AU632603B2 - Nickel-copper matte converters employing nitrogen enriched blast - Google Patents

Description

1_ C Ait97 S F Ref: 135639 FORM COMMONWEALTH OF AUSTRALIA PATENTS ACT 1952 COMPLETE SPECIFICATION

(ORIGINAL)

FOR OFFICE USE: Class Int Class Complete Specification Lodged: Accepted: Published: Priority: Related Art: 0 I Name and Address of Applicant: Address for Service: Inco Limited Royal Trust Tower Toronto-Dominion Centre Toronto Ontario M5K 1N4

CANADA

Spruson Ferguson, Patent Attorneys Level 33 St Martins Tower, 31 Market Street Sydney, New South Wales, 2000, Australia Complete Specification for the invention entitled: Nickel-Copper Blast Matte Converters Employing Nitrogen Enriched The following statement is a full description of this invention, including the best method of performing it known to me/us 5845/5 Il\lJI I U I 7T -1 PC-3137 NICKEL-COPPER MATTE CONVERTERS EMPLOYING NITROGEN ENRICHED BLAST ABSTRACT OF THE DISCLOSURE A process for utilizing nitrogen enriched blasts for control of oxidation and cooling of sulfide derived nickel-copper converter matte. Bessemer quality matte produced and cooled minimizing mush formation and improving suusequent utility.

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;0 rss «t I -1R- PC-3137 6 ti 0 0 NICKEL-COPPER MATTE CONVERTERS EMPLOYING NITROGEN ENRICHED BLAST TECHNICAL FIELD 0 0* The instant invention relates to the pyrometallurgical production of refined nickel-copper matte from sulfide ores in general and, more particularly, to a converter process using 00 0a t nitrogen, air, oxygen and combinations thereof. The introduction of nitrogen or nitrogen/oxygen containing gas controls the oxidation of the resultant matte and assists in cooling it. Debilitating mush 10 formation is substantially reduced resulting in more efficient converter operations.

BACKGROUND ART Nickel-copper Bessemer matte is typically produced by converting molten matte from a primary smelting furnace in Peirce Smith converters which employ blowing of air or air/oxygen mixtures into the bath via tuyeres. The Peirce Smith converter is the most PC-3137 common type of converter used for this application and consists of a horizontally oriented cylinder which has a hooded opening at the top and is rotatable through an arc of about 180 degrees. The plurality of tuyeres are located below the normal working level of the molten matte when in the blowing position and the tuyeres are raised above the bath for pouring and holding.

The feed to the converters usually consists of a homogeneous molten matte including Ni 3

S

2 Cu 2 S, FeS, and small quantities of oxygen, precious metals and other elements. Much of the rock and iron that were in the original metal bearing concentrate were eliminated in the upstream furnacing operation.

The objective of the conversion process is to oxidize the FeS in the matte to form iron oxides, liberating sulfur dioxide and 0000leaving matte comprising nickel and copper sulfides with small but 00*9 0* 15 variable amounts of cobalt, precious metals and dissolved oxygen.

o 0 This is accomplished by blowing an oxygen containing gas (air, oxygen o o enriched air or oxygen) into the matte through the tuyeres. The oO0 oxygen combines with the iron and sulfur to form iron oxide and Ole a sulfur dioxide. The sulfur dioxide passes off as a gas and is subsequently treated to prevent fugitive emissions. The iron oxide unites with added silica flux to form an iron silicate slag that °00° floats on top of the matte now richer in nickel and copper and much *444 *440 lower in iron. The oxidation process is exothermic and the heat *op generated is usually sufficient to cause the operation to be 25 self-sustaining.

After removal of substantially all of the iron by blowing and skimming of the slag, the resulting matte is generally cooled, cast and further treated for recovery of valuable base and precious all.

o metals. Upon cooling, the copper and nickel in the matte form copper 30 sulfide (Cu 2 nickel sulfide (Ni3S2), and a metallic fraction containing small amounts of dissolved sulfur.

The desired composition of the Bessemer mattq product is highly dependent upon the requirements of the downstream processing.

Important parameters are the final iron and sulfur contents. These levels are generally controlled by the degree of blowing and the temperature of blowing. Conversion of the Ni-Cu matte is normally a batch process and is carried out in the following stages: PC-3137 a) "Slag Blows", which involve filling the converter with molten matte and oxidizing FeS to iron oxides and SO 2 gas. The oxides are slagged with a siliceous flux and removed by successive skimmings (removal of the slag by pouring off the top of the matte). The iron content of the matte is kept above about 10% Fe, The temperature during this stage is generally kept between about 1150°C and 1300 0

C.

b) "Finishing Blows", which consist of oxidation of more FeS without taking further molten matte and then producing matte containing approximately 3% Fe.

oa c) "Dry-Up Blows", which are carried out by oxidizing most of the remaining FeS and simultaneously chilling oo the melt by the addition of excessive amounts of flux 15 and cold dope (normally solid crust and drippings from 00 o «matte and slag transfer operations) until the converter melt is at about 1% Fe. At the end of this blow, the melt temperature may vary between 1100°C and 1250°C depending upon the blowing temperature, the 20 availability of the coolant and the matte refining technique.

d) "Cooling", is the last step in the production of Bessemer matte. In this step the residual Fe is oxidized and the melt is cooled by convection and 25 radiation losses to 700 0 C-1100 0 C depending upon matte composition and further processing requirements. This a a step typically yields a final product containing about 1% iron or less and for this stage, the melt is pormally transferred to another similar converter dedicated for this purpose.

During the dry-up blow, particularly towards the end, there is a substantial amount of nickel and cobalt oxidation as well as magnetite (Fe 3 0 4 formation. The result is a very viscous slag that r- I I Is difficult to remove from the converter. Excess fluxing and cold dope addition during this blow further aggravate the situation. When the melt is removed from the converter, a large quantity of "mush" consisting mainly of magnetite, nickel oxide (N10), fayalite slag (xFeO-ySi02) and undissolved flux remain in the converter. This mush must be digested by the furnace matte at the start of the next converting cycle. This imposes limitations on the grade of matte that can be produced by the upstream primary smelting units.

The function of the cooling step is two-fold; removal of most of the iron by cooling and/or minor blowing of the melt, and cooling of the converter melt to temperatures appropriate for the subsequent treatment of the Bessemer matte. Cooling takes place by natural convection and radiation and typically lasts up to four hours.

There are several disadvantages with the current procedures.

First, the large quantity of mush remaining in the converter after dry-up must be redissolved during the first blow of the next converting cycle, and this imposes matte grade limitations. Enough FeS must be present in the incoming matte to provide both fuel to heat the mush and to act as a reductant to aid in dissolution. Second, the lengthy cooling period during the cooling stage places severe restrictions on the efficient use of equipment for converting operations. Third, any material added as coolant only partially dissolves in the matte and the mush also must be redissolved in the next charge.

Summary of the Invention The invention provides a process for treating molten nickel-copper matte derived from sulfide ores, the process comprising: introducing the molten matte into a pyrometallurgical vessel; introducing a nitrogen enriched operating gas into the vessel; and 3removing the matte from the vessel.

30 Accordingly, molten nickel-copper mattes may be finished to Bessemer quality and cooled to the appropriate casting temperature by blowing with nitrogen and/or nitrogen-oxygen (air) mixtures. Use of nitrogen promotes cooling and aids in controlled iron oxidation thus improving control over the final iron level in the Bessemer matte.

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PC-3137 PREFERRED MODE FOR CARRYING OUT THE INVENTION The instant invention utilizes tonnage nitrogen or nitrogen/oxygen (air) mixtures as an operating gas to both control the oxidation of and improve the cooling of Ni/Cu converter matte.

More specifically, it relates to controlling the oxidation rate toward the end of the conversion cycle of.Cu/Ni Bessemer matte; minimizing mush formation; regulating the converting temperature and matte composition during the last stages of conversion; and accelerating the cooling of the matte to a temperature consistent with good skimming, casting and the subsequent refining process.

Cooling by blowing with nitrogen enriched gas streams shortens cycle times and improves converter productivity.

ooe The usage of nitrogen also aids in the overall cost effectiveness of the entire nickel-copper refining operation since 9099 S 15 oftentimes the site must generate and store pure oxygen for various Sunrelated purposes. Rather than throwing off the nitrogen as waste 99 gas, it is collected and further utilized in the instant process.

oiI Many of the enumerated problems can be minimized by blowing with nitrogen and/or nitrogen-oxygen (air) mixtures during the cooling cycle. By adjusting the rate of blowing and the nitrogen o content of the blast, the cooling rate of the matte can be enhanced aoo and simultaneously, the rate of oxidation and final iron and sulfur content of the matte can be controlled. Hence the need for matte transfer to a dedicated vessel and coolant addition is removed resulting in shorter cycle times, increased flexibility and increased productivity.

The addition of nitrogen to the air or oxygen blast can ealso be used as a control over the sulfur levels in Bessemer matte.

In conventional practice, the final sulfur content in Bessemer matte is primarily controlled by blowing temperature raising the temperature decreases the sulfur level and lowering the blowing temperature tends to increase final sulfur. Dilution of the blast with nitrogen tends to purge the bath of sulfur giving added control over the composition of the final Bessemer matte.

Nitrogen addition to the air or oxygen blast is useful for a number of different converter processes. In one instance the

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PC-3137 nitrogen/air or nitrogen/oxygen mixture may be used to finish the matte and control the iron and sulfur contents. Alternatively, the nitrogen may be used primarily for cooling the matte iron and sulfur control in this instance may not be a major factor.

The quantity and duration of the nitrogen addition is a function of the type, temperature and quantity of the matte.

For a typical dry-up finishing blow, the matte generally contains about 3% iron or less. Nitrogen should preferably be mixed with air in about a 0.5-2:1 volume ratio and the mixture delivered to the converter at a rate of about 2.5 7.5 cubic meters/minute per metric tonne of matte. In the event that nitrogen is added to oxygen, the volume ratio should be about 6-14:1 and delivery rate is about 2.5 7.5 cubic meters/minute per metric tonne of matte.

0ooo Clearly, these parameters may be varied to adjust the conditions at 0000 0 0 15 hand.

0*00 So For a typical cooling blow, the finished matte generally o •contains 1-3% iron or less at a temperature of about 1100°C 1250'C.

Nitrogen should preferably be mixed with air or oxygen in about 3 20:1 or 20-100:1 volume ratios respectively. The delivery rates should be about 2.5-7.5 cubic meters/minute per metric tonne of matte. The volumes of gas introduced into the converter should be O0°o chosen to reduce the temperature by about 50'C- 200°C. Again, the 0000 numbers may be varied depending on the circumstances.

Alternatively, nitrogen only may be used to cool the matte.

25 Preferably about 2-4 cubic meters/minute per metric tonne of matte may be added to reduce the temperature of the matte.

Since it is generally easier to measure quantities of oxygen than quantities of nitrogen, it is most useful to employ an 0oo0 oxygen analyzer to calibrate and measure the gas going into the converter. By knowing the oxygen level the nitrogen level can be ascertained. Accordingly, when nitrogen containing operating gas is introduced into t1e converter the blast may contain about 5-15% oxygen (or about 23-70% air) for oxidizing purposes and about oxygen (or 5-20% air) for cooling purposes.

It will be appreciated that advantages may accrue by starting nitrogen dilution immediately after the start of the finishing blows, with about 10% Fe, and progressively increasing the PC-3137 dilution as conversion continues. In this way, close control over matte composition and temperature throughout the final blows may be achieved leading to more consistent final product and temperature.

Three non-limiting examples describe the efficacy of the invention.

Example A: The Use of N,-Air For The Dry-Up Blow Approximately 120 tonnes of partially converted matte at 1230°C and assaying 2.6% Fe were transferred into a Peirce-Smith converter equipped for blowing N 2 -air mixtures through the tuyeres.

The converter was turned into the blowing position and a 3 -1 3 -1 mixture of 311.5 m m 1 (11,000 scfm) of air and 215.2 m m (7600 scfm) of nitrogen was blown through 42 tuyeres for 21 minutes. An oxygen analyzer installed in the line indicated that the blast contained 11.6% 02 by volume. After completion of the blow the matte S 15 assayed 1.3% Fe and was at 11500C. About 5261 kg (5.8 tons) of mush °I "remained in the converter in the form of an 203 mm (8 inch) layer of hard finish. The matte was transferred for further processing and the mush was sampled. Assays showed the mush to be approximately 43% matte, 26% flux and 31% base metal oxides.

oa 20 Example B: The Use of N 2 Air To Cool A Charge Of o0 0 Bessemer Matte Using the same equipment as in Example A, approximately 120 tonnes of finishing matte assaying 0.89% Fe and at 11600C were blown e"°a with a nitrogen-air mixture to cool it to the casting temperature.

3 -1 25 The blast mixture consisted of about 31.1 m m (1100 scfm) of air 3 -1 and 229.3 m m (8100 scfm) of N 2 and was blown for 22 minutes through 25 tuyeres. An oxygen analyzer indicated that the blast contained 3.1% 02 by volume. After completion of the blow, the matte assayed 0.29% Fe and had been cooled to 1000C. The matte was cast.

Only a small amount of mush remained in the converter. Assays showed this mush to be 59% Bessemer matte, 22% flux and 19% base metal oxides.

PC-3137 Example C: The Use Of N,-Air For Dry-Up Followed By Cooling *a 0 0 0 0000 0 9 So e 0 The same equipment employed in Examples A and B was used.

Approximately 120 tonnes of matte at 11500C and assaying 1.3% Fe was blown with 15.7 m 3 m 1 (555 scfm) air and 224 m 3 m-1 (7930 scfm) nitrogen (2.7 volume %02 by analyzers) injected through 25 tuyeres.

The blow lasted a total of 68 minutes and during this period 3629 kgs (4 tons) of flux was added. After the blow the matte temperature was 1000°C and the iron content equalled 0.34%. The Bessemer matte was cast leaving about 5-8 tonnes of hard finish behind. Samples of this mush assayed about 53% Bessemer matte, 28% flux and 10% base metal oxides.

The prior art has taught the use of nitrogen in pyrometallurgy. However, there has been no appreciation that the affirmative introduction of nitrogen enriched blast in a nickel-copper converter would lead to increased oxidation control, cooling and reduced mush formation. For example, U.S. patent 3,671,197 discloses the use of an inert gas, such as nitrogen, to free sulfur from pyrite to form roasted pyrrotite. The gas is subsequently stripped of its sulfur content. The production of iron oxide is the ultimate aim. Canadian patent 973,720 (assigned to the instant assignee) discloses the use of a purge gas, including nitrogen, for refining cemented copper containing impurities. The purge gas causes the copper bath, previously treated to slag iron therein, to volatilize the impurities.

In comparison with the prior practice and the prior art, the following advantages are achieved with the instant process: 1) The amount of mush remaining from the dry-up and cooling cycles is reduced, thus reducing the amount of material which must be redigested in the next cyclp.

2) The rate of matte cooling is enhanced resulting in shorter cycle times and increased productivity.

PC-3137 3) The need for transfer to a dedicated cooling vessel is removed decreasing scrap generation and increasing flexibility and productivity.

4) Nitrogen cooling allows the treatment of higher grade primary mattes.

The process can use by-product nitrogen from the production of tonnage oxygen, a common commodity in many non-ferrous smelters.

6) The nitrogen or N2/air or oxygen mixture can be blown through conventional tuyeres.

eo While in accordance with the provisions of the statute, °there is illustrated and described herein specific embodiments of the invention. Those skilled in the art will understand that changes may be made in the form of the invention covered by the claims and the certain features of the invention may sometimes be used to advantage without a corresponding use of the other features.

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Claims (7)

1. A process for treating molten nickel-copper matte derived from sulfide ores, the process comprising: introducing the molten matte into a pyrometallurgical vessel; C<ot- c r) introducing a nitrogen enriched operating gas into the vessel; and removing the matte from the vessel.

2. The process according to claim 1 wherein the matte is oxidized by the operating gas and cooled by the nitrogen employed.

3. The process according to claim 1 including combining nitrogen and an oxygen containing gas to form the operating gas and introducing the operating gas into the matte.

4. The process of claim 1 wherein the matte includes iron sulfide and additional metal sulfides and the operating gas is formed by combining nitrogen and an oxygen containing gas, comprising the additional steps before removing the matte of: oxidizing at least a portion of the iron sulfide contained in the matte in the presence of the operating gas; forming an iron containing slag on the surface of the matte; and separating the slag from the matte. The process according to claim 4 including cooling the matte with the operating gas.

6. The process according to claim 4 including introducing an operating gas having a nitrogen-oxygen ratio of about 6-14 into the vessel at a rate of about 2.5-7.5 cubic meters/minute per metric tonne of matte.

7. The process according to claim 4 wherein the oxygen level of the operating gas ranges from about 5-15%. 30 8. The process of claim 1 wherein the matte includes iron sulfide and additional metal sulfides, further comprising the step of cooling the matte with the operating gas before removing the matte from the vessel. 9 The process according to claim 8 including introducing into the vessel the operating gas having a nitrogen-oxygen ratio of about

20-100:1 at a rate of about 2.5-7.5 cubic meters/minute per metric tonne of matte. The process according to claim 8 wherein the oxygen level of 0R iamg/0736y 9. -11- the operating gas ranges from about 11. A process for treating molten nickel-copper matte derived from sulfide ores, suV-tantially as hereinbefore described with reference to the Examples. DATED this NINTH day of JULY 1992 Inco Limited Patent Attorneys for the Applicant SPRUSON FERGUSON 4444 4** 4 *s 444 44 '4* amg/0736y 1 s 1- KAT FLA I, *A1VTC,>