Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B15/00—Obtaining copper
  • C22B15/0026—Pyrometallurgy
  • C22B15/0028—Smelting or converting
  • C22B15/003—Bath smelting or converting
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B15/00—Obtaining copper
  • C22B15/0026—Pyrometallurgy
  • C22B15/0028—Smelting or converting
  • C22B15/0047—Smelting or converting flash smelting or converting
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B15/00—Obtaining copper
  • C22B15/0026—Pyrometallurgy
  • C22B15/006—Pyrometallurgy working up of molten copper, e.g. refining

Definitions

• This invention relates to the production of copper.
• the invention relates to the pyrometallurgical production of copper while in another aspect, the invention relates to the pyrometallurgical production of copper using a continuous converting furnace.
• the invention relates to the pyrometallurgical production of copper using a continuous flash converting furnace equipped with a forebay.
• the pyrometallurgical production of copper is a series of multistep concentration, smelting, and refining procedures.
• an ore comprising one or more of a copper sulfide or copper-iron-sulfide mineral such as chalcocite, chalcopyrite and bornite
• the ore is converted to a concentrate containing usually between 25 and 35 weight percent (wt %) copper.
• the concentrate is then converted with heat and oxygen first to a matte (typically containing between 35 and 75 wt % copper), and then to blister copper (typically containing at least 98 wt % copper).
• the blister copper is then refined, usually first pyrometallurgically and then electrolytically, to copper containing less than 20 parts per million (ppm) impurities
• the conversion of copper concentrate to blister copper with heat and oxygen is known generally as smelting, and it comprises two basic steps. First, the concentrate is "smelted" to copper matte and second, the matte is converted to blister copper. Typically these steps are performed in separate furnaces, and these furnaces can vary in design. With respect to the first step, i.e. the smelting step, solid copper concentrates are introduced into a smelting furnace of any conventional design, preferably a flash
• the copper concentrates are blown into the furnace through a burner together with the oxygen-enriched air.
• the copper concentrates are thus partially oxidized and melted due to the heat generated by the oxidation of the sulfur and iron values in the concentrates so that a liquid or molten bath of matte and slag is formed and collected in the basin (also known as the "settler") of the furnace.
• the matte contains copper sulfide and iron sulfide as its principal constituents, and it has a high specific gravity relative to the slag.
• the slag is composed of gangue mineral, flux, iron oxides and the like, and it has a low specific gravity relative to, and thus floats on top of, the matte.
• the molten copper matte and slag are separated in any conventional manner, typically by skimming the molten slag from the matte through tap holes in the furnace walls.
• the slag tapholes are located at an elevation on the furnace walls that allows slag withdrawal from the furnace without removal of molten matte.
• Tapholes for the molten matte are located at a lower elevation on the furnace walls that allows the withdrawal of molten matte without the withdrawal of slag.
• the molten copper matte is then either transferred directly or indirectly (e.g. by way of a holding furnace) to the converting furnace by any conventional means, e.g. launder or ladle, or its converted to solid form, e.g. granulated, for storage and later use as a feed to a converting furnace.
• Converting furnaces are basically of two types, flash (also known as suspension) and bath, and the purpose of both furnaces is to oxidize, i.e. convert, the metal sulfides to metal or metal oxides.
• Representative bath furnaces include those used by Noranda Inc. at its Home, Canada facility, by Mitsubishi Materials Corporation at its Naoshima, Japan facility, and by Inco Limited at its Sudbury,
• Representative flash converting furnaces include that used by Kennecott Utah Copper Corporation at its Magna, Utah facility.
• the converting furnace contains a bath of molten blister copper which was formed by the oxidation of copper matte that was fed earlier by one means or another to the furnace.
• the bath typically comprises blister copper of about
• outlets are provided for the removal of both the slag and blister copper. These outlets include tapholes located at varying elevations on one or more of the furnace walls and in a manner similar to that used with the smelting furnace, each is removed from the furnace independent of the other.
• the bath contents (i.e. the metallurgical melt) of the converting furnace is removed through a forebay or syphon which is attached to the furnace.
• the forebay is in open communication with the settler of the furnace by a passageway that allows for the continuous removal of both slag and blister copper.
• the slag and blister copper maintain their phase-separated relationship as they enter the forebay.
• the forebay comprises a slag skimming chamber or zone equipped with a weir on one end and at least one tapping or overflow notch on at least one sidewalk
• the notch or notches is or are located at an elevation on the sidewall such that only slag enters and is removed from the forebay.
• the bottom of the notch(es) is(are) above the top surface of the metal product.
• the weir of the forebay is located downstream from the slag overflow notch, and it is positioned (usually attached to both forebay side walls) such that it acts as a dam to the slag but not the metal product which underflows the weir to a point beyond the weir in the forebay referred to as the riser chamber or zone.
• the metal overflows this riser chamber through a metal overflow notch(es) on the end and/or side walls.
• the molten metal product continuously overflows the end wall of the forebay into any means, e.g. a launder, tundish, etc. for transfer to another vessel (e.g. a holding furnace, an anode furnace, etc.).
• the syphon Unlike a forebay, only blister copper enters a syphon.
• the opening between the syphon and the settler zone of the furnace is sized and positioned such that only blister copper has access to the syphon, i.e. the opening is positioned below the bottom surface of the slag layer.
• the settler endwall acts as a weir relative to the slag gaining entry to the syphon.
• the slag is removed through tapholes in the settler side or end walls.
• the slag contains copper (usually in the form of cuprous oxide, i.e. Cu 2 O, and copper metal, i.e.
• the blister copper contains various waste and unrecovered mineral values, e.g. sulfur (principally in the form of cuprous sulfide, i.e. Cu 2 S), ferrosilicates, cuprous oxide, etc.
• the copper in the slag is potentially lost metal value which is recovered by recycling the slag back to the smelting furnace.
• the waste and unrecovered mineral values in the blister copper are impurities which are eventually removed either in the anode furnace or through electrorefining.
• the oxidation of copper sulfide at the interface of the slag and blister copper phases is known. However, the beneficial effect of this oxidation is minimized.
• Anode furnaces are generally constructed as cylindrical vessels mounted on girth gear that enable them to rotate. They are generally equipped with a mouth to feed material, a burner to heat the contents, and tuyeres to feed gases into the metal bath. Tuyeres consist of pipes that pass through the vessel shell connected to supplies of inert, oxidizing, and reducing gases..
• Blister copper in conventional operation is batch fed from ladles through the mouth of the vessel until a complete charge has been accumulated over a period of hours. During this time the burner is lit and maintains the charge in a molten condition.
• the vessel Upon achieving a full charge that may weigh typically one hundred to six hundred tons, depending on the size of the furnace, the vessel is rotated one way into position so that the tuyeres are submerged beneath the metal surface and a sequence of gases are blown into the metal. Tuyeres may number typically between one and four depending on the size of the vessel.
• the first sequence of gas blowing is termed the oxidation blow, consisting of the passage of mixtures of inert gas, air and oxygen into the blister copper to lower its sulfur content.
• the actual composition and volume of gases blown in this sequence is variable within limits and determined by the particular composition of the blister copper and the heat balance of the blowing operation.
• the desulfurizing operation is exothermic and the build-up of heat in the furnace can be controlled by varying the gas flow, and its inert (typically nitrogen) and oxygen content.
• slag is generated consisting of the remnants of iron, silica and other impurities from the prior smelting and converting processes.
• the oxidation blow is usually split into two distinct steps separated by a slag removal stage. Slag is removed by turning the vessel back to its initial position, then continuing the rotation to the opposite side so that the mouth on the shell is low enough for slag to be poured off the surface of the metal into a suitable container. This collected slag is returned to the upstream process for valuable metals recovery. The furnace is then returned to its blowing position for further oxidation and removal of sulfur.
• the sulfur is removed from the metal during the first sequence, or oxidation blow, as sulfur dioxide gas that evolves from the metal bath with unreacted oxygen and inert gases.
• the composition of this gas is low in sulfur dioxide, being typically 5,000 ppm during the initial blow when sulfur content is at a maximum, and dropping to less than 500 ppm when almost all of the sulfur has been removed. This gas is unsuitable for recovery of sulfuric acid and is neutralized and captured in gas scrubbing equipment.
• the second sequence of gas blowing is called the reduction blow, consisting of the passage of inert and reducing gases (such as ammonia or natural gas/steam) into the desulfurized copper to reduce its oxygen content and form anode copper.
• gases such as ammonia or natural gas/steam
• the actual volume and composition of the gases blown during this sequence is again variable within limits, and determined by heat transfer and mass transfer considerations.
• the conventional anode refining operation described in the foregoing paragraphs has the following disadvantages: 1.
• the operation is batch, with several stages that involve careful control and operator involvement.
• the conventional batch anode refining operation introduces a potential bottleneck and can disrupt optimum converter operation.
• variable exhaust volume from the batch refining operation requires a gas system capable of a higher-than-average gas flow with consequent higher capital charges and operating costs.
• this invention combines continuous converter operation with continuous refining furnace operation in the following ways and with the following advantages:
• the anode refining furnace performs a continuous refining operation on a continuous stream of molten copper received directly from a continuous converting furnace or via an intermediate holding furnace.
• the blister copper enters at one end of the furnace and exits as refined anode copper at, or towards, the other end.
• the superheat present in the continuous blister stream is utilized directly in the refining operation rather than be dissipated in the batch collection stage.
• the residual sulfur in the blister copper stream is not removed in a separate oxidative stage but is removed to a degree determined by the initial oxygen content of the blister copper.
• the level of sulfur in blister copper suitable for continuous refining is obtained as a natural feature of flash converting operation or as a result of subsequent additional removal in the continuous tapping device or intermediate holding furnace.
• the level of oxygen in blister copper suitable for continuous refining is obtained as a natural feature of continuous converter operation, or if insufficient, is added in the form of a solid, oxygen- donating compound such as copper oxide or is added as gaseous oxygen.
• This insufficiency is corrected by addition to the stream leaving the continuous converter; while it is in transit to the anode furnace or holding furnace; while in the holding furnace; or while in the anode furnace; or by combinations of these methods.
• the essentially continuous sulfur-bearing off-gas from the above continuous refining operation is beneficially routed to the process gas stream of the continuous converter, or associated smelting process.
• the majority of the sulfur dioxide is recovered as sulfuric acid.
• Any tendency to form a copper oxide slag in the continuous refining operation is reduced by the presence of sulfur in the incoming feed. Any such slag formed in the furnace is re-mixed with the high sulfur blister at the feed end of the furnace to utilize the oxygen content of the slag.
• the slag layer untimately formed on the melt being refined in the anode furnace is removed continuously or semi-continuously. Residual gangue in the incoming blister for example silica, lime, iron and alumina,
• the slag properties are controlled by the optional addition of fluxing agents in any suitable manner, e.g. injection.
• the thickness of slag on the refining melt is controlled by the position of the slag removal device, such as notch, tap hole, underflow, according to known principles.
• the melt i.e. anode copper
• cathode copper which typically contains less than about 20 ppm total impurities, e.g. sulfur, oxygen, arsenic, bismuth, antimony, silver, etc.
• the present method of producing anode copper has evolved to a high state of both economic and environmental efficiency, improving operating efficiency is an eternal quest.
• One area of operation that lends itself to improvement is the operation of the anode furnace, specifically elimination of the oxidation stage. With the elimination of this stage, the throughput of the anode furnace can be significantly increased without any changes to the furnace itself.
• the blister copper that is delivered to the anode furnace should ideally have less than about 500 ppm sulfur and less than about 4500 ppm oxygen. This in turn requires operating the upstream equipment, particularly the converting furnace in a manner that produces blister copper with sulfur and oxygen contents less than these numbers.
• copper matte is processed to anode copper without separately oxidizing blister copper in an anode furnace.
• Copper matte in either molten or solid form, is fed to a continuous copper converting furnace in which it is converted to, among other things, blister copper and slag.
• the blister copper and slag collect in the settler region of the furnace and separate into two phases, a blister copper phase and a slag phase (the latter floating upon the former).
• the converting furnace is equipped with means, preferably gas injection means, for stirring or agitating the interface of the blister copper and slag phases such that the sulfur content of the blister
• a melt comprising a slag layer floating on top of a blister copper layer, the slag layer containing an oxygen-containing species (e.g. copper oxide) and the blister copper layer containing a sulfur-containing species (e.g. copper sulfide) and a dissolved oxygen-containing species (e.g. dissolved oxygen), is mixed by introducing a gas into at least one of the slag and blister copper layers such that the sulfur-containing species in the blister copper reacts with either the oxygen-containing species in the slag or the dissolved oxygen-containing species in the blister copper to form copper metal and sulfur dioxide.
• the copper metal enters the blister copper layer, and the sulfur dioxide passes through and out of the slag layer.
• This mixing also promotes the transfer of any copper metal in slag to the blister copper, and the transfer of any mineral waste in the blister copper to the slag. Moreover, this mixing promotes the reduction of the sulfur dioxide partial pressure in the melt which, in turn, promotes the reaction of the sulfur-containing species with the oxygen-containing species, e.g. drives the copper sulfide/copper oxide reaction to the right, i.e. towards the production of the copper metal and sulfur dioxide.
• the gas is introduced into the blister copper by any convenient means, e.g. a porous plug, such that the gas rises to the interface of the molten blister copper and slag so as to increase turbulence or mixing at the interface.
• the gas is introduced into the slag by any convenient means, e.g. a lance, such that the gas creates at least a partial turbulent mixing of the slag and blister copper layers.
• the gas is introduced into both the molten blister copper and slag by any convenient means, e.g. a combination of porous plugs and lances, or porous-wall injectors, etc., so as to increase turbulence or mixing at the interface of the layers or phases.
• the gas is introduced into one or both phases in a manner that expands or blurs the interface between the slag and blister copper layers, it usually is not introduced in a manner that eliminates the slag phase as a separate, discernable phase. In those instances in which such mixing does occur, e.g. in the immediate vicinity in which the gas is injected into the slag from a lance, such time is allowed for the phases to reseparate before one is removed from the other, e.g. by tapping, etc.
• the porous-wall injector used to introduce a gas into both the blister copper and slag layers comprises a perforated gas conduit with a first end adapted to receive gas from a gas source and a second end adapted for discharge of the gas, the conduit encased in a porous sheath, the sheath spaced apart from the conduit by at least one spacing means to form a first gas diffusion region.
• the porous-wall injector further comprises a perforated support plate attached to the second end of the conduit, the support plate encased in a support block fitted with a porous plug located beneath and spaced apart from the support plate to form a second gas diffusion region, a gas conduit with gas pores encased in a refractory sheath.
• the gas is discharged into the surrounding metallurgical melt (both the blister copper and slag layers) through the perforations or gas pores of the conduit into and through the gas diffusion space and into and through the encasing porous sheath.
• the gas leaves the injector as a plume of bubbles that stirs or agitates the blister copper/slag interface.
• blister copper containing less than about 500 ppm sulfur is produced within a continuous copper converting furnace, the furnace comprising a settler zone and a molten blister copper/molten slag interface agitation means, the method comprising the steps of:
• an apparatus for producing anode copper containing less than about 100 ppm sulfur and less than about 1500 ppm oxygen comprises:
• a continuous copper converting furnace for producing blister copper containing less than about 700 ppm sulfur and less than about 7000 ppm oxygen, the furnace having a (i) settler zone, (ii) molten blister copper/molten slag interface agitation means, and (iii) a forebay in open communication with the settler zone;
• An anode furnace having blister copper reducing means for reducing the oxygen content of the blister copper produced in the continuous copper converting furnace to less than about 7000 ppm; and C. Blister copper transfer means for transferring the blister copper containing less than about 700 ppm sulfur from the forebay or tapping device of the continuous copper converting furnace to the anode furnace.
• the sulfur content of the blister copper at the time it is transferred by any suitable means, e.g. launder, ladle, etc., to an anode furnace (either directly or indirectly, e.g. by way of a holding furnace), is less than about 700, preferably less than about 500 and more preferably less than about 300, ppm.
• the blister copper is reduced with a reducing gas, e.g. natural gas, hydrogen, ammonia, reformed gas, etc., to anode copper having an oxygen content less than about 3000, preferably less than about 2000 and more preferably less than about 1500, ppm.
• a reducing gas e.g. natural gas, hydrogen, ammonia, reformed gas, etc.
• FIGURE 1 is a side, cut-away view of a continuous flash converting furnace depicting molten slag floating upon molten blister copper.
• FIGURE 2 is a magnified view of FIGURE 1 within the circle identified by lines 2-2.
• FIGURE 3 is a plan view of a flash converting furnace attached to which is one embodiment of a forebay.
• FIGURE 4A is a top cross-section of the forebay of FIGURE 3.
• FIGURE 4B is a side cross-section of one embodiment of the furnace and forebay of FIGURE 3.
• FIGURE 4C is a side cross-section of another embodiment of the furnace and forebay of FIGURE 3.
• FIGURE 4D is a side cross-section of another embodiment of the furnace and forebay of FIGURE 3.
• FIGURE 5A is a side cross-section of the forebay of FIGURE 3 along the line 5-5.
• FIGURE 5B is a side perspective of a V-shaped slag overflow notch.
• FIGURE 5C is a side perspective of a nonlinear- shaped slag overflow notch.
• FIGURE 6 is a plan cross-section of the forebay of FIGURE 5A along the line
• FIGURE 7 is a front cross-section of the forebay of FIGURE 5A along the line
• FIGURE 8 is a back cross-section of the forebay of FIGURE 5A along the line
• FIGURE 9 is a side cross-section of a porous-wall injector.
• metallurgical melt or simply “melt” means the molten contents of a metallurgical vessel, e.g. a furnace, forebay, etc.
• the melt in the settler of a copper converting furnace typically comprises a slag phase floating on top of a blister copper phase. If a forebay is attached to and in open communication with the settler of the converting furnace, then the melt of the forebay is the same as the melt of the furnace (at least the same as that part of the melt in the settler near the entrance to the forebay).
• continuous flash converting furnace 10 is equipped with a reaction shaft 11 and a riser (or uptake or offtake) shaft 12.
• Granulated matte, oxygen-enriched air and flux are mixed, melted and combusted within reaction shaft 11 to form blister copper and slag which drop into settler zone 13 of the furnace.
• Blister copper 14 pools within settler zone 13, and slag 15 floats on top of the blister copper (due to the fact that the slag has a lower specific gravity than does the blister copper) forming
• Flash converting furnaces include that used by Kennecott Utah Copper Corporation at its Magna, Utah facility. Flash converting furnaces are similar in construction and operation to flash smelting furnaces, and the latter are well described in the art, e.g. USP 4,139,371; 4,169,725; and 4,415,356, all of which are incorporated herein by reference. Other continuous furnaces (converting or otherwise), e.g. the INCO oxygen flash converting furnace and the Mitsubishi converting furnace, can also be used in the practice of this invention.
• Solid copper matte typically in finely divided form such as that produced from granulation and/or grinding
• oxygen-enriched air and flux are mixed, melted and combusted within reaction shaft 1 1 to form blister copper and slag which drop into settler zone 13 of the furnace.
• Blister copper 14 pools within settler zone 13, and slag 15 floats on top of the blister copper (due to the fact that the slag has a lower specific gravity than does the blister copper) forming interface 16.
• Exhaust gases are vented from the furnace through riser 1 1.
• the slag and blister copper form a quiescent, two-phase pool within the settler region of the furnace.
• the slag will contain, among other things, gangue mineral, flux, iron oxides, copper oxides (principally in the form of Cu 2 O) and copper metal (Cu°)
• the blister copper will contain, among other things, copper metal, copper oxides (also principally in the form of Cu 2 O), copper sulfides (principally in the form of Cu 2 S) and gangue mineral.
• the principal source of potentially lost copper values during the converting process is Cu° and Cu 2 O dissolved in the slag. Typically these copper values are recovered by recycling the slag to the smelting furnace.
• cuprous sulfide and cuprous oxide react with one another at interface 16 of the slag and blister copper under normal operating furnace conditions (e.g. at a temperature between about 1100C and about 1500C, preferably between about 1125 and about 1400C and more preferably between about 1150 and about 1350C) to form copper metal and sulfur dioxide (SO 2 ).
• the molten copper metal settles into the blister copper pool, and the sulfur dioxide passes through the slag layer into the freeboard above the layer for ultimate removal from the furnace through riser 12.
• the efficiency of this reaction depends, in large part, upon the ability of sulfur- containing and oxygen-containing species (e.g. cuprous sulfide and cuprous oxide) to react with one another. While the path for this reaction is open to a number of interpretatins, one possible path is for the sulfur-containing species in the blister copper to contact the oxygen-containing species in the slag. Another possible path is for the sulfur-containing species in the blister to react with the oxygen-containing species in the blister upon gas injection which allows for sulfur dioxide formation at low partial pressures, e.g. less than one atmosphere. As the oxygen-containing species in the blister copper is depleted, oxygen-containing species in the slag will begin to diffuse into the blister copper effectively reducing the oxygen content of the slag. In this instance, the copper sulfide in the blister does not need to be in contact with the slag for the reaction to progress.
• sulfur-containing and oxygen-containing species e.g. cuprous sulfide and cuprous oxide
• the efficiency of the copper sulfide/copper oxide reaction is dependent upon, among other things, the amount of time the slag and blister copper phases are in contact with one another within the furnace, the amount of cuprous sulfide in the blister copper, the amount of cuprous oxide in the slag, the depth of the interface of the slag and blister copper layers, and the like.
• the amount of copper lost with the removal of the slag is typically between about 1 and about 5 weight percent (based on the weight of the copper in the matte
• cuprous sulfide in the blister copper is typically between about 5000 and about 20000 ppm (1000 to 4000 ppm sulfur equates to about 5000 to about 20000 ppm Cu,S).
• cuprous oxide in any form is added to the melt in any suitable manner (e.g. through a lance) if the amount of cuprous sulfide in the blister copper exceeds the amount of cuprous oxide in the slag necessary for complete reaction of all the available cuprous sulfide to copper metal.
• cuprous sulfide in any form is added to the melt in any suitable manner (e.g. through a lance) if the amount of cuprous oxide in the slag exceeds the amount of cuprous sulfide in the blister copper necessary for complete reaction of all the available cuprous oxide to copper metal.
• the relative amounts of copper sulfide and copper oxide in the melt are
• the efficiency of the reaction described in Figure 2 is enhanced, i.e. the rate of diffusion of species from one phase to the other is increased, by sparging at a point or points in the blister copper and near the interface a gas, preferably an inert gas such as nitrogen, argon, etc., although reactive gases such as oxygen, carbon monoxide, methane, etc., can also be used for the additional purpose of controlling or influencing the oxidation and/or reduction reactions occurring in the melt.
• a reactive gas is used, preferably it is used in combination with an inert gas, particularly in a combination in which the inert gas comprises a majority of the gas introduced to effect mixing and the reduction of the partial pressure of sulfur dioxide.
• gas lances 17a-c pierce slag layer 15 and discharge a gas, here the inert gas nitrogen, at points below interface (also known as an emulsion) 16.
• a gas here the inert gas nitrogen
• This mixing promotes reaction of the excess sulfur in the blister copper with the excess cuprous oxide in the slag, which in turn simultaneously reduces the amount of cuprous oxide in the slag and the amount of cuprous sulfide in the blister copper.
• the number, placement and design of the lances can and will vary with the design of the furnace, the amounts of cuprous oxide in the slag and cuprous sulfide in the blister copper, and the amount of time after sparging required for the emulsion to reseparate to an extent that will allow for an efficient removal of one layer from the other without entrained material from the other layer.
• the lances will be placed in a pattern about the furnace that will ensure optimum enhancement of the interface mixing of the layers (i.e. will minimize the number and size of stagnant areas) across the total area of the interface.
• One such pattern is arraying the lances across the width of the settler between the reaction shaft and the uptake shaft.
• Variables such as bubble size, rate of gas injection, depth of gas injection relative to the interface, and the like can vary to convenience with the proviso that the integrity of the individual layers are not compromised to an extent that an efficient separation of the phases is significantly impeded.
• This sparging also enhances the settling of copper metal from the slag into the blister copper, especially in those situations in which larger droplets contact with one another and form even larger particles (i.e. the particles coalesce) which are more easily separated from the slag than any of the droplets individually.
• the lances are not in contact with either the blister copper or slag layer.
• the end of the lance from which the gas is discharged remains above the top surface of the slag layer.
• the discharged gas impacts the slag layer with a force at least sufficient to cause the interface between the slag and blister copper layers to enlarge (deepen) and in certain embodiments, with sufficient force to virtually drive the slag layer beneath the lance into the blister copper layer so as to render indiscernible two separate phases, i.e. a slag phase floating on top of a blister copper phase.
• the injection of the gas into the furnace reduces the partial pressure of the sulfur dioxide in the melt and this, in
• the gas is sparged into the blister copper from porous plugs located in the side walls and/or floor of the settler. While effective to the extent that the gas discharged from these plugs gently agitates the interface, this method of sparging is less favored (relative to sparging through top or sidewall mounted lances) for several reasons.
• plugs on the settler floor are more difficult to position relative to the interface (porous plugs are typically nonadjustable once installed whereas lances can be extended into or withdrawn from the metallurgical melt over a rather wide range).
• porous plugs are completely submerged within the blister copper, they are more susceptible to blockage than a lance.
• anything installed on the floor or sidewalls of the settler are more difficult to maintain simply from the logistics of access to the part. Access for maintenance and repair of roof and sidewall mounted lances, on the other hand, is much more readily available.
• Figures 3-9 describe yet another embodiment of this invention.
• Figure 3 shows a flash converting furnace 10 equipped with a reaction shaft 11 and a riser or an uptake shaft 12. Attached in any convenient manner to the converting furnace, typically on the end wall most removed from the reaction shaft, is forebay 18.
• the forebay comprises:
• first end wall 18a (Figures 4B-C) having entrance 21a (Figure 4A) for receiving a two-phase melt, e.g. from converting furnace 10, the melt comprising slag phase 15 floating on top of and forming an interface 16 with metal product phase, e.g. blister copper, 14 (all shown in Figures 4B-D);
• first and second sidewalls 18c-d joining the first and second end walls to one another, and at least one sidewall (here sidewall 18c) having slag overflow notch 23a ( Figure 4A) for discharging the slag phase from the forebay;
• E. weir 24 having first and second faces 24a and 24b, first and second side edges 24c and 24d and top and bottom surfaces 24e and 24f ( Figures 6 and 8), the first and second side edges in sealing contact with the sidewalls (i.e.
• the union or joint of the side edges and sidewalls is essentially impenetrable to both the slag and metal product) at a location between the slag overflow notch and the metal product overflow notch such that (i) the first face of the weir is opposite the entrance for receiving the melt and together with the forebay sidewalls.
• first end wall and floor forms slag skimming chamber (or zone) 18g ( Figures 4A-D), (ii) the second face of the weir is opposite the metal product overflow notch and together with the forebay sidewalls, second end wall and floor forms riser chamber (or zone) 18h ( Figures 4A-D), and (iii) the bottom surface of the weir and the forebay floor form underflow 18i ( Figures 4A-D); and F. cover 18f ( Figures 2B-D and 5) extending over the slag skimming and riser chambers.
• a furnace may have more than one forebay and their locations on the furnace with respect to one another can vary to convenience. Multiple forebays can prove convenient in the context of achieving and maintaining maximum furnace operation time, e.g. when one forebay is out of operation for any reason, the other forebay(s) is(are) available to keep the furnace in operation. Multiple forebays may also be used to promote good metallurgical operation by preventing or reducing static layers (i.e. stagnant areas of slag or metal) from forming in parts of the furnace.
• the forebay can form an integral part of the furnace, i.e. it can be built as an extension of the furnace, or it can be a separate unit, e.g. skid mounted but securely attached to a furnace wall in any conventional manner, e.g. bolted, mortared, etc., preferably with a water-cooled joint.
• the forebay and furnace provide a single closed environment (except, of course, for the product and byproduct discharge zones) for the slag and molten blister copper.
• the forebay comprises slag skimming chamber (also known as a slag skimming zone) 18g connected to slag launder 19 (or in certain embodiments, a spout), and riser zone 18h connected to a blister copper launder (or in certain embodiments, a spout) 20.
• slag skimming chamber also known as a slag skimming zone
• riser zone 18h connected to a blister copper launder (or in certain embodiments, a spout) 20.
• Entrance 21a to forebay 18 is in open communication with furnace opening 21b (shown in Figures 4B-D) in end wall 10a of furnace 10 to which the forebay is attached. Opening 21b and entrance 21a are sized preferably such that both the blister copper and slag layers enter the forebay in the same manner in which they exist within furnace settler zone 13 ( Figure 4B-D), i.e. two relatively immiscible layers with the slag layer floating on top of the blister copper layer.
• Opening 21b is sized and located in furnace wall 10a at a height such that it is either completely submerged beneath the top surface of the slag layer within the furnace (shown in Figures 4B-C), or that a gas space exists between the top surface of the slag layer and the top surface of opening 21b (shown in Figure 4D).
• the blister copper and slag form a gas seal between the environment of furnace freeboard zone 10b and the forebay environment.
• the gaseous environment of furnace freeboard zone 10b and the gaseous environment above the top surface of the slag within slag skimming zone 18g are in open communication with one another.
• opening 21b and entrance 21a can be of any size and configuration, e.g circular, oval, polygonal, etc. and can be the same as or different from one another, but are typically sized and configured to allow the blister copper and slag layers to enter the forebay in a relatively undisturbed state, e.g. without significant mixing of the respective layers.
• the blister copper and slag layers move naturally toward and through the furnace wall opening 21b and entrance 21a into the forebay as a result of the slag and metal product phases seeking levels in relation to their overflow heights in the forebay.
• the forebay is constructed of any suitable material(s), but typically it consists of a metal shell lined with refractory appropriate to working with molten blister copper and slag.
• the particular dimensions of the forebay are scaled to the size, capacity and design of the converting furnace (including the number and location of forebays ultimately attached to the furnace).
• the forebay may be equipped with devices, e.g. cooling blocks, resistance heaters, etc., not shown and optional to its operation.
• Slag overflow notch 23a is located in slag skimming chamber side wall 18c at a height from floor 18e such that slag overflow notch 23a is above the slag/blister copper interface.
• the shape of the overflow notch can vary and in addition to the rectangular shape of 23a shown in the Figures 4A and 5, the shape of the notch includes a V-shape (23b in Figure 5B) and various nonlinear shapes, e.g. semicircular (23c in Figure 5C).
• a slag overflow notch is located on side wall 18d (i.e. opposite the slag overflow notch shown in the Figures) while in another embodiment of the invention (also not shown), each side wall has one or more slag overflow notches (of the same or different cross-sectional configuration) located in the slag skimming zone.
• the size, i.e. the cross-sectional area, of the slag overflow notch can be enlarged or reduced during operation with the removal or addition of suitable materials to vary the height of the top surface of the slag phase in relation to the sidewall of the forebay.
• the slag is collected in transportable vessels, e.g. ladle/crane assemblies, pots on rails, etc., while in another embodiment, the slag is immediately subjected to granulation by any convenient technique, e.g. water granulation, air granulation, rotating disk granulation, etc.
• the slag in whatever form, is then recycled or otherwise processed for recovery of various metal values, or disposed in any safe and environmentally acceptable manner.
• the forebay is stepped, i.e. it is characterized by the bottoms of opening 21 b and entrance 21 a located sufficiently above settler floor 10c such that a significant part of the blister copper bath within the settler cannot move into the forebay.
• the stepped design does require for separate draining of the settler zone below the bottom surface of opening 21 b, but it also provides for retention of some, if not most, of the blister copper bath in the event the forebay is disabled for whatever reason.
• the forebay is full-depth, i.e. it is characterized by the bottoms of opening 21b and entrance 21a corresponding to or at a near approximation to furnace floor 10c (i.e. the floor of settler zone 13).
• furnace floor 10c i.e. the floor of settler zone 13
• the full depth forebay can be converted to a stepped forebay by the addition of refractory to floor 18e.
• underflow 18i in one embodiment it is in the form of a well or recess in floor 18e into which extends weir 24 (as illustrated in Figures 4A and 4B) while in another embodiment, it is simply an extension of floor 18e under weir 24 without a well or recess (as illustrated in Figure 4C).
• underflow 18i is a well in the floor of a full-depth forebay, e.g. the forebay illustrated in Figure 4C but with a well below weir 24, or an extension of floor 18e in a stepped forebay, e.g.
• Underflow 18i is of any convenient configuration
• Figures 4A, 6 and 8 show the cross-sectional shape of one such configuration.
• This shape shows a generally rectangular configuration on that side of weir 24 nearest the slag overflow notch, and a generally tapered configuration on that side of weir 24 furthest from the slag overflow notch (this side known as riser zone 18h).
• the taper is narrowest at the recessed floor and widest at blister copper overflow notch 22.
• the stepped taper shown in Figures 4A, 5A, 6 and 8 is a preferred configuration because the relatively narrow bottom reduces heat loss and the relatively wide top facilitates heat input from any overhead heating device, e.g. burner, direct current arc, plasma torch, etc.
• this configuration is relatively easy to construct from rectangular refractory bricks although like the cross-section of the slag overflow notch, this preferred taper can also have a V- or nonlinear cross-sectional shape.
• floor 18e does not form a recess or well under weir 24.
• weir 24 extends into underflow 18i in such a manner as to block the passage of slag from slag skimming chamber 18g to blister copper overflow notch 22, but not the passage of molten blister copper from slag skimming chamber 18g to blister copper overflow notch 22.
• weir 24 contains cooling block 24g for purposes of extending refractory life.
• bottom cooling passage 24h ( Figure 8) in cooling block 24g is preferably located above the level of the blister copper in the forebay (as illustrated in Figures 4B-D) so that if a water leak occurs, it does not leak into the blister copper
• riser lip i.e. blister copper lip
• the blister copper overflows from riser lip 22 into launder or spout 20 for routing to another vessel, e.g. an anode or holding furnace.
• the static phases in the forebay are maintained in a molten state by a heating system of any convenient design.
• a heating system of any convenient design.
• one or more oxygen-fuel or plasma torches are employed while in another embodiment, an induction heater is used.
• the flow of molten material through the forebay is easily stopped by damming the overflow notch and blister copper overflow notch with refractory or clay.
• cover 18f ( Figures 4B-C and 7) which ideally forms a gas tight seal with the side walls of the forebay (with the understanding that openings exist for the discharge of slag and blister copper).
• cover 18f is equipped with burners 25a and 25b to maintain the blister copper in a molten state.
• the burners can be of any conventional design, and are preferably located downstream from the slag overflow notch(es). If burners are employed in the cover, then the gases generated by them and the molten slag and/or blister copper must have a vent for their removal from the forebay.
• divider 26 (typically constructed of refractory and illustrated in Figures 4A-D) is built between top weir surface 24e and the inside surface of cover
• this divider serves to provide distinct zones within the forebay, but it also forms a seal with respect to the gases above the slag and blister copper in slag skimming zone 18g and riser zone 18h, respectively.
• the forebay is optionally mounted on skid supports 27a and 27b ( Figures
• the forebay is also equipped with cooling
• the phase levels within the forebay, and therefore within the furnace settler, are controlled by well known barometric relationships.
• the barometric head of blister copper in the riser zone of the forebay balances the combined barometric heads of blister copper and slag in the slag skimming chamber.
• the level of blister copper in the furnace settler is preferably controlled by the height of the blister copper overflow notch relative to the forebay floor. This lip is always higher than the lowest point of the opening to/entrance of the forebay (e.g. the bottoms of opening 21b and/or entrance 21a). In addition to controlling the phase levels, this protects the settler refractory near and about the end wall opening to the forebay because blister copper, unlike slag, has a low corrosivity to refractory brick.
• the level of blister copper above the bottom of the opening to/entrance of the forebay can be raised by raising the height of the blister copper overflow notch.
• the level of slag above the blister copper layer can be raised by raising the height of the slag overflow notch. Accordingly, the levels of the phases in both the forebay and the furnace settler can be controlled independently of one another for optimum metallurgical efficiency.
• the slag layer With respect to the slag layer, good metallurgical practice requires monitoring, by any conventional means, the size, i.e. depth, of this layer. If the slag layer becomes too deep, then it can push slag beneath the weir such that it under flows the weir and enters the riser zone from which it ultimately overflows into the blister copper launder or spout.
• the optimum depth of the slag layer will vary with a number of furnace design and operating factors. In operation, molten slag and blister copper enter, due to the influence of gravity, the forebay from the converting furnace through opening 21b and entrance 21a in essentially the same arrangement in which they exist within the settler of the furnace, i.e. molten slag floating upon molten blister copper.
• the forebay 25 may be created within the furnace. If the molten slag and blister copper enter the forebay in a manner as illustrated in Figure 4D, i.e. the top surface of the slag layer is below the top of the entrance to the forebay, then the forebay is not flooded. In this circumstance, a gas space in open communication with both the furnace and the forebay is created, and the pressure in the furnace and the forebay is essentially the same. In certain circumstances, operation of the furnace at a negative pressure relative to the forebay (or the surrounding environment, for that matter) is desirable because it results in certain operating efficiencies relative to energy usage, product yield, etc.
• phase interface is relatively well-defined. As this two phase mixture moves into the slag skimming chamber, the molten slag layer is continuously removed due to overflowing through the slag overflow notch. The weir blocks the forward progress of the slag layer, and thus the only exit from the forebay for this layer is through the notch.
• the forebay is equipped with means for stirring or agitating the interface of the blister copper and slag phases such that the sulfur content of the blister copper phase is reduced, and the copper oxide and copper metal content of the slag phase is reduced.
• means for stirring or agitating the interface of the blister copper and slag phases such that the sulfur content of the blister copper phase is reduced, and the copper oxide and copper metal content of the slag phase is reduced.
• These means include mechanical agitators, e.g. paddles, stirrers, etc.; electrical agitators, such as induction stirrers; and gas agitators, e.g. lances, porous plugs, etc.
• Gas agitators are the means of choice for this invention, and porous- wall injectors and porous plugs are the preferred gas agitators.
• porous plugs are arrayed across the floor of the slag skimming chamber in any suitable pattern while in another embodiment, one or more
• porous- wall injectors are mounted to the roof or lid of the forebay in any suitable array over the slag skimming chamber such that when the lid is in a closed position, the porous injector(s) extends through the slag layer into the blister copper layer.
• the plugs and injectors can also be used in combination with one another.
• One or more gases e.g. nitrogen or nitrogen in combination with an oxygen-containing gas, is discharged from the injector or plug in a manner that interface 16 is gently agitated or stirred.
• the forebay is sized such that it can also accommodate the equipment (e.g. lances, porous plugs, etc.) and residence time necessary to effect this further processing. This may result in a forebay with physical dimensions larger than that required simply to drain and separate the melt as received from the furnace.
• the injector itself is shown in greater detail in Figure 9, and it comprises pipe or other gas conduit 38 of any cross-sectional geometry containing gas holes or pores 39a-g.
• Pipe 38 is encased in but spaced from porous refractory shroud 40 which comprises porous refractory segments 40a-d which are joined to one another by grouted labyrinth joints 41a-c.
• Inner surface 42 of porous refractory shroud 40 is spaced from outer surface 43 of pipe 38 by spacers 44a-c to form gas diffusions spaces 45a-d.
• Pipe 38 extends from a gas source (not shown) located external to the forebay to support plate 46 itself containing at least one gas pore 47.
• Beneath support plate 46 is bottom porous plug 48, and the end of pipe 38, support plate 46 and bottom porous plug 48 are encased in injector support block 49.
• Support plate 46 and bottom porous plug 48 are positioned one from the other within injector support block 49 such as to create gas diffusion space 50.
• the injector passes through sealing plate 51 which is attached by any suitable means (e.g. welding, mechanical fasteners, etc.) to the forebay roof or lid. Sealing plate 51 is protected from the heat and corrosion of the metallurgical melt, of course, by a suitable refractory shield.
• the injector further comprises a means for injecting a finely divided solid into the melt.
• a means for injecting a finely divided solid into the melt is an injector which comprises two concentric conduits, e.g. tubes or pipes. The finely divided solid is injected into the melt through the inner conduit, and the gas is injected into the melt through the annulus defined by the outer surface of the inner conduit and the inner surface of the outer conduit.
• the porous- wall injector can be used as a means for adding, for example, copper oxide to the melt in those situations
• the porous-wall injector can be used as a means for adding copper sulfide to the melt in those situations in which the melt contains an insufficient amount of copper sulfide to react with the amount of copper oxide in the melt.
• porous- wall injector 37 extends from the roof or ceiling of forebay 18 (and in other embodiments of this invention, and/or from the ceiling of furnace 10) into and through slag layer 15 and interface 16, and into blister copper layer 14 such that bottom surface 52 of bottom porous plug 48 is positioned near (e.g. within 15 cm) slag skimming chamber floor 18e. Gas is fed through pipe 38 under sufficient pressure
• porous- wall injector provides a number of benefits with respect to stirring gently the interface that are not available from standard lances or porous plugs.
• the porous- wall injector discharges gas from near its entire length and not just from its bottom plug (as would a lance), the gases stir all of the material about the injector.
• the interface stirred from the blister copper layer, but it is also stirred from the slag layer (as opposed to either a lance or a porous plug which will stir only the layer in which its discharge opening is located (typically the blister copper layer)).
• the gases create currents within each layer that result in more volume from each layer coming into contact with more volume of the other layer (and thus more opportunity for the cuprous sulfide and cuprous oxide to react with one another, and more opportunity for copper metal to settle into the blister copper layer and more opportunity for slag mineral values to rise into the slag layer).
• the porous-wall injector since the porous-wall injector is engulfed in its own gas plume, it suffers less corrosive wear than a porous plug or lance because the gas plume not only stirs the material surrounding the injector, but it also keeps it spaced from the surface of the injector. In other words, the discharged gas acts also a protective envelope
• the porous-wall injectors are used alone, at least with respect to stirring the blister copper/slag interface (as opposed to using the lances and/or plugs for another purpose, e.g. introducing an oxidant into the blister copper or a reductant into the slag).
• continuous anode refining blister copper is continuously fed from a continuous copper converter via a forebay or other tapping device.
• the blister copper is preferably continuously fed by gravity through a heated metal launder to a suitable feed point in the anode furnace.
• the blister copper passes through an intermediate holding furnace.
• gases from the continuous tapping device; the optional holding furnace; and the interconnecting metal launders are collected and routed into a process gas system.
• the process gas system can be that from the continuous converter.
• the process gas system can be that from other smelting processes of convenient location.
• the process gases can be from the continuous anode refining furnace that are subsequently directed into yet another process gas system.
• the principle of operation is the beneficial recovery of the sulfur dioxide content of low grade gases from the continuous tapping device; metal launders; holding furnaces; and continuous anode refining furnaces by ducting them into a process gas system of higher gas strength.
• process gas can be tolerated subject to the limitations set by the associated acid plant.
• the flash smelting furnace and flash converting furnace installed at the Magna smelter of the Kennecott Utah Copper Corporation produces process off-gas containing sulfur dioxide at 35-40% by volume. This gas is subsequently diluted to the maximum concentration of 14% acceptable to the associated acid plant.
• the sulfur content of blister copper entering the anode furnace is less than 500 ppm and the oxygen content is less than 5,000 ppm. In a further embodiment, the sulfur content is less than 300 ppm and the oxygen content is less than 5,000 ppm.
• the blister copper achieves these levels before leaving the flash converter. However, if the sulfur level is higher than the preferred 500 ppm, it can be reduced to this level, or to the more preferred level of less than 300 ppm by nitrogen injection into the continuous tapping device; or metal launder; or holding furnace. This nitrogen injection can be supplemented by the injection of air or oxygen by known methods, e.g. lances, to further reduce the level of sulfur.
• blister copper Upon receipt of blister copper with this preferred analysis, it is fed into the anode furnace by any suitable means, e.g. through a launder in the end of the anode furnace, or through a drop hole in the uppermost surface of the cylinder body of the anode furnace.
• any suitable means e.g. through a launder in the end of the anode furnace, or through a drop hole in the uppermost surface of the cylinder body of the anode furnace.
• the blister copper preferably enters the melt in the anode furnace at the opposite end to the point of discharge of refined anode copper. It does this to maximize the distance along the furnace through which it must travel while being progressively refined. This principle of operation is most important when the residence time is short, i.e. when the anode furnace is small and the level of melt in the furnace is low. On the other hand, if the furnace capacity is large, then the residence time increases, and it is not as important to separate the feed and discharge points at opposite ends of the furnace. In an extreme case, the residence time will be adequate to refine blister copper with no concentration gradient along the length of the anode furnace, i.e. the bulk concentration of the melt in the anode furnace is in all places equal to the composition of refined anode copper. The blister copper can then be added at any point that does not short-circuit the furnace.
• the anode furnaces have a capacity of 600 tons of blister copper.
• the following table of actual operating data shows the initial and final compositions of the reduction blow, i.e. the removal of oxygen with the tuyeres feeding a mixture of natural gas and steam.
• the time- averaged residence time is 10 hours for a 600 ton melt, indicating sufficient time to refine blister copper continuously to anode copper containing less than about 30 ppm sulfur and 1 ,500 ppm oxygen.
• the blister copper not exceeding around 700 ppm sulfur and around 5,000 ppm oxygen, continuous refining of blister copper is achieved.
• Higher levels of sulfur and oxygen can be accommodated by increasing the number of tuyeres and/or increasing the gas blowing rate in the tuyeres.
• the sulfur values in the blister copper are continuously subjected to oxidation until reduced to less than about 700, preferably less than about 500, more preferably to less than about 100 and even more preferably to less than about 50 ppm (the lower the sulfur content of the blister copper, the easier the subsequent refining).
• This continuous oxidation is accomplished by the stirring or agitation of the blister copper/slag interface with a gas while the phases remain in the settler region of the furnace and, optionally, while the phases remain in contact with one another in the forebay (in those embodiments in which the phases are separated through the use of a forebay). In those embodiments in which the phases are separated while in the settler region of the furnace, e.g.
• sulfur removal can be supplemented by stirring or agitation in the metal launders and holding furnace(s) during its continuous passage to the anode furnace.
• One, or a combination, of these methods can be used to effect the reduction of sulfur levels into the preferred range.
• the copper converting furnace is operated in any known manner such that the oxygen content of the blister copper does not exceed about 7000, preferably 5000, ppm by the time that it (the blister copper) is ready for transfer from the forebay to the anode furnace (or an intermediate vessel, e.g. a holding furnace, between the forebay and the anode furnace).

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• 1999
  • 1999-02-01 AU AU24883/99A patent/AU2488399A/en not_active Abandoned
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