru

ABSTRACT

Today pyrometallurgy is the most widely applied industrial practice of copper

recovery in Kazakhstan. More than one half copper in Kasakhstan is produced by

Vanyukov smelting. Ores occurred in Kazakhstandiffer for their varied compositions.

Moreover, high contents of zinc, lead and arsenic sulfides while low contents of iron sulfide

in copper concentrates shall be noted. Reduced concentrations of iron sulfides lead to

shifting heat balance of autogenous smelting process that requires increased extent of

desulfuration which, in its turn, results in changed slag compositions,altered mechanical

propertiesand increased copper losses. One of the ways to solve this problem could be

using additional fuel; other way is increasing oxygen content in blowing gas mix.

We managed to enhance matte and slag removingthrough supply of additional fuel by

special designed burners, oxygen-enriched blowing to 95%, decreasedmagnetite content in

slag and so on.

Pyrometallurgy

PY88

CHUQUICAMATA SMELTER: PRESENT AND FUTURE

J. Ahumada, A. Moyano, J.C. García, P. Durán, and J. Font

Chuquicamata Smelter, CODELCO-Chile Chuquicamata Division

Chuquicamata, Chile

jfont@codelco.cl

ABSTRACT

In the last decade (2003-2013), the Chuquicamata smelter has faced several changes

in the anodic copper production processes (startup/shutdown of the tilting slag cleaning

furnace, starting up of the slag cleaning electric furnace), and in the programmed smelter

plan (environmental law) allowing new operational strategies and major investments.

The extraction methodology change of the Chuquicamata mine from open-pit to

underground, and the new projects of the Codelco North District (Ministro Hales Division,

DMH) have allowed the Chuquicamata smelter to evaluate major investments that will

secure the fulfillment of the environmental regulation in the new scenario of smelting

concentrates and calcine produced in the District.

Instead, during 2012 the Chuquicamata concentrates processing was highly uneven,

especially for their copper, sulfur, and iron contents, and their impurities and gangue

contents which produced a complex scenario for the even operational continuity of the

Chuquicamata smelter.

This work presents in a critical way the Chuquicamata smelter last year experience

and a projection for the future operational scenario lined up with the new environment

regulations when processing unlike concentrates coming from the Chuquicamata mine and

DMH calcine.

Pyrometallurgy

PY89

LATEST DEVELOPMENT OF OXYGEN BOTTOM-BLOWING COPPER

SMELTING TECHNOLOGY

Yan Jie

China ENFI Engineering Corporation

NO. 12 Fuxing Avenue, Haidian Disctrict,

Beijing, China 100038

yanj@enfi.com.cn

ABSTRACT

The Oxygen Bottom-blowing Copper Smelting Technology is a new copper smelting

process developed by China ENFI Engineering Corporation. This paper describes the

characteristics of this technology, summarizes production of the oxygen bottom-blown

smelting furnace, analyzes problems occurring in the production and proposes

countermeasures for coping with these problems. The paper also discusses the future

development orientation of the oxygen bottom-blowing copper smelting technology. By

continuous exploring, development and improvement, advantages and potentiality of the

technology will be brought into full play.

Pyrometallurgy

PY90

DEVELOPMENT OF COPPER/GOLD SULFIDE CONCENTRATES

PYROMETALLURGICAL PROCESS

Li Feng

China ENFI Engineering Corporation

NO. 12 Fuxing Avenue, Haidian Disctrict,

Beijing, China 100038

lif@enfi.com.cn

ABSTRACT

This paper introduces the development orientation of “Matte Making for Au/Ag

Recovery” technology, with the reference to the status-quo of technologies adopted in gold

smelters. It focuses on the characteristics of the different processes for copper smelting and

converting which involves “Matte makting for Au/Ag Recovery”, describes in particular

the development of Continuous Bottom-blowing Cu Smelting Technology, coming to the

conclusion that copper continuous smelting technology has become the trend for Greenfield

or Brownfield copper/gold smelters.

Pyrometallurgy

PY91

INDUSTRIAL TEST DEVELOPMENT OF CONTINUOUS BOTTOM BLOWN

OXYGEN COPPER SMELTING PROCESS

Zhixiang Cui, Zhi Wang, Juntao Zheng, Ruimin Li

Dongying Fangyuan Nonferrous Metals Co., Ltd,

No 99 of Liuyanghe Road, Economic Developments Zone,

Dongying City, Shandong Province, China

wangzhi7612126@sohu.com

ABSTRACT

The paper describes the continuous bottom blown oxygen Copper smelting process.

Based on this process, tests were carried out processing both cool and steamed high grade

matte with different processes to research the effects of different devices, slag type,

blowing intensity, oxygen level and blowing smelting end to the indexes of converting

blister; also the lances arrangement and life and the refractory lining validity was

researched. The series of tests empowered us to develop the continuous Copper smelting

process and devices and finally realized producing anode Copper directly with continuous

converting reactor.

Pyrometallurgy

PY92

NEW DEVELOPMENT OF BOTTOM BLOWN OXYGEN SMELTING

TECHNOLOGY IN DONGYING FANGYUAN

NONFERROUS METALS CO. LTD

Zhixiang Cui, Zhi Wang, Ruimin Li

Dongying Fangyuan Nonferrous Metals Co., Ltd,

No 99 of Liuyanghe Road, Economic Developments Zone,

Dongying City, Shandong Province, China

wangzhi7612126@sohu.com

ABSTRACT

Bottom blown oxygen smelting process was successfully industrialized in

Dongying Fangyuan Nonferrous Metals Co., Ltd. in 2008. By continuous technical

innovation and process upgrade during the last 4 years, new breakthroughs have been

achieved one after another and the energy consumption has been lower and lower.

Even though, we can guarantee sound smelting effect, i.e. the matte concentration is

over 73% while the copper content in slag is 2-3%. Meanwhile we have developed a

series of new technologies respecting to it including processing high impurity anode

plate, processing the fume dust in heavy metals smelting, waste acid processing

technology and comprehensive recovery technology of the value elements.

Environmental copper smelting and low-carbon production have been finally realized.

Pyrometallurgy

PY93

COPPER SMELTING FLUE DUST CHARACTERIZATION AS A KEY ISSUE IN

THEIR TREATMENT

Eduardo Balladares

Departamento Ingeniería Metalúrgica

Universidad de Concepción

ABSTRACT

This presentation discusses the importance of a proper characterization of the

copper smelting flue dust produced in a copper smelter in view of the best process

definition or process design in the treatment of these materials, both for efficient removal of

contaminants and economic recovery of valuable elements.

To illustrate the problem, some cases of application together with the analytical

tools employed are shown. Similarly, the need to implement methodological tools that

systematize the flue dust characterization from nonferrous industry is discussed. Relevant

cases are those related to the characterization of synthetic phases, which shows, by one

side, very particular chemical-mineralogical properties and, secondly, significantly

different metallurgical behaviour of natural phases of the same chemical composition.

Pyrometallurgy

PY95

DESIGN OF A HEAT RECOVERY COOLING CHAMBER SYSTEM FOR

COPPER SMELTERS

L.A. Campos, D.E. Wimmer and F.J. González

Coprim Ingeniería S.A., Chile

ABSTRACT

According to growing need to reduce operating costs and minimize the use of

limited resources as water, Coprim has designed a heat recovery cooling chamber, which

seeks reuse or replace the existing radiative or evaporative cooling chambers and transform

them into equipment that is capable of capturing and transferring the absorbed heat, without

altering the foot-print of these.

The design is based on the modification of existing cooling chambers inserting into

them a heat exchanger composed internally by cooled panels with thermal oil which

operates in a closed circuit. It is pumped from a storage tank to a power generating plant.

The chamber considers a refrigerated pre-chamber, located with the purpose of decrease the

dust burden incoming into the heat transfer zone (panels). Panels are located parallel to

each other inside the chamber, where the flow of metallurgical gas is cooled. The thermal

oil flows counter-flow with the gas flow, increasing the heat transfer efficiency. The design

allows an easy maintenance and replacement of panels.

The metallurgical gas has thermal energy which can be transformed into electric

power with at least 15% of efficiency. This design minimize the investment level and

implementation time.

Pyrometallurgy

PY96

COMPARATIVE ANALYSIS OF PYROMETALLURGICAL METHODS

FOR PROCESSING OF SULFIDE COPPER CONCENTRATION

FROM UDOCAN DEPOSIT

L.B. Tsymbulov, A.B. Portov, I.V. Tereshchenko and L.Sh. Tsemekhman

LLC “Gipronickel Institute”, OJSC “MMC “Norilsk Nickel”

11 Grazhdansky Prospect, Saint-Petersburg, 195220, Russia

Lbcym@nickel.spb.ru

D.A. Lapshin

LLC “Baikalskaya Mining Company”

28 Rublevskoe Highway, Moscow, 121609, Russia

ABSTARCT

In the nearest future development of Udokan deposit – on of the world largest

deposits of complex oxide-sulfide copper ores, located in the Chita oblast of Russia - will

be started. The characteristic feature of copper sulfide concentrates, produced after ore

concentration, has low Fe content in the concentrate (3-4 wt.%) with high grade of silicon

oxide (35-45 wt.%). In this work two methods of pyrometallurgical processing are studied:

- smelting with blister copper production in a two-zone Vaniukov’s furnace;

- concentrate roasting in a fluidized bed furnace followed by cinder reduction

smelting in a direct current furnace.

There are presented results of laboratory scale and enhanced laboratory

investigations. Comparative analysis of the proposed technological flow-sheets are

performed, their merits and demerits are discussed.

Pyrometallurgy

PY97

OPTIMAL SLAG COMPOSITION FOR PROCESSING OF COPPER NICKEL

MATTES AND CONCENTRATES IN A VANIUKOV TWO-ZONE CONVERTER

THAT PRODUCES BLISTER COPPER

L.B. Tsymbulov and S.P. Pigarev

LLC “Gipronickel Institute”, OJSC “MMC “Norilsk Nickel”

11 Grazhdansky Prospect, Saint-Petersburg, 195220, Russia

Lbcym@nickel.spb.ru

F. Kongoli, I. McBow

FLOGEN Technologies Inc.

1255 Laird Blvd., Ste.388

Mont-Royal, Quebec Canada H3P 2T1

E.N. Selivanov, V.M. Chumarev

Institute of Metallurgy UrO RAN

101 Amundsena Street, Ekaterinburg, 620016, Russia

ABSTARCT

The Gipronickel Institute in cooperation with the Canadian company “Flogen

Technologies Inc.” and the Ural Institute of Metallurgy has developed a new technology for

processing of copper nickel mattes and concentrates in a Vaniukov two-zone converter that

produces blister copper. The slags formed in this process lies within a multi-component

Cu2O-NiO-FeOx-SiO2-CaO-Al2O3 system. One of the most important technological tasks in

a new pyrometallurgical process development is the optimal slag composition choice. The

work presents the optimal slag composition for this process based on the study of their

structure and characteristic features.

Pyrometallurgy

PY98

ARSENIC REMOVAL FROM BLISTER COPPER USING MOLTEN SODIUM

AND CALCIUM SULPHATES

P.Coursol and N.Stubina

Barrick Gold Corporation

161 Bay Street suite 3700

Toronto, Ontario, Canada, M5J 2S1

pcoursol@barrick.com

P.J.Mackey

Mackey Technology Inc.,

Kirkland, QC, Canada, H9J 1P7

M. Zamalloa

Koniambo Nickel SA,

New Caledonia

ABSTRACT

New mineral deposits found nowadays are generally of lower grade and of

increasing complexity compared to those seen in earlier times. In the case of copper,

arsenic is one important impurity element often associated with the newer, complex copper

ores. Some 10 years ago, the present authors were involved in the development of a novel

technology using molten calcium/sodium sulfate salts for the removal of arsenic from

blister copper. Using appropriate flux proportions, more than 90% arsenic elimination

could be obtained while both minimizing slag production and the copper level in the

refining slag. In light of renewed interest in the treatment of copper concentrates containing

arsenic, this paper re-examines this process.

Advanced thermodynamic models are used to generate process maps showing the

impact of slag composition and oxygen content in copper on the equilibrium level of

arsenic in the fire-refined copper. The modeling results are also compared with available

published data showing that the process operates under conditions having extremely rapid

reaction kinetics. Finally, limitations for utilizing this type of salt in modern smelters

including the refining furnace heat balance, reagent cost and availability are discussed.

With increasing arsenic content in copper concentrates and with stricter environmental

regulations in the copper industry, this process is considered to be superior to conventional

fire refining practices using soda for arsenic removal.

Pyrometallurgy

PY99

ON THE POSSIBILITY OF USING HIGH OXYGEN ENRICHMENT IN

TENIENTE CONVERTERS

M. Rosales-Vera, O. Saavedra, H. Jara, R. Fuentes

Instituto De Innovacion En Mineria Y Metalurgia- Im2

A. Moyano, J. Font, R. Mackay

Codelco Chile

ABSTRACT

The increasing competitivity and specific capacity of the Teniente Converter

Reactor is a strategic issue for the future competitivity of the Codelco-Chile smelters.

Due to this, several conceptual studies were developed to phenomenologically

establish the factors governing and limitating the reactor smelting capacity.

The use of high levels of oxygen enrichment in the air flow through tuyeres in the

Teniente Converter, historically was associated with refactary wear in the tuyeres line. In

this paper we analyze theoretically, the possibility of using air blast with high levels of

oxygen enrichment. The paper shows that high levels of oxygen enrichment not necessarily

implies damage to the refractory and tuyeres line and with a good control of the bath

temperature in the reactor, the oxygen enrichment can be increased over the usual levels.

Pyrometallurgy

PY101

COPPER LOSSES CONTROL IN FLASH SMELTING SLAG AT

CHUQUICAMATA SMELTER

G. Wastavino, C. Pizarro

instituto de innovacion en mineria y metalurgia- im2

A.Moyano, J. Font

codelco norte

ABSTRACT

In order to accomplish the concentrate composition changes which are being

feeding to the smelting unit, specially the Flash furnace, the Chuquicamata Smelter has

during 2010 carried out a campaign of industrial tests to process this eventually new

concentrates, which are featured by its low calorific value (low pyrite content) and high

level of gangue material.

The aim of the industrial test was to evaluate the use of a fayalite-type slag shifting

slightly to the olivine-type slag. The traditional use of the fayalite-type slag to treat this

type of concentrates normally generates a sharp increase in the slag viscosity which

increases the copper losses, allow foaming phenomena and other kinds of operational

nature problems.

The slight addition of limestone flux along the silica flux increases the CaO content

in the slag in the range of 2.5 to 5%, changing the physical properties of the slag and allows

the efficiently smelting of this kind of concentrates, which is featured mainly by its low

pyrite content of 18% against the traditional levels of 27% (FeS2) and by its high gangue

material content of 14% against the standard value of 9%. Thus, the industrial tests results

shows an average copper content in the slag of less than 1.5% for a CaO content of 2.5%.

Additionally, for a CaO content of about 3%, the slag showed a significant decrement in the

distribution of the arsenic toward the matte phase, and also lower copper losses at the matte

grade of 62% Cu. Therefore, for treating concentrates with low pyrite content and high

gangue levels, the use of this olivine type of slag has been evaluated to be an interesting

operational option.

Pyrometallurgy

PY103

CONTROLLING SO3 FORMATION IN THE OFF-GASES PROCESS FROM THE

ISASMELTTM

FURNACE AT SOUTHERN PERU ILO SMELTER

Enrique Herrera and Leopoldo Mariscal

southern peru

Fundición Ilo, Punta Tablones S/N

Ilo, Peru

eherrera@southernperu.com.pe / lmariscal@southernperu.com.pe

ABSTRACT

The Ilo Copper Smelter operates from 2007 mainly with an ISASMELTTM

furnace as

a single smelting unit (1,200,000 tpy of copper concentrates), four PS converters (two

blowing), and two acid plants.

Excessive sulfur trioxide (SO3) concentration in the off-gas process of the smelting

furnace generates corrosion problems in the subsequent gas line and affects the weak acid

treatment of the acid plants. This paper describes the modifications and improvements

carried out at the controlling SO3 formation.

Pyrometallurgy

PY104

SERVICE LIVE INCREASE OF TSL LANCES, USING IONIC LIQUID COOLING

TECHNOLOGY

Stefan Konetschnik, Andreas Filzwieser and Iris Filzwieser

METTOP GmbH, Peter-Tunner-Strasse 4, 8700 Leoben, Austria

ABSTRACT

TSL reactors are state-of-the-art vessels for the primary and secondary nonferrous

industry. Although the efficiency of smelting and metallurgical reactions is excellent in

these furnaces, the uptime is rather low due to the necessity of replacing the consumed

lance tip regularly.

Basic of the presented approach is a modified and cooled lance tip. The cooling

intensity is set in order to form a so called freeze lining, much more distinctive than in the

case of conventional lances. However, a water cooled lance would result in an

insurmountable safety risk as a leakage and breakthrough cannot be completely excluded.

A combination with METTOP’s “Ionic Liquid Cooling Technology” (ILTEC) leads

to a revolutionary solution for the metallurgical industry: The possibility of cooling TSL

lance tips without the risk of introducing water below bath level. The cooling medium will

not react with liquid metal or slag – it decomposes above a certain temperature under

formation of gaseous components.

Pyrometallurgy

PY105

AN UPDATE ON KENNECOTT UTAH COPPER’S USE OF PRAXAIR’S

COHERENT JET TECHNOLOGY IN ANODE REFINING – DEVELOPMENTS

SINCE 2010

Arsenio (Jun) Enriquez, Colin Nexhip, David Krippner, Kyle Wright, Rio Tinto

Kennecott Utah Copper LLC

12000 West 2100 South

Magna, UT, USA

Adrian Deneys, Yi Ma, Steve Manley

Praxair, Inc.

2430 Camino Ramon

San Ramon, CA, USA

ABSTRACT

Rio Tinto through its subsidiary Kennecott Utah Copper (KUC) installed Praxair’s

Coherent Jet (CoJet®) system in 2007 to increase scrap melting in one Anode Furnace.

Based on positive results, the CoJet system was further integrated in both Anode Furnaces

early 2013 with the installation of a diverter valve system. A temperature measurement

system is under development to provide better copper temperature control to maintain

furnace integrity. Two additional developments on lance and jet performance were also

investigated. Further research and development initiatives using the CoJet technology in the

Flash Smelting process for cleaning slag are also underway. This paper discusses the

attributes of the CoJet system in the Anode Furnace process and other future developments.

Pyrometallurgy

PY106

AUTOMATIC SCHEDULING OF ALTONORTE OPERATIONS

USING GREEDY ALGORITHMS

Alessandro Navarra

Universidad Católica del Norte

0610 Angamos, Antofagasta, Chile

anavarra@ucn.cl

Oscar Mendoza

Altonorte Smelter, Xstrata Copper

Panamericana Norte Km 1348, Antofagasta, Chile

omendoza@xstratacopper.com

ABSTRACT

Algorithms have been implemented at the Altonorte Smelter (Northern Chile), to

automatically schedule daily production. The resulting schedules respect all of the

operational constraints, including maintenance plans and furnace productivity, as well as

the availability of converters, offgas treatment, fire refining and casting. The algorithms

are classified formally as greedy, following the terminology from computer science.

Schedule automation is the first step toward advanced optimization techniques.

Pyrometallurgy

Copper 2013 Novel Methodology for Quantifying Fugitive SO2 Emissions 1 of 1

PY134

A NOVEL METHOD FOR QUANTIFYING SMELTER SO2 FUGITIVE

EMISSIONS USING AN OPEN PATH FOURIER TRANSFORMS INFRARED

(FTIR) ANALYSER

Gert Erasmus, Arne Weissenberger

Hatch (Pty) Limited

Johannesburg, South Africa

ABSTRACT

Hatch developed a novel in-situ sampling method for measuring SO2 fugitive

emissions from “uncontrolled” buoyant plumes of varying sizes, concentrations and

flowrates. The test procedure uses an Open Path Fourier Transforms Infrared (FTIR)

analyser which is able to “count” SO2 molecules along its reflected beam path, which

therefore allows calculation of average SO2 concentration across the emission plumes.

Continuous plume videography was used in conjunction to record gas volumetric

flow with time. The data was correlated to develop actual continuous SO2 fugitive

emission mass flowrates for specific smelter events and operations. As a result,

quantitative emission factors were developed for furnace and converter operations which

Hatch now applies to predict fugitive emissions generated at similar smelting facilities.

Pyrometallurgy

PY135

OBSERVATIONS ON THE REDUCTIVE PYRO DE-ARSENIFICATION OF

ENARGITE.

Thomas Zabev

Process Research ORTECH

Gus Van Weert

Oretome Limited

Pascal Coursol

Barrick Gold

ABSTRACT

This paper discusses the removal of sulphur and arsenic directly from enargite

bearing concentrates by pyro-decomposition in a variety of gaseous atmospheres, including

vacuum, to yield a low volume of disposable arsenic/ sulphur mixture. Experimental results

are presented for various process routes.

Treatment in a N2 gas flushed reactor of a 4:1 enargite/ metallic iron charge at 700 0C consistently transformed enargite into bornite and chalcopyrite with less than 0.1% As

in the product.

Pyrometallurgy

PY136

FORTY YEARS OF OPERATION OF THE NORANDA REACTOR PROCESS

Y. Prévost, C. Levac

Xstrata Copper, Horne Smelter, Rouyn-Noranda, Québec, Canada

prevosty@xstratacopper.ca

ABSTRACT

The Noranda Continuous Smelting Process at Xstrata’s Horne Smelter was

commissioned in March 1973. Since then, it has evolved to follow the trends of feed

complexity, material recycling and international competition.

Process control was improved, new auxiliary equipments were tested, and blowing

enrichment was increased. This paper presents an overview of the main Noranda Reactor

improvements that have occurred since its commissioning and the effect they had on the

capacity and control of the vessel.

Pyrometallurgy

PY137

PHENOMENOLOGY OF COPPER MATTE CONTINUOUS CONVERTING IN A

PACKED BED

A.Warczok, G. Riveros and L. Voisin

Universidad De Chile

Departamento Ingenieria de Minas

Av. Tupper 2069

Santiago, Chile

awarczok@bell.net

ABSTRACT

The new technology of continuous copper converting, developed by Universidad de

Chile with ENAMI, generates a series of questions about the mechanisms of a liquid copper

matte oxidation, formation of the slag, affecting the rate and efficiency of converting

process.

The CFD, mass and heat transfer modeling together with detailed analysis of

phenomena taking place at the copper matte/gas , matte/slag , slag/gas and blister

copper/gas interfaces allowed for determination of key factors affecting the rate of

oxidation. The process requires specific self-melting fluxes being able to infiltrate the

porosity of ceramic, packed bed and dissolve iron oxides as the product of oxidation,

forming the slag, which properties permit for the flow inside the bed, separation from

blister copper and continuous tapping out.

It was found that the rate of sulphides oxidation is controlled by mass transfer and

formation of iron oxide film separating sulphides and oxygen containing gas phase.

Therefore, slag formation affects the rate of iron sulphide oxidation

Pyrometallurgy

PY138

A MASS TRANSFER MODEL FOR MOLTEN COPPER DEOXIDATION

L. Díaz, F. Reyes and A. Ingalls

Depto. de Ingeniería Química Metalúrgica

Facultad de Química, Edificio D, UNAM

Circuito de la Investigación Científica s/n

México,04510 D.F., México

A. Almaraz and G. Plascencia

CIITEC – IPN

Cerrada Cecati s/n

México, 02250 D.F.,México

g.plascencia@utoronto.ca

ABSTRACT

The final refining step in copper making is fire refining. Fire refining consists of

several stages, but the most important are oxidation and reduction. These operations results

from the interaction between an injected gas and the melt. In this paper, we present a mass

transfer model that represents the reduction stage.

It has been found that two mechanisms control the deoxidation of copper: i)

Transport of the reducing gas from the gas bubbles towards the melt/bubble interface and

ii) Transport of dissolved oxygen from the melt towards the melt/bubble interface. The

former occurs in the early stages of deoxidation, while the latter controls towards the end of

the reduction of copper. Fluid flow of the gases in the refining furnace has a strong effect

on the dissolved oxygen transport.

Pyrometallurgy

PY139

DUST EXPLOSIONS AT THE CHAGRES SMELTER DUE TO SPONTANEOUS

SELF-HEATING OF DRIED COPPER CONCENTRATES

M. Gous, B. Martinich and P.A. Reyes

ANGLO AMERICAN SUR

Chagres Smelter

Av. Pedro de Valdivia 291

Santiago, Chile CP 7500524

mia.gous@angloamerican.com

R.A. Parra

Metallurgical Department

University of Concepción

Edmundo Larenas 285

Concepción, Chile

ABSTRACT

During the latter part of 2012 and the early months of 2013, the Chagres Copper

Smelter has experienced several incidents, varying in intensity, of self-heating of the dried

concentrate feed in the flash furnace feed bin. These events lead to small fires in the feed

transport, air circulation and concentrate storage systems and in the worst cases, dust

explosion incidents within the dry concentrate feed bin.

Self-heating is a term that defines spontaneous heating of sulphide concentrates under

certain moisture and oxygen conditions. No external heat source is required. These types

of events are not uncommon to copper smelters, although it was the first series of events of

this magnitude experienced at Chagres in more than 50 years of operation.

An investigation was launched to identify which of the concentrate characteristics had

substantially changed to activate the self-heating reaction and special conditions that can

promote explosions. This investigation has allowed the identification of the required

remedial actions to ensure safe, continued high performance operation of the smelter.

Pyrometallurgy

PY140

APPLICATION OF MPE MODEL TO DIRECT-TO-BLISTER FLASH SMELTING

AND DEPORTMENT OF MINOR ELEMENTS

Chunlin Chen, Ling Zhang

CSIRO Process Science & Engineering

Sharif Jahanshahi

CSIRO Minerals Down Under Flagship

Box 312, Clayton South, Victoria, 3169, Australia

Chunlin.Chen@csiro.au

ABSTRACT

Copper losses in slag vary from process to process during pyrometallurgical

production of copper, depending on the slag chemistry and operating conditions. Minimize

copper losses is one of major focuses in considering the optimal operating condition for

copper smelting/converting processes. At the same time, the deportment of minor elements

between various phases during copper smelting is of great interest by the smelters. This

interest is driven by the gradual depletion of high-grade ore with low levels of minor

elements such as arsenic, the requirements to manage the emission of toxic elements to the

biosphere, and a growing need to produce high-purity saleable products.

The Multi-Phase Equilibrium (MPE) is a thermodynamic package developed by

CSIRO for simulating reactions between phases in multi-component and multi-phase

systems. Over the years the capability of the MPE model has been extended to cover the

behavior of a large number of elements in high temperature system. The sulphide smelting

module of the MPE, which covers the minor elements such as As, Bi, Sb, Pb, Se, Te, Sn,

Co and Zn, is capable of modeling the deportment of major and minor elements between

various phases during the smelting of complex ores/concentrates.

In the present paper validation of the MPE model and databases against published

experimental data on multi-component and multiphase systems are presented. Results

obtained from application of the model in predicting the copper losses in slag, direct

recovery of copper to blister in direct-to-blister smelting process, as well as the arsenic

deportment between matte, slag and gas phases of various commercial copper smelting

processes will be presented. These results should allow process metallurgists in developing

practices for improved management of copper losses and minor elements during smelting

of feed materials.

Pyrometallurgy

PY141

CHARACTERIZATION METHODOLOGY FOR CU-DROPLET LOSSES IN

SLAGS

Evelien De Wilde, Stephanie Vervynckt, Mieke Campforts, Kim Vanmeensel, Nele

Moelans, Kim Verbeken

ABSTRACT

In order to have an efficient Cu-smelting process, metal losses in the slag need to be

minimized. A major cause of metal losses is the entrainment of metal droplets in the slag.

One important factor for mechanically entrained metal droplets in slags is their attachment

to solid spinel particles, which are also present in the slag phase. Consequently, these

particles hinder the settling of the metal droplets. In order to improve phase separation it is

important to identify the fundamental mechanisms governing this attachment.

Two complementary methodologies have been developed to study the tendency of

metal droplets to attach to solid particles. In one methodology, the interaction between Cu-

alloys and spinel particles is studied by high temperature contact angle measurements. In

the other, the entrainment is studied using a simplified synthetic PbO based slag (PbO-

CaO-SiO2-Cu2O-FeO-ZnO) containing solid spinel particles.

Pyrometallurgy

PY142

COPPER LOSSES CONTROL IN FLASH SMELTING SLAG AT

CHUQUICAMATA SMELTER

G. Wastavino, C. Pizarro

Instituto De Innovacion En Mineria Y Metalurgia- Im2

A. Moyano, J. Font

Codelco Norte

ABSTRACT

In order to accomplish the concentrate composition changes which are being

feeding to the smelting unit, specially the Flash furnace, the Chuquicamata Smelter has

during 2010 carried out a campaign of industrial tests to process this eventually new

concentrates, which are featured by its low calorific value (low pyrite content) and high

level of gangue material. The aim of the industrial test was to evaluate the use of a fayalite-

type slag shifting slightly to the olivine-type slag. The traditional use of the fayalite-type

slag to treat this type of concentrates normally generates a sharp increase in the slag

viscosity which increases the copper losses, allow foaming phenomena and other kinds of

operational nature problems.

The slight addition of limestone flux along the silica flux increases the CaO content

in the slag in the range of 2.5 to 5%, changing the physical properties of the slag and allows

the efficiently smelting of this kind of concentrates, which is featured mainly by its low

pyrite content of 18% against the traditional levels of 27% (FeS2) and by its high gangue

material content of 14% against the standard value of 9%. Thus, the industrial tests results

shows an average copper content in the slag of less than 1.5% for a CaO content of 2.5%.

Additionally, for a CaO content of about 3%, the slag showed a significant decrement in the

distribution of the arsenic toward the matte phase, and also lower copper losses at the matte

grade of 62% Cu. Therefore, for treating concentrates with low pyrite content and high

gangue levels, the use of this olivine type of slag has been evaluated to be an interesting

operational option.

Pyrometallurgy

PY143

CONTROL STRATEGY FOR REDUCING COPPER LOSS FROM MITSUBISHI

PROCESS

Bhavin Desai and Biswajit Basu

Aditya Birla Science & Technology Company Ltd.

Plot No. 1 & 1-A/1, MIDC Taloja, Taluka Panvel, Dist. Raigad 410208

Maharashtra, India

bhavin.desai@adityabirla.com

Dilip Gaur, Kaushik Vakil and Anil Singh

Hindalco Birla Copper

Po: Dahej, District Bharuch – 392130

Gujarat, India.

ABSTRACT

The Mitsubishi process at Hindalco Birla Copper has been in operation now for

more than 5 years and this mature process has attained a high level of performance. Owing

to the degradation in concentrate grade, the copper loss from the discarded slag was above

the upper specification limit. From an industry perspective there is an ongoing need to

adequately describe the phase chemistry of slag systems in order to optimize process

performance and thus minimize copper loss.

The selection of the optimum process conditions in this work has been greatly

assisted by the use of a chemical thermodynamic model of the system. A new control

strategy with respect to the determination of optimum slag chemistry and temperature has

been developed to minimize the copper loss to below the upper specification limit

consistently. The strategy is based on thermodynamic modeling using phase diagram

concept and concentrate mineralogy. A new control strategy comprises determining the slag

liquidus and slag viscosity from the known operating parameters such as slag chemistry,

temperature and oxygen potential, and providing a safe operating window with respect to

the slag chemistry and the temperature. The new strategy along with improved plant

practice has resulted in copper loss in slag to below upper specification limit.

Pyrometallurgy

PY144

IN PURSUIT OF IMPROVED FLASH-SMELTING BURNER PERFORMANCE

M. U. Jastrzebski, A. Lamoureux, T. Gonzales, R. Veenstra

Hatch

2800 Speakman Dr.

Mississauga, Canada L5K 2R7

mjastrzebski@hatch.ca

ABSTRACT

Inefficient combustion has been shown to be the principal cause of a number of

operational problems in Outokumpu flash smelting. A considerable volume of

computational fluid dynamics (CFD) and physical study results have been published on

particular problems; however, more general investigations of the behavior of the flash

smelting process have been rare. A review of a number of modeling studies and plant-

driven practical burner improvement studies published to date has identified important

parameters that affect performance.

These have been further investigated using a “burner geometry independent” CFD

model of the flash-smelting process taking place in a hypothetical reaction shaft. The study

confirms that high oxygen enrichment and velocity control are strong levers in controlling

dust rates and combustion efficiency, while burner diameter and combustion gas / feed

injection angle are aspects of design with a strong impact on performance.

Pyrometallurgy

PY145

APPLICATION OF ROTATION-SUSPENSION SMELTING PROCESS AND

PULSE CYCLONE BURNER IN XIANGGUANG COPPER

Songlin Zhou

Vice President

Xiangguang Copper Co., Ltd

No.1 Xiangguang Road

Shifo Town, Yanggu County, 252327, China

ABSTRACT

This paper introduces the principle of rotation-suspension copper smelting process,

feature of pulse cyclone burner and their production application. Professor Songlin Zhou of

Xiangguang Copper puts forward a reaction mechanism of particle collision for smelting

intensification and develops rotation-suspension copper smelting process and pulse cyclone

burner on the basis of this mechanism, and has successfully applied to smelting and

converting furnaces in Xiangguang Copper.

Four years practice indicates: pulse cyclone burner has some advantages-big

production capacity, complete reaction, stable furnace running, high availability, low flue

dust, high thermal load, less wear of reaction shaft wall and etc. Thanks to these

advantages, maximum feed volume is 400t/h, availability rate is 98%, flue dust rate is 4%

and thermal load is 3000 MJ/m3.h.

Pyrometallurgy

PY146

APPLICATION OF SPECIALIZED NON-DESTRUCTIVE TESTING

(NDT) FOR OPERATING COPPER PROCESS VESSELS

Afshin Sadri, Wai Lai Ying and Pawel Gebski

ABSTRACT

Monitoring refractory condition in process vessels allows plant owners and

operators to proactively identify problem areas in the linings. Short and long term

maintenance planning can then be implemented to prolong vessel campaign life and

minimize the possibility of catastrophic failures such as molten metal run-outs. The

refractory lining of copper process vessels such as flash and slag cleaning furnaces,

reactors, converters, and absorption acid towers is known to ultimately fail, resulting in a

shorter campaign life. Refractory wear, refractory hydration, refractory lining failure, and

hearth lifting are well known failure mechanisms of process vessels.

In this paper specialized Non-Destructive Testing (NDT) techniques available for

monitoring operating copper process vessels will be discussed. We will demonstrate how

the application of such techniques has been used to identify deterioration, ultimately

allowing plant owners and operators to prolong the service life of process vessels through

proactive maintenance planning and action.

Pyrometallurgy

PY147

DEVELOPMENT PLAN CALETONES SMELTER

G. Richter P.

General Manager - Codelco-Chile

C. Carrasco O.

Smelter Engineering Superintendent - Codelco-Chile

ABSTRACT

With the aim of improving the environmental standards and competitiveness of

Caletones Smelters, been conceptualized in a development plan that considers increase

melting concentrate capacity from 1,4 Mt to 1,75 Mt, and increase sulfur and arsenic

capture.

This Plan includes three phases; The 1er

Optimization to 1,45 Mt/y, 2do

Increase sulfur

and arsenic capture, and 3er

Increase melting concentrate capacity to 1,75 Mt/y. Major

projects to be implemented are:

New casting wheel Twin M-16

Increase conversion white metal

Replacement slag cleaning process for flotation plant

Reduction emission actual acid plant

New smelting reactor

New hood reactors and handling gas modification

New acid plant

The main results are projected:

Pyrometallurgy

Caletones Smelter Scenarios

Indicators Units Base Optimization Development

Smelter Capacities Kta 1.400 1.450 1.750

Sulfur / Arsenic Capture % 94 / 91 96,5 / 96 96,5 / 96

Metallurgical Recovery % 97,6 98,1 98,1

Operation Cost US$c/lb 27,0 26,0 22,9

Productivities t/h-y 612 612 754

This paper summarizes the projects to be undertaken, constructive and interference.

Pyrometallurgy

PY148

THE SAVARD-LEE SHROUDED INJECTOR: A REVIEW OF ITS ADOPTION

AND ADAPTATION FROM FERROUS TO NON-FERROUS

PYROMETALLURGY

J.P. Kapusta

BBA Inc.

630, René-Lévesque Blvd. West, Suite 1900

Montréal, Québec, Canada H3B 4V5

Joel.Kapusta@bba.ca

Robert G.H. Lee

Air Liquide Canada (Retired)

Calgary, Alberta, Canada

ABSTRACT

Pyrometallurgical processes for iron and base metals present major similarities since

they occur at high temperatures and in molten state. Pyrometallurgists, therefore, have long

believed that some technologies from ferrous metallurgy could be beneficially adapted (and

transferred) to non-ferrous metallurgy, and vice versa. The Savard-Lee shrouded injector is

one such technology. Developed for steelmaking, the concept has inspired non-ferrous

pyrometallurgists for decades and is now receiving renewed interest in light of recent

commercial successes in high intensity smelting, particularly in Asia. This paper provides a

review of key non-ferrous pyrometallurgical processes that have innovatively adapted and

implemented the shrouded injector concept. Such processes include bath smelting of lead

and copper (QSL, SKS), bath converting of copper and nickel (Hoboken and SMC with

ALSI Technology, SKS), copper pyro-refining (O2/N2/H2 injectors) and lead-silver

cupellation (BBOC). The authors highlight how the injector was adapted from its original

steel refining design for oxygen bottom metallurgy (OBM) into new designs for non-

ferrous applications. The authors also offer their views on the future of bath smelting and

converting with high oxygen submerged injection, especially at times when energy

conservation and efficiency, lower quality concentrate, and environmental footprint

awareness are at the forefront of the industry preoccupations.

Pyrometallurgy

PY149

DEBOTTLENECKING AND OPTIMISATION OF COPPER SMELTERS

LEVERAGING SIMULATION

A P Campbell

WorleyParsons

PO Box 7637

Cloisters Square Perth WA 6850 Australia

andrew.campbell@worleyparsons.com

M Reed

WorleyParsons

Level 12 115 Grenfell Street

Adelaide SA 5000 Australia

michael.meed@WorleyParsons.com

A E M Warner

WorleyParsons

2645 Skymark Avenue

Mississauga, Ontario, L4W 4H2 Canada

tony.warner@WorleyParsons.com

ABSTRACT

WorleyParsons has used Discrete Event Simulation (DES) methods in conjunction

with more traditional process models to assess the performance of copper smelting

operations. The DES model allows for a more complete and realistic picture of an operation

to be developed based on the plant capacities and accounting for breakdowns and

shutdowns. This paper outlines methods used to identify the opportunities to de-constrain

existing operations and demonstrate that other constraints will not impact the overall

improvement to the production. Examples of aisle and typical smelting operations are

covered.