WO2019071797A1 - 一种由含镍与铁的混合熔渣生产的方法 - Google Patents

一种由含镍与铁的混合熔渣生产的方法 Download PDF

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WO2019071797A1
WO2019071797A1 PCT/CN2017/115652 CN2017115652W WO2019071797A1 WO 2019071797 A1 WO2019071797 A1 WO 2019071797A1 CN 2017115652 W CN2017115652 W CN 2017115652W WO 2019071797 A1 WO2019071797 A1 WO 2019071797A1
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slag
iron
smelting
copper
reaction
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PCT/CN2017/115652
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English (en)
French (fr)
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张力
张武
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东北大学
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Publication of WO2019071797A1 publication Critical patent/WO2019071797A1/zh

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    • 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
    • C22B11/00—Obtaining noble metals
    • C22B11/02—Obtaining noble metals by dry processes
    • 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
    • C22B13/00—Obtaining lead
    • C22B13/02—Obtaining lead by dry processes
    • 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
    • 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
    • C22B19/00—Obtaining zinc or zinc oxide
    • C22B19/30—Obtaining zinc or zinc oxide from metallic residues or scraps
    • 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
    • C22B23/00—Obtaining nickel or cobalt
    • C22B23/02—Obtaining nickel or cobalt by dry processes
    • 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
    • C22B26/00—Obtaining alkali, alkaline earth metals or magnesium
    • C22B26/10—Obtaining alkali metals
    • 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
    • C22B30/00—Obtaining antimony, arsenic or bismuth
    • C22B30/06—Obtaining bismuth
    • 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
    • C22B58/00—Obtaining gallium or indium
    • 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
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/04—Working-up slag
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • the invention belongs to the technical field of slag metallurgy, and in particular relates to a method for producing a mixed slag containing nickel and iron.
  • the nickel smelting slag includes the nickel smelting slag produced by the “smelting smelting” process, the depleted slag after the “copper ice nickel blowing” process, and the top blowing smelting.
  • Nickel settled slag China Jinchuan Company uses “flash smelting” and “top blowing smelting” to carry out nickel concentrate smelting, which produces 1 million tons of nickel smelting slag per year. The accumulated accumulated storage capacity is over 10 million tons.
  • the valuable components such as copper, iron, nickel, cobalt, zinc, lead, gold and silver in the nickel smelting slag are stacked for a long time, which wastes resources and pollutes the environment.
  • the iron content in the nickel smelting slag is as high as 50wt%, far exceeding the current 26wt% recoverable grade, and the slag contains up to 0.2wt% copper, of which the iron component is mainly present in the fayalite phase.
  • the research and utilization of nickel smelting slag mainly focuses on direct reduction of iron or molten iron. During the reduction process, the reduction of copper, nickel and cobalt components into molten iron is not conducive to the subsequent steelmaking process.
  • Lead smelting slag is produced in the process of lead smelting process "sintering-blast furnace reduction-smoke furnace” or "oxidation blowing-high lead slag reduction-smoke furnace".
  • Lead smelting slag includes lead smelting slag and smelting furnace slag.
  • “Sintering blast furnace reduction” or “solid high-lead slag reduction” or “liquid high-lead slag reduction process” reduction process produces lead-containing smelting slag
  • lead-containing smelting slag is produced by smelting furnace to produce smelting furnace slag
  • lead smelting slag (smoke
  • the furnace slag and lead-containing smelting slag contain copper, gold, silver, iron, zinc, lead and other components, which are important secondary resources.
  • the temperature of lead smelting slag (lead smelting slag or smelting furnace slag) is ⁇ 1050 °C. Lead smelting slag is an important physical heat resource, but there is no reasonable process for its effective use.
  • Blast furnace slag, steel slag and ferroalloy slag contain high content of metal iron, iron oxide, chromium oxide, phosphorus pentoxide, SiO 2 , CaO, MgO and other valuable components are important secondary resources; from blast furnace, refining
  • the steel furnace and the iron alloy furnace discharge the molten slag temperature ⁇ 1300 ° C. Therefore, the molten blast furnace slag, molten steel slag and molten iron alloy slag are also important physical thermal resources. However, without reasonable process utilization, it can only be piled up in large quantities, resulting in waste of resources and environmental pollution.
  • Nickel smelting slag, lead smelting slag, blast furnace slag, steel slag, iron alloy slag contain a large amount of metallurgical fluxes such as SiO 2 , CaO, MgO, Al 2 O 3 , etc., which have strong chemical reaction activity and are slag systems with excellent physical and chemical properties. Clinker.
  • the molten nickel smelting slag, molten lead smelting slag, molten blast furnace slag, molten steel slag and molten iron alloy slag flowing out of the metallurgical furnace contain abundant thermal energy resources and contain a large amount of hot metallurgical flux.
  • the existing copper pyrometallurgical process is suitable for treating copper sulfide ore, but it is difficult to treat copper oxide ore. How to simultaneously process copper oxide minerals, copper sulfide minerals and copper-containing materials on a large scale to achieve copper and iron production is particularly important.
  • the present invention provides a method of producing a mixed slag containing nickel and iron.
  • the method has the advantages of short reaction time, short process flow, high metal recovery rate, low production cost, large processing capacity, environmental friendliness and high economic benefit, and can effectively solve the problem of efficient recycling of metallurgical resources and thermal energy; the invention is a new melting
  • the slag metallurgy process not only reduces the copper content of the slag to make the slag contain copper ⁇ 0.1wt%, but also realizes efficient recovery and inclusion of copper, nickel, cobalt, gold, silver, iron, zinc, lead, indium, antimony, sodium and potassium components.
  • the treatment of copper-nickel materials can obtain low-copper iron-containing materials (iron concentrate and pig iron), and solve the problem of large accumulation of slag, environmental pollution, and heavy metal pollution.
  • the main technical solutions adopted by the present invention include:
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • S1 slag mixing: adding nickel smelting slag to the smelting reaction device, adding one or more of lead smelting slag, blast furnace slag, steel slag and iron alloy slag, stirring to form mixed slag; heating the mixed slag to molten state At the same time, adding one or more of copper oxide mineral, copper sulfide mineral, nickel oxide mineral, nickel sulfide mineral and copper-containing material; mixing uniformly, as reaction slag, and monitoring reaction slag in real time, through regulation The mixed reaction slag simultaneously satisfies the condition a and the condition b, obtains the slag after the reaction, or pours the slag after the reaction into the heat preservation device;
  • condition a is controlling the reaction slag temperature to be 1050 to 1450 ° C;
  • the slag after the reaction in the step S1 is kept for 5 to 50 minutes, and the copper-rich nickel phase layer in the bottom molten state, the iron-rich phase in the middle and lower molten state, and the iron-containing silicic acid in the middle and upper molten state are separated and obtained.
  • the salt mineral phase simultaneously forms the soot containing the zinc component and the lead component, the gold component and the silver component enter the copper-rich nickel phase, and the nickel-containing component and the cobalt-containing component enter the copper-rich nickel phase and the iron-rich phase, respectively. ; recycling each phase.
  • the method for regulating the condition a is:
  • the heating function of the reaction device itself is used, or fuel or molten nickel smelting slag, molten lead smelting slag, molten blast furnace slag, molten steel slag or molten iron alloy slag are added to the slag.
  • fuel or molten nickel smelting slag, molten lead smelting slag, molten blast furnace slag, molten steel slag or molten iron alloy slag are added to the slag.
  • the preheated oxidizing gas is simultaneously injected, so that the temperature of the reaction slag reaches 1050 to 1450 ° C;
  • nickel smelting slag copper oxide mineral, copper sulfide mineral, nickel oxide mineral, nickel sulfide mineral, copper-containing material, blast furnace slag, steel slag, One or more of iron alloy slag, metallurgical flux, iron-containing material or fluorine-containing material, so that the temperature of the mixed reaction slag reaches 1050 ⁇ 1450 ° C;
  • the method for regulating the condition b is:
  • the reaction device is a heat preservation device or a rotatable smelting reaction device or a smelting reaction device with slag or iron slag flowing out; wherein the heat preservation device is pourable Smelting reaction slag irrigation or insulation pit;
  • the rotatable smelting reaction device is a converter and a smelting reaction slag tank;
  • the smelting reaction device with slag or iron slag can flow out is a plasma furnace, a direct current arc furnace, an alternating current arc furnace, a submerged arc furnace, a blast furnace, a blast furnace, an induction furnace, a cupola furnace, a side blowing molten pool smelting furnace, Bottom-blow pool smelting furnace, top-blow pool smelting furnace, reverberatory furnace, Osmet furnace, Aisa furnace, Waten Kraft melting pool melting furnace, side blowing rotary furnace, bottom blowing rotary furnace, top blowing rotary furnace .
  • the oxide is reduced to metallic copper, metallic nickel, metallic cobalt and FeO, respectively, and the metallic iron content in the slag is ⁇ 3%. It can be regulated by adding one or both of a reducing agent and a carbon-containing iron-containing material, wherein the reducing agent and/or the carbon-containing iron-containing material is used in an amount of copper oxide and nickel oxide in the slag.
  • the theoretical amount of metal, cobalt oxide and iron oxide reduced to metal copper, nickel, cobalt and FeO is 110-140%;
  • the carbon-containing iron-containing material is steel dust and soot, iron concentrate carbon pre-reduction ball Group, iron concentrate carbon-containing metallized pellets, wet zinc smelting kiln slag, coke oven dust and soot.
  • the nickel smelting slag is a nickel smelting slag produced by a "smelting smelting" process, a blowing slag after a "copper ice nickel blowing” process, and a "copper ice nickel blowing"
  • the nickel smelting slag is in a molten state or a cold state, wherein: the molten nickel smelting slag is obtained from a slag opening of a nickel smelting furnace, or the nickel smelting slag is heated to a molten state;
  • the blast furnace slag, steel slag and iron alloy slag are in a molten state or in a cold state, wherein: molten slag (blast slag, steel slag and iron alloy slag) is obtained from a slag outlet, or cold slag (blast slag, steel slag and iron alloy slag) Heating to molten state; the steel slag is molten iron pre-desulfurization slag (desulfurization slag, desiliconization slag, dephosphorization slag), converter slag, electric furnace slag, VOD/VAD slag, VD slag, tundish slag; the iron alloy slag is The slag produced in the ferroalloy production process includes slag produced by smelting carbon ferromanganese, slag produced by smelting ferrochrome, slag produced by smelting ferronickel, slag produced by smelting vanadium iron
  • the copper oxide mineral comprises one or more of a cuprite, a black copper ore, a malachite, a blue copper ore, a chrysocolla, a cholesterium;
  • the copper sulfide mineral comprises a copper ore, copper blue, brass One or more of ore, porphyrite, arsenic, copper ore;
  • the copper-containing material is blister copper copper fire refining slag, copper tailings, copper slag, zinc smelting slag, zinc smelting soot and dust, lead and zinc tailings, lead smelting slag, lead copper, arsenic copper, One or more of crude lead fire refining slag, lead smelting soot and dust, lead acid battery, copper smelting soot and dust, copper, copper-containing garbage, copper-containing circuit board, tin smelting slag, tin tailings
  • the zinc smelting slag is zinc smelting slag produced by wet zinc smelting and pyrometallurgical smelting, including leaching slag, iron slag, copper cadmium slag, goethite slag, hematite slag, volatile kiln residue , vertical tank zinc slag, blast furnace slag, vortex furnace slag, smelting
  • the iron-containing material is ordinary iron concentrate, ordinary iron concentrate direct reduced iron, ordinary iron concentrate sintered ore, ordinary iron concentrate pellet, ordinary iron concentrate metallized ball.
  • ordinary iron concentrate carbon pre-reduction pellets, steel slag, zinc smelting slag, coke smelting soot and dust, steel soot and dust, nickel-containing smelting slag, copper slag, lead smelting slag, zinc smelting slag, tin smelting
  • the steel dust and dust include blast furnace gas mud, converter dust, electric furnace dust, heat or Cold rolled sludge, sintered dust, pellet dust, dust collection in ironworks, blast furnace gas ash, electric furnace dust ash, rolled steel oxide scale;
  • the copper-containing material and the iron-containing material are in a hot state or a cold state, wherein the hot material is directly obtained from the metallurgical furnace discharge port or the slag outlet; the wet zinc slag and the dust sludge are dehydrated and dried;
  • the fuel and the reducing agent are one or more of a solid, liquid or gaseous fuel, which is injected by spraying or feeding, and is loaded with a gas of 0 to 1200 ° C, the gas is an oxidizing gas, argon.
  • the gas is an oxidizing gas, argon.
  • the solid fuel and reducing agent are one or more of coal powder, coke powder, coke, fly ash, bituminous coal or anthracite coal, and the shape is granular or powdery, granular
  • the material has a particle size of 5 to 25 mm, the powdery material has a particle size of ⁇ 150 ⁇ m;
  • the liquid fuel and the reducing agent are heavy oil, and the gaseous fuel and the reducing agent are gas and/or natural gas;
  • the metallurgical flux is a mineral or slag containing CaO or SiO 2 ;
  • the fluorine-containing material is one or more of fluorite, CaF 2 or fluorine-containing blast furnace slag;
  • the alkaline material is lime powder, red One or more of mud, decalcified red mud, calcium carbide slag, dolomite powder or quicklime powder;
  • the alkaline iron-containing material is CaO/SiO 2 >1 alkaline sinter, basic iron concentrate, One or more of an alkaline pre-reduction pellet, an alkali metallized pellet, a steel slag or a blast furnace slag;
  • the acidic material is one or more of silica, gold-silver-silica, fly ash, coal gangue;
  • the iron-containing material is CaO/SiO 2 ⁇ 1 iron-containing material, acid sinter, acid iron
  • concentrate acid pre-reduction pellets, acid metallized pellets, copper slag, lead smelting slag, zinc smelting slag, nickel smelting slag, tin smelting slag, iron alloy slag, and blast furnace slag.
  • the copper-rich nickel phase, the iron-rich phase and the iron-containing silicate mineral phase may be separately treated, or any two phases may be combined. .
  • the separation and recovery in the step S2 is performed by any one of the following methods 1 to 5:
  • Method 1 When the slag can be used to flow out of the smelting reaction device, after the slag separation after the reaction is completed, the following steps are performed:
  • Method A directly used as a cement raw material after water quenching or air cooling;
  • Method B partially or completely returning to the reaction slag as a hot metallurgical flux
  • Method C the iron-containing silicate mineral phase is used for pouring glass ceramics or as slag wool;
  • Method D blowing a preheated oxidizing gas at a temperature of 0 to 1200 ° C into the iron silicate mineral phase slag in the smelting reaction device, and ensuring that the silicate slag temperature is >1450 ° C;
  • the ferrous oxide content percentage is ⁇ 1%, and the oxidized slag is obtained;
  • the oxidized slag is directly air-cooled or water-quenched, and is used as a slag cement, a cement conditioner, an additive in cement production or a cement clinker;
  • Method E The iron-containing silicate mineral phase is used to produce high value-added cement clinker, including the following steps:
  • the slag mixture material is blown into the oxidizing gas with a preheating temperature of 0-1200 ° C, and the slag mixture material temperature is >1450 ° C; when the ferrous oxide weight percentage content is ⁇ 1%, the oxidation is obtained.
  • the oxidized slag is subjected to air cooling or water quenching to obtain a high value-added cement clinker;
  • Method F the iron-containing silicate mineral phase slag is used as a blast furnace ironmaking raw material or a direct reduction ironmaking raw material: the slag containing the iron silicate mineral phase is air-cooled, water quenched or slowly cooled, and used as a blast furnace Iron or direct reduction of ironmaking raw materials, after direct reduction, magnetic separation or electric furnace melting, magnetic separation products are metal iron and tailings, electric furnace melting, the product is molten iron and slag;
  • the separation is performed by the following method: magnetic separation after slag modification: slag flowing into the heat preservation device, blowing 0-1200 ° C Preheating the oxidizing gas, and ensuring that the slag temperature is >1250 ° C, completing the transformation of magnetite in the slag; slowly cooling the oxidized slag to room temperature, crushing, magnetic separation, and the product is magnetite Mine and tailings, tailings as building materials;
  • Method G The iron-containing silicate is subjected to reduction ironmaking, comprising the following steps:
  • the temperature of the reaction slag is 1350-1640 ° C and the reaction melting
  • the alkalinity CaO/SiO 2 ratio of the slag is 0.6 to 2.4, and the slag after completion of the reaction is obtained;
  • the method of controlling the temperature of the reaction slag is:
  • a metallurgical flux is added to the reaction slag, so that the temperature of the reaction slag reaches 1350-1640 ° C, wherein
  • the metallurgical flux is a mineral containing CaO or SiO 2 , specifically one or more of quartz sand, gold-silver quartz sand, red mud, red mud after desoda, calcium carbide slag, dolomite or limestone;
  • the method of controlling the alkalinity of the reaction slag is:
  • Method I Pour the mixed slag after reduction into a heat preservation slag tank, and cool to room temperature to obtain slow cooling slag; wherein, the metal iron is settled to the bottom of the reaction device to form iron slag, and the remaining chilled slag contains metal iron layer , crushed to a particle size of 20 to 400 ⁇ m, grinding, magnetic separation to separate the remaining metal iron and tailings;
  • Method II the mixed slag after reduction, cooling and sedimentation, separation of slag-gold, obtaining molten iron and reduced slag; and the slag after reduction is melted according to one or several methods of methods A to E Slag treatment; the molten iron is sent to a converter or an electric furnace for steelmaking;
  • part of the zinc-containing component and the lead-containing component volatilize, and enter the soot as an oxide
  • part of the gold-containing component and the silver-containing component enter the copper-rich nickel phase, and the nickel and cobalt components respectively enter the copper-rich nickel phase and the iron-rich phase;
  • the iron-rich phase layer is subjected to water quenching or air cooling or poured into a heat preservation device for slow cooling, and is used as a blast furnace smelting ferronickel raw material or a direct reduction smelting ferronickel raw material or a smelting reduction smelting ferronickel raw material or flotation Copper raw material; during flotation, the flotation products are copper concentrate, nickel concentrate, nickel-containing alloy and iron concentrate, iron concentrate as blast furnace ironmaking raw material or direct reduction ironmaking raw material or smelting reduction ironmaking raw material;
  • the direct reduction process uses a rotary hearth furnace, a tunnel kiln, a vehicle bottom road, a shaft furnace, a rotary kiln or an induction furnace as a reduction device, using gas-based or coal-based reduction technology, gas-based reduction using natural gas and/or gas, coal-based reduction Using one or more of anthracite, bituminous coal, lignite, coking coal, coke breeze or coke, the controlled reduction
  • the red mud contains potassium, sodium, dust, and steel soot containing lead, zinc, antimony, and indium silver, when these materials are added, some indium, antimony, potassium, and sodium groups are added. It is volatilized and enters the soot as an oxide.
  • Method 2 When the smelting reaction device through which the slag can flow out is used, the obtained iron-rich phase and the iron-containing silicate mineral phase treatment method are treated by one or more of the methods A to G described in the first method, Or pour the copper-rich nickel phase after the slow cooling of the heat preservation device, and send it to a converter or a rotary furnace or as a raw material for copper, cobalt and nickel separation.
  • Method 3 using the slag rotatable converter and the reaction slag tank, obtaining the iron-containing silicate mineral phase, and the treatment method is treated by one or several of the methods A to G described in the first method; or The iron-rich phase is treated in the first step S2-1-05; in a molten state or poured into the copper-rich nickel phase after the slow cooling of the heat preservation device, sent to a converter or a rotary furnace or used as a raw material for copper, cobalt and nickel separation.
  • Method 4 using a molten slag rotatable converter and a reaction slag tank, the obtained molten iron-containing silicate mineral phase and the iron-rich phase are obtained, and the treatment method is one or more of the methods A to G described in the first method.
  • the molten copper-rich nickel phase is poured into a heat preservation device and slowly cooled, and then sent to a converter or a rotary furnace or used as a raw material for copper cobalt nickel separation.
  • Method 5 When using a heat preservation device, or using a smelting reaction device through which slag can flow out, when pouring the slag into the heat preservation device, perform the following steps:
  • the slag is cooled to room temperature to obtain slow cooling slag; the copper-rich nickel phase is settled to the bottom of the reaction device to form copper-rich nickel ruthenium; the iron-containing silicate mineral phase floats; the middle is slow cooling
  • the slag is an iron-rich phase, and at the same time, a zinc-containing component and a lead-containing component are formed; wherein the gold and silver components migrate to the copper-rich nickel phase, and the nickel and cobalt components migrate to the nickel-rich copper phase and the iron-rich phase, respectively;
  • S202 separating: manually taking out the copper-rich bismuth settled at the bottom, sending it to a converter or a converting furnace or as a raw material for separating copper, cobalt and nickel; the iron-rich phase is used as a blast furnace smelting nickel-iron raw material or directly reducing nickel-iron raw material or melting Reduction of nickel-iron raw materials or smelting reduction of nickel-iron raw materials or flotation of copper raw materials; flotation products are copper-containing concentrates, nickel concentrates, nickel alloys and iron concentrates, iron concentrates as blast furnace ironmaking raw materials or direct reduction Ironmaking raw material or smelting reduction ironmaking raw material;
  • the oxidizing gas is one of preheated air, oxygen, oxygen-enriched air, nitrogen-air, argon-air, oxygen-nitrogen, oxygen-argon.
  • the mixing is uniformly mixed by natural mixing and stirring, and the stirring and mixing is performed by argon stirring, nitrogen stirring, nitrogen-argon gas mixture stirring, and reducing property.
  • gas agitation oxidative gas agitation, electromagnetic agitation or mechanical agitation;
  • the sedimentation is natural sedimentation or spin sedimentation or centrifugal sedimentation;
  • the cooling mode when cooling sedimentation is natural cooling or rotary cooling or centrifugal cooling, and the gravity sorting method is a shaker. Sorting, chute sorting or a combination of the two.
  • the method for producing a mixed slag containing nickel and iron can treat hot slag and make full use of molten nickel smelting slag and molten metallurgical slag (lead smelting slag, molten blast furnace slag, molten steel slag, melting)
  • molten nickel smelting slag and molten metallurgical slag lead smelting slag, molten blast furnace slag, molten steel slag, melting
  • One or more of the iron alloy slag physical thermal resources and hot metallurgical flux, which can also process cold slag, and realize slag metallurgical modification by slag mixing or cold mixing
  • (2) mixing slag The slag metallurgical reaction, the disintegration of the olivine, the iron oxide is fully released, to achieve growth and sedimentation, the metal iron component in the mixed slag is aggregated, grown and settled, and the iron-rich phase includes metallic iron and FeO phase
  • copper component, nickel cobalt component, gold and silver components in the mixed slag are respectively enriched in copper Nickel phase, and achieve growth and sedimentation; wherein, the copper-rich nickel phase includes copper, blister copper, copper ice nickel, copper-rich nickel-cobalt phase, a plurality of iron-containing components, or part of the copper component into the rich Iron phase; (4) The zinc component and the lead component in the mixed slag are respectively concentrated in the soot Recycling; part of the indium-containing component, antimony component, potassium-containing component, sodium-containing component volatilized into the soot for recovery; (5) migration of silicon, calcium and phosphorus components in the mixed slag, enrichment in silicic acid Salt mineral phase, floating; (6) free calcium oxide and magnesium oxide disappeared in the mixed slag, mixed slag to achieve quenching and tempering; (7) manual sorting, magnetic separation, re-
  • the present invention realizes a copper component, an iron component, a zinc component, a lead component, a nickel component, a cobalt component, a gold component, a silver component, a bismuth component in a nonferrous metallurgical slag and a steel metallurgical slag,
  • the comprehensive utilization of sodium component, potassium component and valuable component solves the problem of large accumulation of slag and environmental pollution.
  • the invention can not only process ferroalloy slag, steel slag, blast furnace slag, lead smelting slag, copper-containing slag, but also copper oxide mineral, copper sulfide mineral and copper-containing material.
  • the present invention can treat cold copper-containing and iron-containing materials.
  • the raw material of the present invention may be one or more of liquid molten nickel smelting slag ( ⁇ 1200 ° C) and molten metallurgical slag (melted lead smelting slag, molten blast furnace slag, molten steel slag, molten iron alloy slag) flowing out of the slag discharge port.
  • molten metallurgical slag melted lead smelting slag, molten blast furnace slag, molten steel slag, molten iron alloy slag
  • Species, ⁇ 1050°C featuring high temperature and high heat, making full use of slag physical heat resources
  • mixed slag contains a large amount of hot metallurgical flux, which is a slag system with excellent physical and chemical properties. Efficient utilization of metallurgical resources and thermal resources; fully utilizing the characteristics of high reactivity chemical reactivity of mixed slag, and achieving slag metallurgy.
  • the present invention enriches the copper group, the nickel-cobalt component, the gold component and the silver component in the slag to the copper-rich nickel phase by mixing the slag, holding or blowing the gas; wherein the copper-rich nickel phase is further Including copper phase, white copper, copper ice nickel, copper-rich nickel-cobalt phase, iron-containing components, to achieve aggregation, growth and sedimentation, or part of the copper component into the iron-rich phase, to achieve aggregation, growth And sedimentation, the iron-rich phase includes a plurality of metal iron, FeO phase, and fayalite phase, as a raw material for blast furnace ironmaking or direct reduction or smelting reduction ironmaking; the lead component and the zinc component are enriched in the soot to be recovered; The indium component, the bismuth component, the sodium component, and the potassium component are volatilized, and are collected into the soot to be recovered.
  • the cold material and the molten nickel slag are added to avoid the slag temperature being too high, and the life of the heat preservation device is increased; adding the cold material and the molten nickel slag improves the processing amount of the raw material, and can not only treat the liquid slag Moreover, a small amount of cold material can be processed, and the raw material is highly adaptable; the cold material is added to realize the efficient use of the chemical heat released by the slag metallurgical reaction and the physical heat of the slag.
  • the copper component, the nickel-cobalt component and the gold-silver component in the slag are respectively concentrated in the copper-rich nickel phase, and the aggregation, growth and sedimentation are realized, and the iron component in the slag Enriched in the iron-rich phase, and achieves aggregation, growth and settlement;
  • the slag-containing insulation device is placed on the rotating platform to accelerate the accumulation, growth and settlement of the copper-rich nickel phase and the iron-rich phase;
  • the method of the invention adopts manual sorting, magnetic separation, re-election or slag-gold separation to respectively distribute low-iron silicate mineral phase, iron-rich phase and copper-rich nickel phase distributed in the upper part, the middle part and the bottom part. Separation is carried out to achieve efficient recovery of copper component, nickel component, cobalt component, gold and silver component, indium component, antimony component and iron component in the slag, and the obtained iron-containing silicate phase and iron-rich phase are obtained.
  • the slag of the component contains ⁇ 0.1wt% copper.
  • the amount of slag to be sorted is small, the mineral grindability is increased, and the cost of grinding, magnetic separation and re-election is increased. Low; the subsequent separation process uses magnetic separation or re-election, the separated medium is water, and there is no environmental pollution during the separation process; tailings are used as cement raw materials, building materials, instead of crushed stone as aggregate and road material.
  • the present invention precipitates through a copper-rich nickel phase, and the iron-containing silicate phase and the iron-rich component have a copper content of less than 0.1%, and are used as a raw material for blast furnace ironmaking or direct reduction or smelting reduction to obtain metallic iron and molten iron.
  • the invention fully utilizes the slag physical heat resource and the hot metallurgical flux, and can also treat the cold slag, realizes the slag metallurgy, the copper component, the nickel component, the cobalt component, the gold and silver group in the slag Divided into a copper-rich nickel phase, And to achieve aggregation, growth and sedimentation, iron components are enriched in the iron-rich phase, to achieve aggregation, growth and sedimentation, separation of copper-rich nickel phase and iron-rich phase in different parts, to achieve valuable components in the slag Efficient recovery; can process solid copper-containing materials, this method has short process flow, high metal recovery rate, low production cost, strong adaptability of raw materials, large processing capacity, environmental friendliness, high economic returns, and can solve high-efficiency recovery of metallurgical resources and heat energy. Use the problem.
  • the invention provides a method for producing a mixed slag containing nickel and iron, which comprises the following steps:
  • Step 1 slag mixing:
  • the nickel smelting slag is added to the smelting reaction device in which the smelting can be discharged or the molten slag can be added, and one of the lead smelting slag (the smelting furnace slag and/or the lead smelting slag), the blast furnace slag, the steel slag and the iron alloy slag is added.
  • One or more kinds, forming mixed slag simultaneously adding one or two of copper oxide mineral, copper sulfide mineral, nickel oxide mineral, nickel sulfide mineral, copper-containing material; mixing uniformly as nickel-containing and iron reactive melting Slag, and monitoring the reaction slag in real time, through the regulation and ensuring the following two parameters (a) and (b), obtaining the slag after the completion of the reaction, or pouring the slag after the completion of the reaction into the heat preservation device; (a) The reaction temperature of nickel and iron reaction slag is 1050 ⁇ 1450 ° C;
  • the control method is:
  • the method of controlling the temperature of the reaction slag containing nickel and iron in the set temperature range is:
  • the heating function of the reaction device itself is added, or fuel or molten nickel smelting slag, molten lead smelting slag, molten blast furnace slag, and melting are added to the slag.
  • One or more of steel slag or molten iron alloy slag when injected into the fuel, simultaneously injected into the preheated oxidizing gas, so that the temperature of the reaction slag reaches a set temperature range;
  • nickel smelting slag copper oxide mineral, copper sulfide mineral, nickel sulfide mineral, nickel oxide are added to the reaction slag containing copper and iron.
  • the slag After 5 to 50 minutes of heat preservation, the slag after the completion of the reaction, sedimentation, and slag-gold separation, obtain copper-nickel rich in the bottom molten state, iron-rich phase in the middle and lower molten state, and iron-containing silicate mineral phase in the middle and upper molten state. Simultaneously forming a zinc-containing component and a lead-containing component, wherein the indium, antimony, nickel, cobalt, gold, and silver components migrate to the copper-rich nickel phase, and part of the nickel-cobalt component migrates to the iron-rich phase; Recycling is carried out.
  • the iron-rich phase is obtained by water quenching or air cooling or pouring into a heat preservation device, or by manual sorting and re-election, as a raw material for blast furnace ironmaking or direct reduction of nickel-iron raw materials or smelting reduction of nickel-iron raw materials or float Selecting copper and nickel raw materials; flotation products are copper concentrate, nickel concentrate, nickel-containing alloy and iron concentrate, iron concentrate as blast furnace ironmaking raw material or direct reduction ironmaking raw material or smelting reduction ironmaking raw material;
  • the reduction process uses a rotary hearth furnace, a tunnel kiln, a vehicle bottom road, a shaft furnace, a rotary kiln or an induction furnace as a reduction device, using gas-based or coal-based reduction technology, gas-based reduction using natural gas and/or gas, and coal-based reduction using anthracite
  • One or more of bituminous coal, lignite, coking coal, coke breeze or coke, the controlled reduction temperature is 900-1400 ° C, and the control al
  • Iron-containing silicate mineral phase as cement raw material Iron-containing silicate mineral phase as cement raw material
  • the iron-containing silicate mineral phase is directly quenched or air-cooled as a cement raw material or further processed into a high value-added cement raw material;
  • Method B Part or all of the iron-containing silicate mineral phase is returned to the copper-containing reaction slag:
  • Method C iron-containing silicate mineral phase Pouring glass-ceramic or as slag wool;
  • Method D Air-cooling or water quenching after oxidation of iron-containing silicate slag:
  • the preheated fuel and the preheated oxidizing gas are injected, the heat is burned, the heat is supplemented, or the device is heated by itself, so that the silicate slag temperature is >1450 ° C;
  • Method E Treatment of high value-added cement clinker by treatment with iron silicate slag:
  • E-1 Add molten steel slag, lime, limestone, iron alloy slag, fly ash, alkaline iron ore, bauxite, molten blast furnace slag, red mud to the iron-containing silicate slag in the smelting reaction device. , one or more of red mud or calcium carbide slag after de-sodium, fully mixed to obtain a slag mixture;
  • Method F Iron-containing silicate mineral phase slag as blast furnace ironmaking raw material or direct reduction ironmaking raw material: slag containing iron silicate mineral phase is air-cooled, water quenched or slowly cooled, used as blast furnace ironmaking or Direct reduction of ironmaking raw materials, after direct reduction, magnetic separation or electric furnace melting, magnetic separation products are metal iron and tailings, electric furnace melting, the product is molten iron and slag;
  • the separation is performed by the following method: magnetic separation after slag modification: slag flowing into the heat preservation device, blowing 0-1200 ° C Preheating the oxidizing gas, and ensuring that the slag temperature is >1250 ° C, completing the transformation of magnetite in the slag; slowly cooling the oxidized slag to room temperature, crushing, magnetic separation, and the product is magnetite Mine and tailings, tailings as building materials;
  • the zinc-containing component and the lead-containing component are volatilized, and enter the soot as an oxide
  • G-1 smelting silicate slag in the reaction device, or adding iron-containing material, adding reducing agent to the slag, performing smelting reduction, monitoring the reaction slag in real time, and ensuring the following (a) and (b) ) two parameters to obtain the slag after the completion of the reaction;
  • the control method is:
  • the method for controlling the temperature of the reaction slag in the set temperature range is:
  • the heating function of the reaction device itself is added, or the fuel and the preheated oxidizing gas are added to the slag to make the temperature of the reaction slag reach the set temperature range;
  • reaction slag When the temperature of the reaction slag is lower than the upper limit of the set temperature range, one or more of a metallurgical flux, an iron-containing material or a fluorine-containing material is added to the reaction slag to bring the temperature of the reaction slag to a set temperature range. ;
  • G-2 smelting and reducing the oxidizing gas after preheating into the slag to form reduced slag, wherein: the oxidizing gas is preheated at a temperature of 0 to 1200 ° C, and is passed during the blowing process. Regulation also guarantees two parameters (a) and (b):
  • the temperature range and the alkalinity control method are the same as the method G step (1);
  • Method I Perform the following steps:
  • Method II Perform the following steps:
  • the gas produced by the reduction is secondarily burned on the surface of the slag to provide heat, and the gas flowing out of the furnace can be used as a heat source for the drying furnace material and the heat preservation device;
  • the molten iron-containing silicate mineral phase is subjected to slag treatment by a slag treatment by one or more of the methods A to G in the separation and recovery method 1 of the step 2;
  • the step of containing the iron-rich phase is carried out by the step (4) in the first method;
  • the molten iron-containing silicate mineral phase and the iron-rich phase are subjected to slag treatment in a specific manner: one or more of the methods A to G in the separation and recovery method 1 of the step 2 are used;
  • Method 5 When using a heat preservation device, or using a smelting reaction device through which slag can flow out, when the slag is poured into the heat preservation device, the slag after the reaction is completed is as follows:
  • the nickel smelting slag is in a molten state or a cold state, wherein: the molten nickel smelting slag is obtained from a slag opening of a nickel smelting furnace, or the nickel smelting slag is heated To the molten state; the nickel smelting slag is the nickel smelting slag produced by the "smelting smelting" process, the copper smelting nickel blowing process, the blowing slag after the process blowing, and the blowing slag after the "copper ice nickel blowing" process blowing Depleted slag produced by depletion, nickel smelting slag produced by top-blown smelting, and one or more of sedimentation slag produced by sedimentation of nickel smelting slag produced by top-blown smelting;
  • the copper material in the step 1 is crude copper fire refining slag, copper slag, copper tailings, zinc smelting slag, zinc smelting soot and dust, lead smelting slag, lead zinc tailings, lead copper, arsenic ice Copper, crude lead fire refining slag, lead smelting soot and dust, lead acid battery, copper smelting soot and dust, copper, copper-containing garbage, copper-containing circuit board, tin smelting slag, tin tailings Or several; zinc smelting slag is zinc smelting slag produced by wet zinc smelting and pyrometallurgical smelting, including leaching slag, iron slag slag, copper cadmium slag, goethite slag, hematite slag, volatile kiln slag, vertical Smelting zinc slag, blast furnace slag, smelting furnace s
  • the copper slag is a copper-containing smelting slag, a copper-containing blowing slag, a depleted slag, a flotation tailings
  • the copper smelting slag is produced in the "smelting and smelting" process of the copper smelting process
  • the copper smelting slag is produced in the copper smelting process "Blowing" process
  • depleted waste slag is copper smelting slag and copper-containing blowing slag depleted and then slag
  • flotation tailings are copper smelting slag and copper-containing slag slag after beneficiation
  • the iron alloy slag is in a molten state, or in a cold state, wherein: molten slag (lead smelting slag, blast furnace slag, steel slag and iron alloy s
  • the copper oxide mineral comprises one or more of a cuprite, a chert, a malachite, a azurite, a chrysocolla, a cholesteric Copper sulfide minerals include one or more of chalcopyrite, copper blue, chalcopyrite, porphyrite, sulphide arsenite, and beryllium copper.
  • the smelting reaction device through which the slag can flow is a rotatable smelting reaction device or a smelting reaction device with a slag port or an iron port;
  • the heat preservation device is a pourable smelting reaction slag irrigation and heat preservation pit
  • the rotatable smelting reaction device is a converter and a smelting reaction slag tank;
  • the smelting reaction device with the slag port or the iron slag flowing out is a plasma furnace, a direct current arc furnace, an alternating current arc furnace, a submerged arc furnace, a blast furnace, a blast furnace, an induction furnace, a cupola, and a side blowing molten pool melting furnace.
  • the two parameters (a) and (b) are ensured at the same time, and the copper oxide, nickel oxide, cobalt oxide and iron oxide in the slag are reduced to metal copper and metal nickel.
  • Metal cobalt and FeO, the metal iron content in the slag is ⁇ 3%. It can be regulated by adding one or both of a reducing agent and a carbon-containing iron-containing material, wherein the reducing agent and/or the carbon-containing iron-containing material is used in the amount of copper oxide and nickel oxide in the slag.
  • the carbon-containing iron-containing material is steel dust and soot, iron concentrate carbon pre-reduction pellets Iron concentrates containing carbon metallized pellets, wet zinc smelting kiln slag, coke oven dust and soot.
  • the fuel and the reducing agent are one or more of a solid, a liquid or a gas, which are sprayed in a spray manner, and the loading gas is an oxidizing gas, nitrogen gas or argon gas.
  • the preheating temperatures of the loaded gas are 0 to 1200 ° C; the blowing method is to insert the slag into the slag by using a refractory spray gun or to blow into the upper part or the side of the reaction slag containing copper and iron.
  • the solid fuel and the reducing agent are one or more of pulverized coal, fly ash, coke powder, coke, bituminous coal or anthracite coal, and the shape is granular or powdery or massive, and the granular material has a particle size of 5 to 25 ⁇ m, and the powder
  • the granular material has a particle size of ⁇ 150 ⁇ m
  • the liquid fuel and the reducing agent are heavy oil
  • the gaseous fuel and the reducing agent are one or both of gas and/or natural gas
  • the metallurgical flux is a mineral containing CaO or SiO 2 , specifically It is one or more of quartz sand, gold-silver quartz sand, red mud, high-calcium red mud after desoda, calcium carbide slag, dolomite or limestone;
  • the iron-containing material is ordinary iron concentrate, ordinary iron concentrate direct reduced iron, ordinary iron concentrate sintered ore, ordinary iron concentrate pellet, ordinary iron concentrate metallized pellet, ordinary iron concentrate carbon-bearing pre- Reducing pellets, steel slag, zinc smelting slag, coke smelting soot and dust, steel soot and dust, nickel smelting slag, copper slag, lead smelting slag, zinc smelting slag, tin smelting slag, red mud, high after sodium removal
  • the fluorine-containing material is one or more of fluorite, CaF 2 or fluorine-containing blast furnace slag.
  • the method of controlling the temperature of the mixed slag in the set temperature range is:
  • the copper-containing material, the iron-containing material and the fluorine-containing material are pellets or powdery materials or granulation; wherein the granular material has a particle size of 5 to 25 ⁇ m, the powdery material has a particle size of ⁇ 150 ⁇ m, and the powdery material is sprayed.
  • Injecting the gas into one or more of argon gas, nitrogen reducing gas (gas and/or natural gas), and oxidizing gas, and the preheating temperature of the loaded gas is 0 to 1200 ° C.
  • the blowing method is to insert the slag into the slag by using a refractory spray gun or to blow into the upper part or the side of the reaction slag containing copper and iron;
  • the copper-containing material and the iron-containing material are in a hot or cold state, and the hot material is a hot material directly produced from a metallurgical furnace, and the temperature of the hot material is 200 to 1550 °C.
  • the wet zinc slag and dust are subjected to dehydration and drying.
  • zinc smelting slag and soot, lead smelting slag and soot contain indium and antimony, lead, silver, zinc and antimony; red mud contains sodium and potassium, and steel soot and dust contain indium, antimony and silver.
  • Sodium and potassium the above materials all have iron, lead smelting slag and zinc smelting slag contain copper, copper soot and dust contain indium and antimony, so in the method of the invention, indium, antimony, sodium, potassium, zinc, lead will The fumes are entered in the form of oxides for recycling.
  • the method of controlling the temperature of the mixed slag in the set temperature range is:
  • one or more of nickel smelting slag, copper-containing material, iron-containing material, blast furnace slag, steel slag, iron alloy slag, metallurgical flux or fluorine-containing material are added. Avoid excessive temperature and protect refractory materials; another function of adding fluorine-containing materials is to reduce the viscosity, accelerate the accumulation of copper-rich nickel phase and iron-rich phase in the slag, grow and settle, and facilitate the silicate to float;
  • the copper component, the nickel-cobalt component, the gold-silver component in the slag is enriched in the copper-rich nickel phase, and the aggregation, growth and sedimentation are realized, and the iron component is The olivine is released and enriched in the iron-rich phase to achieve aggregation, growth and sedimentation.
  • the zinc component, lead component, indium component and strontium component in the slag enter the soot respectively, and the soot is recovered as oxide.
  • the copper-rich nickel phase is copper, white copper, copper ice nickel, copper-rich nickel-cobalt, a plurality of iron-containing components, or a part of the nickel-cobalt component enters the iron-rich phase, and the iron-rich phase includes metallic iron and FeO phase. And a variety of fayalite phases;
  • the alkaline material when the alkalinity is adjusted, may be one or more of lime powder, red mud, red mud after desoda, calcium carbide slag, dolomite powder or quicklime powder;
  • the alkaline iron-containing material is an alkaline sinter of CaO/SiO 2 >1, steel slag, iron alloy slag, alkaline iron concentrate, alkaline pre-reduction pellet, alkaline metallized pellet, steel slag or blast furnace slag One or several;
  • the acidic material when the alkalinity is adjusted, may be one or more of silica, fly ash and coal gangue;
  • the acidic iron-containing material is CaO/SiO 2 ⁇ 1 Iron-containing material, acid sinter, acid iron concentrate, acid pre-reduction pellet, acid metallized pellet, copper slag, lead smelting slag, zinc smelting slag, nickel smelting slag, tin smelting slag, iron alloy slag, blast furnace slag
  • copper-containing pyrolysis slag and copper-containing tailings is CaO/SiO 2 ⁇ 1 Iron-containing material, acid sinter, acid iron concentrate, acid pre-reduction pellet, acid metallized pellet, copper slag, lead smelting slag, zinc smelting slag, nickel smelting slag, tin smelting slag, iron alloy slag, blast furnace slag
  • the copper-rich nickel phase and the iron-rich phase in the slag are aggregated, grown and settled, which is favorable for the silicate to float.
  • zinc smelting slag and soot, lead smelting slag and soot contain indium and antimony, lead, silver, zinc and antimony; red mud contains sodium and potassium, and steel soot and dust contain indium, antimony and silver.
  • Sodium and potassium the above materials all have iron, lead smelting slag and zinc smelting slag contain copper, copper soot and dust contain indium and antimony, so in the method of the invention, indium, antimony, sodium, potassium, zinc, lead will The fumes are entered in the form of oxides for recycling.
  • the mixed slag is sufficiently mixed while ensuring the two parameters (a) and (b), and the mixing mode is natural mixing or stirring mixing, and the stirring mode is one of the following modes: argon stirring. , nitrogen stirring, One or more of argon-nitrogen mixed gas, reducing gas stirring, oxidizing gas stirring, electromagnetic stirring, mechanical stirring, gas preheating temperature is 0 to 1200 ° C;
  • the oxidizing gas is one of air, oxygen, oxygen-enriched air, nitrogen-oxygen, argon-oxygen, and the oxidizing gas preheating temperature is 0 to 1200 ° C, and the blowing method is One or more of the slag is inserted into the slag or placed in the upper or side or bottom of the reaction slag.
  • the direct reduction process uses a rotary hearth furnace, a tunnel kiln, a vehicle bottom road, a shaft furnace, a rotary kiln, an induction furnace as a reduction device, and a gas-based or coal-based reduction technique
  • the gas base is natural gas.
  • coal-based reduction to one or more of anthracite, bituminous coal, lignite, coking coal, coke breeze, coke, reduction temperature of 900-1400 ° C, alkalinity CaO / SiO 2 ratio 0.7 ⁇ 1.9;
  • the copper-containing material and the iron-containing material are in a hot state or a cold state, and the hot material is a hot material directly produced from a metallurgical furnace, and the temperature of the hot material is 200 to 1750. °C.
  • the cooling mode is natural cooling or rotary cooling or centrifugal cooling
  • the sedimentation mode is natural sedimentation or rotary sedimentation or centrifugal cooling
  • the specific operation of the rotation and the centrifugal cooling is: the device containing the slag after the reaction is completed is placed on the rotating platform, and is rotated according to a certain speed, and the rotation speed is determined according to the quality of the slag and the height or depth of the heat preservation device, and the rotation is performed.
  • the time depends on the quality of the slag and the solidification of the slag; the device containing the slag after the completion of the reaction is placed on a rotating platform for the purpose of accelerating the accumulation of copper-rich nickel phase, iron-rich phase, growth and sedimentation, Conducive to the silicate floating, shortening the settling time, improving the settlement effect and improving production efficiency.
  • step 2 in the slag cooling process after the completion of the reaction, most of the copper-rich nickel phase and the iron-rich phase settle in the middle and lower portions due to the difference in density and mineral size;
  • the copper component and the nickel-cobalt component gold and silver components in the slag after the completion of the reaction are continuously enriched in the copper-rich nickel phase, and are grown and settled, or partially enriched in the iron-rich phase; the iron component in the mixed slag Continue to enrich the iron-rich phase and achieve growth and settlement.
  • the finally obtained slag contains copper ⁇ 0.1%, the final iron recovery rate is ⁇ 89%, the zinc recovery rate is ⁇ 91%, the lead recovery rate is ⁇ 92%, and the nickel enrichment rate is ⁇ 91%, the enrichment rate of cobalt is ⁇ 91%, the enrichment rate of gold is ⁇ 94%, and the enrichment rate of silver is ⁇ 94%.
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing: the molten nickel smelting slag obtained from the slag smelting process of the smelting process is added to the DC arc furnace by the slag venting port of the "copper ice nickel blowing" process, and the cold state is added at the same time.
  • Step 2 separation and recovery method 1:
  • the slag After 50 min of heat preservation, the slag is naturally settled, and the slag-gold is separated to obtain a molten copper-rich nickel phase layer, an iron-rich phase layer and an iron-containing silicate mineral phase, and at the same time, a zinc component and a lead component are formed, and the following steps are carried out: 1) In the molten state, the iron-containing silicate mineral phase is treated by the external slag, and the method F is used. After the silicate slag is air-cooled, it is used as a direct reduction ironmaking raw material, and the rotary kiln is used for direct reduction and gas reduction.
  • the gas-based reducing agent is natural gas and gas
  • the reduction temperature is 900 ° C
  • the alkalinity CaO / SiO 2 ratio is 0.8
  • the metal iron and slag are obtained by melting in a magnetic furnace, and the melting temperature is 1550 ° C
  • the molten copper-rich nickel phase is sent to the converter; (3) the iron-rich phase layer is poured into the heat preservation device, and the ferronickel is used as the blast furnace to smelt the nickel-iron raw material; (4) the zinc component, the indium component, the lead component, and the bismuth group
  • the potassium component and the sodium component volatilize and enter the soot recovery in the form of oxide.
  • the finally obtained slag contains copper ⁇ 0.1%, zinc recovery rate is 92%, lead recovery rate is 92%, and iron recovery rate is 92%.
  • Indium recovery rate is 92%, hydrazine recovery rate is 94%, sodium recovery rate is 95%, potassium recovery rate is 96%, iron 96% yield, 93% enrichment of nickel, cobalt enrichment was 95%, 96% enrichment of gold, silver was 94% enrichment.
  • the slag-containing copper refers to the slag phase after the nickel-rich copper phase separation, specifically the copper content in the iron-rich phase and the silicate mineral phase, and the enrichment ratio of nickel and cobalt.
  • the enrichment ratio of gold and silver means that the content of gold and silver in the copper-rich nickel phase accounts for gold and silver in the raw material. The percentage of the total.
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 Slag mixing: molten nickel smelting slag obtained from the slag smelting slag exiting process of the smelting process and molten smelting slag obtained by the "copper ice nickel blowing" process slag slag passing through the slag outlet of the lean furnace Adding a pourable smelting reaction slag, adding iron alloy slag produced by molten smelting ferrochrome obtained from the slag outlet to form mixed slag, adding copper oxide concentrate and nickel sulfide concentrate at the same time; using preheating temperature of 800 °C oxygen-enriched air, 20mm anthracite and coke particles, and blowing natural gas, heating the mixed slag to a molten state, forming a reaction slag containing copper and iron, and electromagnetically stirring the reaction slag to achieve mixing; Monitoring the reaction slag, and simultaneously controlling the two parameters (a) and (b) to obtain the slag after completion of the reaction;
  • Step 2 Separation and recovery method 2: heat preservation for 15 min, slag spin sedimentation after completion of reaction, slag-gold separation, obtain molten copper-rich nickel phase layer, iron-rich phase layer and iron-containing silicate mineral phase, and simultaneously generate The zinc component, the lead component and the indium component enter the soot and are recovered as an oxide, and the following steps are carried out: (1) the molten silicate mineral phase and the iron-rich phase layer, and the method G is used to carry out the slag outside the furnace Treatment, smelting and smelting reduction of ferronickel, the steps are as follows: (1-1) slag is poured into a pourable converter, and anthracite and bituminous coal having a particle size of 20 mm are added to the slag for smelting reduction, and the reaction slag is monitored in real time.
  • the final slag contains copper ⁇ 0.1%, zinc recovery rate is 92%, lead recovery rate is 92%, iron recovery rate is 91%, and indium recovery rate. 96%, the recovery rate of cesium is 96%, the recovery rate of sodium is 97%, the recovery rate of potassium is 98%, the enrichment rate of nickel is 92%, the enrichment rate of cobalt is 96%, and the enrichment rate of gold is 94%. , The enrichment was 95%.
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing: the molten nickel smelting slag obtained from the slag smelting slag smelting port of the smelting process and the molten nickel smelting slag obtained by smelting the smelting slag from the top blowing molten pool to the slag outlet of the settling electric furnace are added to the DC arc furnace At the same time, the steel slag obtained from the slag outlet of the converter steelmaking is added to form the mixed slag, and the copper sulfide concentrate and the copper oxide concentrate are simultaneously added; the oxygen having a preheating temperature of 800 ° C is used to spray the anthracite and coke having a particle size of 20 mm.
  • the mixed slag is heated to a molten state to form a reaction slag containing copper and iron, and the slag is mixed; the slag is monitored in real time, and two parameters (a) and (b) are ensured by regulation.
  • Step 2 separation and recovery method 2: heat preservation for 12 min, slag natural sedimentation, slag-gold separation, obtain molten copper-rich nickel phase, iron-rich phase layer and iron-containing silicate mineral phase, and simultaneously form zinc-containing components and
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing: the molten nickel smelting slag obtained by melting the smelting slag in the cold state by the top blowing molten pool and passing through the slag outlet of the sedimentation electric furnace is added to the plasma furnace, and the converter steel slag, electric furnace steel slag obtained by the slag outlet, and the smelting are added.
  • Ferroalloy slag obtained by ferronickel, forming mixed slag, adding copper oxide concentrate and copper-containing material (wet zinc leaching slag, wet zinc smelting kiln slag); heating molten slag to molten state to form
  • the reaction slag between copper and iron is sprayed with argon gas at a preheating temperature of 700 ° C, and the reaction slag is mixed; the reaction slag is monitored in real time, and two parameters (a) and (b) are simultaneously controlled to obtain a reaction.
  • the temperature of the reaction slag containing copper and iron is 1670 ° C, adding red mud, sulfuric acid slag, fluorite, lead copper, lead-containing soot, zinc-containing to the reaction slag Soot, arsenic matte and wet zinc slag, the temperature is reduced to 1320 ° C;
  • the reaction slag basicity CaO / SiO 2 ratio of copper and iron is 2.9, copper is blown into the reaction slag Slag, the ratio of alkalinity of slag containing copper to iron is reduced to 1.1; natural gas is sprayed, Blowing air with a particle size of 20mm the coke, the metallic iron content of the slag was 2.5%;
  • Step 2 separation and recovery method 4: heat preservation for 42 min, after the reaction is completed, the slag is poured into the natural cooling sedimentation, and the slag-gold separation, obtaining the molten copper-rich nickel phase, the iron-rich copper phase layer and the iron-containing silicate mineral phase, Carry out the following steps: (1) molten copper-rich nickel phase, sent to the converter; (2) molten iron-rich phase layer and iron-containing silicate mineral phase step 2 separation and recovery method 1 method F, oxidation modified magnetic separation Separation: 1 Pour the slag into the slag pot, spray oxygen-enriched air with preheating temperature of 900 °C into the slag to realize the transformation of magnetite; 2 slowly cool to room temperature, magnetic separation and separation, and obtain iron concentrate And tailings; (3) part of the zinc-containing component, antimony component, indium component and lead-containing component volatilization, into the dust recovery, slag containing copper ⁇ 0.1%, iron recovery rate of 90%, zinc recovery The rate is 92%, the lead recovery
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing: the molten nickel smelting slag obtained from the slag smelting slag exit of the smelting process, and the molten nickel smelting slag obtained from the slag outlet of the "copper ice nickel blowing" process blowing furnace are added to the reverberatory furnace.
  • the molten steel slag obtained from the slag outlet is added to form mixed slag, copper oxide concentrate and copper-containing material (lead smelting slag, smelting furnace slag, lead sulphide and arsenic matte); preheating temperature is 800
  • the air of °C is sprayed with 20mm bituminous coal and coal powder, and the mixed slag is heated to a molten state to form a reaction slag containing copper and iron, and the reaction slag is mixed; the reaction slag is monitored in real time, and the control is simultaneously controlled.
  • the two parameters (a) and (b) are guaranteed to obtain the slag after the completion of the reaction; corresponding to (a): the reaction slag temperature of copper and iron is 1310 ° C; (b): the reaction of copper and iron with slag alkali Degree CaO / SiO 2 ratio of 1.5, are within the required range; metal iron content in the slag is 1.6%;
  • Step 2 Separation and recovery method 5: Pour the slag after completion of the reaction into the insulation pit, and carry out the slag treatment outside the furnace, and perform the following steps: (1) Settlement cooling: heat preservation for 42 min, the slag naturally after the reaction is completed Cooling to room temperature, obtaining slow cooling slag; copper-rich nickel phase settles to the bottom of the reaction device to form copper-rich nickel ruthenium; iron-containing silicate mineral phase floats; copper-rich nickel phase metal lanthanum and silicate mineral intermediate slow slag For the iron-rich phase, the zinc-containing and lead-containing components are simultaneously formed; (2) separation: the copper-rich nickel ruthenium precipitated at the bottom is manually taken out, and the product is used as a raw material for separating copper-nickel-chromium; the iron-rich phase layer in the middle is used as blast furnace nickel-making (3) manually take out the upper iron-containing silicate mineral phase, obtain silicate tailings, use as cement raw material; (4) part of zinc component and lead component volatilize,
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing: the cold nickel smelting slag obtained by the "osmosis process” process, the cold nickel smelting slag obtained by the "copper ice nickel blowing process” blowing slag through the depleting furnace is added to the alternating current arc furnace, Adding iron alloy slag produced by cold smelting ferrovanadium and ferroalloy slag produced by smelting ferrosilicon to form mixed slag, adding copper sulfide concentrate, nickel oxide concentrate, nickel sulfide concentrate and copper-containing material (containing copper smelting slag, Copper-containing blowing slag and copper fire refining slag); heating the mixed slag to a molten state to form a reaction slag containing copper and iron, blowing an argon-nitrogen mixed gas having a preheating temperature of 1100 ° C and melting the reaction Slag mixing; real-time monitoring of reaction slag, through regulation and control of (a) (b) two
  • Step 2 separation and recovery method 1: heat preservation for 19 min, the slag after the completion of the reaction is naturally settled, slag-gold separation, obtaining molten copper-rich nickel phase, iron-rich phase layer and silicate mineral phase, and zinc and containing Lead component, the following steps are carried out: (1) molten iron-containing silicate mineral phase adopts step 2 separation and recovery method method A, water quenching directly as cement raw material; (2) molten copper-rich nickel phase, sent to converter (3) The iron-rich layer is poured into the heat preservation device to cool, and the nickel-iron is directly reduced; (4) part of the zinc-containing and lead-containing components are volatilized, and are collected into the dust as oxides, and the slag contains copper ⁇ 0.1%, and the iron is recovered.
  • the rate is 91%, the recovery rate of zinc is 92%, the recovery rate of lead is 92%, the enrichment rate of nickel is 95%, the enrichment rate of cobalt is 93%, and the enrichment rate of gold is 94%.
  • the enrichment rate is 96%.
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing: molten nickel smelting slag obtained from the slag smelting process of the smelting process, and molten smelting slag obtained from the slag outlet of the "copper ice nickel blowing" process blowing furnace are added to the submerged arc furnace At the same time, the slag produced by the smelting of the slag and the slag produced by the smelting of the ferromolybdenum are added to form the mixed slag, and the copper oxide concentrate is added at the same time (the copper fire depleted waste residue, the copper slag flotation tailings, the Copper tailings); heating the mixed slag to a molten state, forming a reaction slag containing copper and iron, and allowing the reaction slag to be blown with nitrogen to achieve mixing; real-time monitoring of the reaction slag, while ensuring (a) and (b) Two parameters to obtain the slag after the completion of the reaction; corresponding
  • Step 2 separation and recovery method 3: heat preservation for 35 min, the slag is naturally settled after the reaction is completed, and the slag-gold separation results in a molten copper-rich nickel phase, an iron-rich phase, an iron-containing silicate mineral phase, and a zinc component and lead.
  • the components are subjected to the following steps: (1) a copper-rich nickel phase and a converter; (2) an iron-rich phase layer and a silicate mineral, which are specifically subjected to the method F of the separation and recovery method of the second step, after water quenching, as a direct Reducing the raw material of nickel-iron; (3) part of the zinc-containing component and the lead-containing component volatilize, and enter the soot recovery as an oxide, and finally obtain the slag containing copper ⁇ 0.1%, the iron recovery rate is 91%, zinc The recovery rate was 93%, the lead recovery was 92%, the nickel enrichment rate was 91%, the cobalt enrichment rate was 97%, the gold enrichment rate was 98%, and the silver enrichment rate was 96%.
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing: molten nickel smelting slag obtained from the slag smelting slag exiting process of the smelting process, and molten smelting slag obtained by the "copper ice nickel blowing" process slag slag passing through the slag outlet of the lean furnace Adding to the blast furnace, adding blast furnace slag and electric furnace steel slag obtained from the slag outlet to form mixed slag, adding copper sulfide concentrate and copper-containing material (including copper soot, copper-containing garbage and copper mixed); 600 ° C air, spray particle size of 20mm bituminous coal and coal powder, the mixed slag is heated to a molten state, forming a reaction slag containing copper and iron, and the reaction slag is mixed; real-time monitoring of reaction slag, through regulation At the same time, the two parameters (a) and (b) are guaranteed to obtain the slag after the completion of the reaction; corresponding to (a):
  • Step 2 separation and recovery method 3: heat preservation for 14 min, after the completion of the reaction, the slag is naturally settled, and the slag-gold separation, obtaining a copper-rich nickel phase and a middle-upper iron-containing silicate mineral phase, and simultaneously forming a zinc-containing and lead-containing group
  • the following steps are carried out: (1) the iron-containing silicate mineral phase is poured into a smelting device to carry out the slag treatment outside the furnace, and the second step is used to separate and recover the slag, and the middle and upper slag are all returned to the copper-containing slag.
  • Reactive slag with iron as a hot metallurgical flux, adjust the composition of copper and iron reaction slag, control its temperature; (2) copper-rich nickel phase sent to converter or converter, iron-rich phase as direct reduction nickel iron (3) Part of the zinc-containing component and the lead-containing component are volatilized, and are enriched in the form of oxides and collected into the soot to be recovered.
  • the finally obtained slag contains copper ⁇ 0.1%, the iron recovery rate is 90%, and the zinc recovery rate. 92%, lead recovery is 92%, nickel enrichment rate is 97%, cobalt enrichment rate is 93%, gold enrichment The rate was 94% and the silver enrichment rate was 96%.
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 Mixing slag: molten nickel obtained by melting the smelting slag from the top-blown molten pool to obtain the molten nickel slag obtained by the slag discharge port of the sedimentation furnace and the molten nickel obtained by the "copper ice nickel blowing" process blowing slag through the slag outlet of the depleted furnace
  • the smelting slag is added to the side-blown rotary kiln, and the molten blast furnace slag and VD slag obtained from the slag outlet are simultaneously added to form mixed slag, and copper sulfide and copper-containing material (copper-refined copper slag) are simultaneously added;
  • the mixed slag is heated to In the molten state, a reaction slag containing copper and iron is formed, and the reaction slag is mixed with argon gas; the reaction slag is monitored in real time, and two parameters (a) and (b) are simultaneously controlled to obtain the reaction.
  • reaction slag temperature containing copper and iron is 1340 ° C
  • reaction slag basicity CaO / SiO 2 ratio of copper and iron is 1.2, both meet the requirements;
  • the air having a hot temperature of 900 ° C is sprayed with coke particles having a particle size of 20 mm, and the content of metal iron in the slag is 2.4%;
  • Step 2 separation and recovery method 4: heat preservation for 29 min, after the completion of the reaction, the slag is naturally settled, and the slag-gold is separated to obtain a copper-rich nickel phase and a medium-top iron-containing silicate mineral phase, and a zinc-containing and lead-containing component.
  • the molten iron-containing silicate mineral phase is poured into the smelting device, and the second step is used to separate and recover the method, the middle method C, and the iron silicate mineral phase slag is poured into the glass ceramic;
  • the lower molten copper-rich nickel phase is sent to the converter for treatment, and the iron-rich phase is used as the raw material for the blast furnace nickel-iron;
  • part of the zinc-containing and lead-containing components are collected into the dust as zinc oxide and lead oxide, and finally the slag is obtained.
  • the set rate is 95% and the silver enrichment rate is 96%.
  • a method for producing a mixed slag containing nickel and iron comprising the steps of:
  • Step 1 slag mixing:
  • the molten pool smelting produces smelting slag
  • the molten nickel smelting slag obtained by the slag outlet of the settling electric furnace is added to the heat preservation pit, and the cold steel slag is added to form the mixed slag, and the copper oxide concentrate is added at the same time; with the oxygen-enriched air, the spray size is ⁇ 150 ⁇ m bituminous coal
  • the mixed slag is heated to a molten state to form a copper-containing reaction slag, and the reaction slag is mixed; the reaction slag is monitored in real time, and two parameters (a) and
  • the temperature of the reaction slag containing copper and iron is 1430 ° C;
  • the final obtained slag contains copper ⁇ 0.1%, iron recovery rate is 90%, zinc recovery rate is 92%, lead recovery The rate was 92%, the nickel enrichment rate was 95%, the cobalt enrichment rate was 96%, the gold enrichment rate was 95%, and the silver enrichment rate was 97%.

Abstract

一种由含镍与铁的混合熔渣生产的方法，其包括如下步骤：S1、炉渣混合：将镍冶炼渣加入反应装置中，加入铅冶炼渣、高炉渣、钢渣和铁合金渣中的一种或多种，形成混合熔渣；将混合熔渣加热至熔融状态，同时加入氧化铜矿物、硫化铜矿物、氧化镍矿物、硫化镍矿物、含铜物料中的一种或几种；混合均匀作为反应熔渣，并实时监测反应熔渣，同时通过调控使混合后的反应熔渣同时满足条件a和条件b，所述条件a为控制反应熔渣温度为1050～1450℃，所述条件b为控制反应熔渣的碱度CaO/SiO2比值＝0.15～1.5；获得反应后的熔渣；S2、分离回收。

Description

一种由含镍与铁的混合熔渣生产的方法 技术领域
本发明属于熔渣冶金技术领域，具体涉及一种由含镍与铁的混合熔渣生产的方法。
背景技术
镍的火法冶炼过程中，产生大量镍冶炼渣，镍冶炼渣包括“造锍熔炼”工艺产生的镍熔炼渣、“铜冰镍吹炼”工艺吹炼后的贫化炉渣、顶吹熔炼产生的镍沉降炉渣。我国金川公司采用“闪速熔炼”与“顶吹熔炼”进行镍精矿冶炼，每年产生100万吨镍冶炼渣，目前累计堆积储存量超过1000万吨。镍冶炼渣中铜、铁、镍、钴、锌、铅、金、银等有价组分，长期堆放，既浪费资源，又污染环境。
镍冶炼渣中铁含量高达50wt％，远超目前26wt％可采品位，渣含铜高达0.2wt％以上，其中铁组分主要以铁橄榄石相存在。目前，镍冶炼渣的研究利用主要集中直接还原提铁或熔融炼铁。在还原过程中，铜、镍、钴组分还原进入铁水，不利于后续的炼钢过程。
铅的火法冶炼过程“烧结-鼓风炉还原-烟化炉”或“氧化吹炼-高铅渣还原-烟化炉”等工艺中，产生铅冶炼渣。铅冶炼渣包括含铅熔炼渣与烟化炉渣。“烧结矿鼓风炉还原”或“固态高铅渣还原”或“液态高铅渣还原工艺”还原工艺产生含铅熔炼渣，含铅熔炼渣通过烟化炉冶炼产生烟化炉渣，铅冶炼渣(烟化炉炉渣与含铅熔炼渣)含有铜、金、银、铁、锌、铅等组分，是重要的二次资源。铅冶炼渣(含铅熔炼渣或烟化炉炉渣)温度在≥1050℃，铅冶炼渣是重要的物理热资源，但是还没有一种合理的工艺可对其进行有效利用。
高炉渣、钢渣与铁合金炉渣含有较高含量的金属铁、铁氧化物、铬氧化物、五氧化二磷、SiO2、CaO、MgO等有价组分是重要的二次资源；由高炉、炼钢炉与铁合金炉排放出熔融炉渣温度≥1300℃，因此，熔融高炉渣、熔融钢渣与熔融铁合金炉渣也是重要的物理热资源。但是没有合理工艺进行利用，只能大量堆放，造成资源的浪费及环境的污染。
镍冶炼渣、铅冶炼渣、高炉渣、钢渣、铁合金炉渣中含有大量SiO2、CaO、MgO、Al2O3等冶金熔剂，化学反应活性强，是物理化学性质优良的熔渣体系，是冶金熟料。由冶金炉流出的熔融镍冶炼渣、熔融铅冶炼渣、熔融高炉渣、熔融钢渣与熔融铁合金炉渣，蕴含丰富热能资源，含大量热态冶金熔剂。现有铜的火法冶金工艺适于处理硫化铜矿，但难以处理氧化铜矿。如何大规模同时处理氧化铜矿物、硫化铜矿物与含铜物料，实现铜、铁的生产就显得尤为重要。
发明内容
(一)要解决的技术问题
为了解决现有技术的上述问题，本发明提供含镍与铁的混合熔渣生产的方法。该方法反应时间短、工艺流程短、金属回收率高、生产成本低、处理量大、环境友好、经济收益高、可有效解决冶金资源与热能高效回收利用问题；本发明是一种新的熔渣冶金工艺，不仅降低渣含铜使渣含铜<0.1wt％，而且实现铜、镍、钴、金、银、铁、锌、铅、铟、铋、钠、钾组分的高效回收与含铜镍物料的处理，获得低铜含铁物料(铁精矿与生铁)，并解决目前炉渣大量堆积，环境污染问题，及重金属元素污染问题。
(二)技术方案
为了达到上述目的，本发明采用的主要技术方案包括：
一种由含镍与铁的混合熔渣生产的方法，其包括如下步骤：
S1、炉渣混合：将镍冶炼渣加入熔炼反应装置中，同时加入铅冶炼渣、高炉渣、钢渣和铁合金渣中的一种或多种，搅拌形成混合熔渣；将混合熔渣加热至熔融状态，同时加入氧化铜矿物、硫化铜矿物、氧化镍矿物、硫化镍矿物、含铜物料中的一种或几种；混合均匀，作为反应熔渣，并实时监测反应熔渣，通过调控使混合后的反应熔渣同时满足条件a和条件b，获得反应后的熔渣，或将反应后的熔渣倒入保温装置；
其中，所述条件a为控制反应熔渣温度为1050～1450℃；
所述条件b为控制熔渣的反应碱度CaO/SiO2比值＝0.15～1.5；
S2、分离回收：所述步骤S1反应后的熔渣，保温5～50min，分离获得底部熔融态的富铜镍相层、中下部熔融态的富铁相与中上部熔融态的含铁硅酸盐矿物相，同时生成含锌组分与含铅组分的烟尘，金组分、银组分进入富铜镍相，含镍组分、含钴组分分别进入富铜镍相与富铁相；对各相进行回收处理。
如上所述的方法，优选地，在所述步骤S1中，对于所述条件a调控的方法为：
当所述反应熔渣的温度＜1050℃时，利用反应装置自身的加热功能，或向熔渣中加入燃料或熔融镍冶炼渣、熔融铅冶炼渣、熔融高炉渣、熔融钢渣或熔融铁合金渣的一种或多种，喷入燃料时，同时喷入预热的氧化性气体，使反应熔渣的温度达到1050～1450℃；
当所述反应熔渣的温度＞1450℃时，向反应熔渣中加入镍冶炼渣、氧化铜矿物、硫化铜矿物、氧化镍矿物、硫化镍矿物、含铜物料、高炉渣、钢渣、铁合金渣、冶金熔剂、含铁物料或含氟物料中的一种或几种，使混合反应熔渣的温度达到1050～1450℃；
对于所述条件b调控的方法为：
当所述含铜与铁的熔渣中碱度CaO/SiO2比值<0.15时，向反应熔渣中加入碱性物料和/或碱性含铁物料；
当含铜反应熔渣中碱度CaO/SiO2比值>1.5时，向反应熔渣中加入酸性物料和/或酸性含铁物料。
如上所述的方法，优选地，所述反应装置为保温装置或可转动的熔炼反应装置或带有渣口或铁口熔渣可流出的熔炼反应装置；其中，所述保温装置为可倾倒的熔炼反应渣灌或保温地坑；
所述可转动的熔炼反应装置为转炉、熔炼反应渣罐；
所述带有渣口或铁口熔渣可流出的熔炼反应装置为等离子炉、直流电弧炉、交流电弧炉、矿热炉、鼓风炉、高炉、感应炉、冲天炉、侧吹熔池熔炼炉、底吹熔池熔炼炉、顶吹熔池熔炼炉、反射炉、奥斯麦特炉、艾萨炉、瓦钮可夫熔池熔炼炉、侧吹回转炉、底吹回转炉、顶吹回转炉。
如上所述的方法，优选地，在所述步骤S1中，满足所述条件a和b的同时，应同时满足，控制所述反应熔渣中铜氧化物、镍氧化物、钴氧化物和铁氧化物分别还原为金属铜、金属镍、金属钴和FeO，熔渣中金属铁含量<3％。可通过加入还原剂、含碳的含铁物料中的一种或两种进行调控，其中，所述还原剂和/或含碳的含铁物料的的用量为熔渣中铜氧化物、镍氧化物、钴氧化物和铁氧化物还原为金属铜、镍、钴和FeO的理论量110～140％；所述含碳的含铁物料为钢铁尘泥与烟灰、铁精矿含碳预还原球团、铁精矿含碳金属化球团、湿法炼锌挥发窑渣、焦炭炉尘泥与烟灰。
如上所述的方法，优选地，所述镍冶炼渣是“造锍熔炼”工艺产生的镍熔炼渣、“铜冰镍吹炼”工艺吹炼后的吹炼渣、“铜冰镍吹炼”工艺吹炼后的吹炼渣经贫化产生的贫化炉渣、顶吹熔炼产生的镍熔炼渣、顶吹熔炼产生的镍熔炼渣经电炉沉降产生的沉降渣中一种或多种；所述镍冶炼渣为熔融态或冷态，其中：熔融镍冶炼渣由镍冶炼炉出渣口获得，或将镍冶炼渣加热至熔融状态；
所述高炉渣、钢渣与铁合金渣为熔融态，或冷态，其中：熔融态炉渣(高炉渣、钢渣与铁合金渣)由出渣口获得，或将冷态炉渣(高炉渣、钢渣与铁合金渣)加热至熔融状态；所属钢渣为铁水预脱硫渣(脱硫渣、脱硅渣、脱磷渣)、转炉渣、电炉渣、VOD/VAD渣、VD渣、中间包弃渣；所述铁合金炉渣为铁合金生产过程中产生的炉渣，包括冶炼碳素锰铁产生的炉渣、冶炼铬铁产生的炉渣、冶炼镍铁产生的炉渣、冶炼钒铁产生的炉渣、冶炼硅铁产生的炉渣、冶炼铌铁产生的炉渣、冶炼钼铁产生的炉渣；
所述氧化铜矿物包括赤铜矿、黑铜矿、孔雀石、蓝铜矿、硅孔雀石、胆矾中的一种或多种；硫化铜矿物包括辉铜矿、铜蓝、黄铜矿、斑铜矿、硫砷铜矿、黝铜矿的一种或多种；
所述含铜物料为粗铜铜火法精炼渣、选铜尾矿、铜渣、锌冶炼渣、锌冶炼烟灰与尘泥、铅锌尾矿、铅冶炼渣、铅冰铜、砷冰铜、粗铅火法精炼渣、铅冶炼烟灰与尘泥、铅酸电池、铜冶炼烟灰与尘泥、杂铜、含铜垃圾、含铜电路板、锡冶炼渣、锡尾矿中的一种或几种；其中，所述锌冶炼渣为湿法炼锌与火法炼锌产生的锌冶炼渣，包括浸出渣、铁矾渣、铜镉渣、针铁矿渣、赤铁矿渣、挥发窑渣、竖罐炼锌渣、鼓风炉渣、旋涡炉渣、烟化炉渣、电炉炼锌渣；含铅冶炼渣为烟化炉炉渣与含铅熔炼渣，“ISP铅锌鼓风炉还原”或“烧结矿鼓风炉还原”或“固态高铅渣还原”或“液态高铅渣还原工艺”还原工艺产生含铅熔炼渣，含铅熔炼渣通过烟化炉冶炼产生含铅烟化炉渣；所述铜渣是含铜熔炼渣、含铜吹炼渣、贫化弃渣、浮选尾渣、湿法炼铜渣中的一种或多种，含铜熔炼渣产生于铜的火法冶炼工艺的“造锍熔炼”过程；所述含铜吹炼渣产生于铜的火法冶炼工艺的“铜锍吹炼”过程；贫化弃渣为含铜熔炼渣与含铜吹炼渣贫化后弃渣，浮选尾渣为含铜熔炼渣与含铜吹炼渣选矿后尾渣。
如上所述的方法，优选地，所述含铁物料为普通铁精矿、普通铁精矿直接还原铁，普通铁精矿烧结矿、普通铁精矿球团矿、普通铁精矿金属化球团、普通铁精矿含碳预还原球团、钢渣、锌冶炼渣、焦炭冶炼烟尘与尘泥、钢铁烟尘与尘泥、含镍冶炼渣、铜渣、铅冶炼渣、锌冶炼渣、锡冶炼渣、赤泥、脱钠后高钙赤泥、煤粉灰、硫酸烧渣中的一种或几种；所述钢铁烟尘与尘泥包括高炉瓦斯泥、转炉尘泥、电炉尘泥、热或冷轧污泥、烧结粉尘、球团粉尘、出铁厂集尘、高炉瓦斯灰、电炉除尘灰、轧钢氧化铁皮；
所述含铜物料与含铁物料为热态或冷态，其中热态物料由冶金炉出料口或出渣口直接获得；湿法的炼锌渣与尘泥需经脱水、干燥；
所述燃料与还原剂为固体、液体或气体燃料中的一种或多种，以喷吹或投料的方式喷入，用0～1200℃的气体载入，所述气体是氧化性气体、氩气、氮气中的一种或多种；所述固体燃料与还原剂为煤粉、焦粉、焦炭、粉煤灰、烟煤或无烟煤中的一种或多种，形状为粒状或粉状，粒状物料粒度为5～25mm，粉状物料粒度为≤150μm；所述液体燃料与还原剂为重油，所述气体燃料与还原剂为煤气和/或天然气；
所述冶金熔剂为含CaO或SiO2的矿物与炉渣；所述含氟物料为萤石、CaF2或含氟高炉渣中的一种或几种；所述的碱性物料为石灰粉、赤泥、脱钠后赤泥、电石渣、 白云石粉或生石灰粉中的一种或几种；所述的碱性含铁物料为CaO/SiO2>1碱性烧结矿、碱性铁精矿、碱性预还原球团、碱性金属化球团、钢渣或高炉渣中的一种或几种；
所述酸性物料为硅石、含金银硅石、粉煤灰、煤矸石中的一种或多种；所述酸性含铁物料为CaO/SiO2≤1的含铁物料、酸性烧结矿、酸性铁精矿、酸性预还原球团、酸性金属化球团、铜渣、铅冶炼渣、锌冶炼渣、镍冶炼渣、锡冶炼渣、铁合金渣、高炉渣中的一种或几种。
如上所述的方法，优选地，在所述步骤S2中分离回收中，对所述富铜镍相、富铁相与含铁硅酸盐矿物相可分别进行处理，或将任两相结合处理。
具体地，所述步骤S2中的分离回收，采用如下方法一到方法五中任一方法处理：
方法一、采用熔渣可流出熔炼反应装置时，反应完成后的熔渣分离后进行如下步骤：
S2-1-01、所述含铁硅酸盐矿物相，进行如下方法A-G中的任一种处理；
方法A：水淬或空冷后直接用作水泥原料；
方法B：部分或全部返回到所述反应熔渣中作为热态冶金熔剂；
方法C：所述含铁硅酸盐矿物相用于浇筑微晶玻璃或作为矿渣棉；
方法D：向熔炼反应装置内的含铁硅酸盐矿物相熔渣中，吹入温度为0～1200℃的预热氧化性气体，并保证硅酸盐熔渣温度>1450℃；当熔渣氧化亚铁重量百分比含量<1％，获得氧化后的熔渣；所述氧化后的熔渣直接空冷或水淬，用作矿渣水泥、水泥调整剂、水泥生产中的添加剂或水泥熟料；
方法E：所述含铁硅酸盐矿物相用于生产高附加值的水泥熟料，包括如下步骤：
E-1、向所述含铁硅酸盐矿物相的熔渣中，加入熔融钢渣、石灰、石灰石、铁合金炉渣、粉煤灰、碱性铁贫矿、铝土矿、熔融高炉渣、赤泥、脱钠后高钙赤泥或电石渣中的一种或几种，充分混合，获得熔渣混合物料；
E-2、向上熔渣混合物料中吹入预热温度为0～1200℃的氧化性气体，并保证熔渣混合物料温度>1450℃；当氧化亚铁重量百分比含量<1％，获得氧化后的熔渣；
E-3、所述氧化后的熔渣，进行空冷或水淬，制得高附加值的水泥熟料；
方法F：所述含铁硅酸盐矿物相熔渣作为高炉炼铁原料或直接还原炼铁原料：将含铁硅酸盐矿物相的熔渣空冷、水淬或缓冷后，用作高炉炼铁或直接还原炼铁原料，直接还原后，采用磁选分离或电炉熔分，磁选产物为金属铁与尾矿，电炉熔分，产物为铁水与熔渣；
或将所述含铁硅酸盐矿物相的熔渣倒入保温装置后，采用以下方法进行分离：熔渣改性后磁选分离：向保温装置中的熔渣，吹入0～1200℃的预热的氧化性气体，并保证其熔渣温度>1250℃，完成熔渣中磁铁矿的转化；将上述氧化后的熔渣缓冷至室温，破碎、磁选，产物为磁铁矿精矿与尾矿，尾矿作为建筑材料；
方法G：所述含铁硅酸盐进行还原炼铁，包括如下步骤：
G-1、向含铁硅酸盐熔渣中加入含铁物料、还原剂，进行熔融还原，实时监测反应熔渣，通过调控同时满足条件：反应熔渣的温度为1350～1640℃和反应熔渣的碱度CaO/SiO2比值＝0.6～2.4，获得反应完成后的熔渣；
其中，控制反应熔渣的温度的方法为：
当反应熔渣的温度＜1350℃，通过反应装置自身的加热，或向熔渣中加入燃料与预热的氧化性气体，使反应熔渣的温度达到1350～1640℃；
当反应熔渣的温度＞1640℃，向反应熔渣中加入冶金熔剂、含铁物料或含氟物 料中的一种或几种，使反应熔渣的温度达到1350～1640℃，其中，所述的冶金熔剂为含CaO或SiO2的矿物，具体为石英砂、含金银石英砂、赤泥、脱钠后赤泥、电石渣、白云石或石灰石中的一种或几种；
控制反应熔渣的碱度的方法为：
当反应熔渣中碱度CaO/SiO2比值<0.6时，向熔渣中加入碱性物料和/或碱性含铁物料；
当反应熔渣中碱度CaO/SiO2比值>2.4时，向熔渣中加入酸性物料和/或酸性含铁物料；
G-2、所述G-1中熔融还原时还需向熔渣中喷吹0～1200℃预热后的氧化性气体进行熔融还原，形成还原后的熔渣；
G-3、分离回收：采用以下方法中的一种：
方法Ⅰ：将还原后的混合熔渣倒入保温渣罐，冷却至室温，获得缓冷渣；其中，金属铁沉降到反应装置的底部，形成铁坨，将剩余缓冷渣中含金属铁层，破碎至粒度20～400μm，磨矿，磁选分离出剩余金属铁与尾矿；
方法Ⅱ：还原后的混合熔渣，冷却沉降，渣-金分离，获得铁水与还原后的熔渣；所述还原后的熔渣，按照方法A～E中的一种或几种方法进行熔渣处理；所述铁水，送往转炉或电炉炼钢；
S2-1-02、所述富铜镍相，送往转炉或吹炼炉炼铜或作为铜钴镍分离的原料；
S2-1-03、部分所述含锌组分与含铅组分挥发，以氧化物形式进入烟尘；
S2-1-04、部分含金组分与含银组分进入富铜镍相，镍、钴组分分别进入富铜镍相与富铁相；
S2-1-05、所述富铁相层进行水淬或空冷或倒入保温装置缓冷后，作为高炉炼镍铁原料或直接还原炼镍铁原料或熔融还原炼镍铁原料或浮选提铜原料；浮选过程中，浮选产物为铜精矿、镍精矿、含镍合金与铁精矿，铁精矿作为高炉炼铁原料或直接还原炼铁原料或熔融还原炼铁原料；所述直接还原过程采用转底炉、隧道窑、车底路、竖炉、回转窑或感应炉作为还原设备，利用气基或煤基还原技术，气基还原采用天然气和/或煤气，煤基还原采用无烟煤、烟煤、褐煤、焦煤、焦粉或焦炭中的一种或几种，控制还原温度为900～1400℃，控制碱度CaO/SiO2比值＝0.8～1.5；还原产生的煤气在熔渣表面二次燃烧，提供了热量，而且由炉内流出的煤气可以作为烘干炉料与保温装置的热源；
此外，因赤泥中含有钾、钠，尘泥与钢铁烟灰中含有铅、锌、铋、铟银，所以添加这些原料时，部分铟组分、铋组分、含钾组分、含钠组分挥发，以氧化物形式进入烟尘。
方法二、采用熔渣可流出的熔炼反应装置时，获得的所述富铁相和含铁硅酸盐矿物相处理方法用方法一中所述方法A～G中一种或几种进行处理，或倒入保温装置缓冷后的富铜镍相，送往转炉或吹炼炉或作为铜钴镍分离的原料。
方法三、采用熔渣可转动的转炉与反应渣罐时，获得所述含铁硅酸盐矿物相，处理方法用方法一中所述方法A～G中一种或几种进行处理；或含有所述富铁相采用方法一步骤S2-1-05进行处理；熔融态或倒入保温装置缓冷后的富铜镍相，送往转炉或吹炼炉或作为铜钴镍分离的原料。
方法四、采用熔渣可转动的转炉与反应渣罐时，获得的熔融态含铁硅酸盐矿物相与富铁相，处理方法用方法一中所述方法A～G中一种或几种进行处理；所述熔融态富铜镍相或倒入保温装置缓冷后，送往转炉或吹炼炉或作为铜钴镍分离的原料。
方法五：采用保温装置时，或采用熔渣可流出的熔炼反应装置，将熔渣倒入保温装置时，进行如下步骤：
S201、沉降冷却：熔渣冷却至室温，获得缓冷渣；所述富铜镍相沉降到反应装置的底部，形成富铜镍坨；所述含铁硅酸盐矿物相上浮；中间为缓冷渣为富铁相，同时生成含锌组分与含铅组分；其中，金、银组分迁移到富铜镍相，镍、钴组分分别迁移到富镍铜相与富铁相；
S202、分离：人工取出沉降在底部的富铜坨，送往转炉或吹炼炉或作为铜钴镍分离的原料；所述富铁相作为高炉炼镍铁原料或直接还原炼镍铁原料或熔融还原炼镍铁原料或熔融还原炼镍铁原料或浮选提铜原料；浮选产物为含铜精矿、镍精矿、镍合金与铁精矿，铁精矿作为高炉炼铁原料或直接还原炼铁原料或熔融还原炼铁原料；
S203、人工取出上部的含铁硅酸盐矿物相，获得硅酸盐相作为高炉炼铁原料或直接还原炼铁原料或熔融还原炼铁原料或水泥原料；
S204、部分锌组分与铅组分挥发，以氧化物形式进入烟尘回收；
S205、添加有赤泥中或尘泥与钢铁烟灰这些原料时，部分铟组分、铋组分、含钾组分、含钠组分挥发，进入烟尘回收。
如上所述方法，优选地，所述氧化性气体为预热的空气、氧气、富氧空气、氮气-空气、氩气-空气、氧气-氮气、氧气-氩气中的一种。
如上所述方法，优选地，在所述步骤S1中，所述混合均匀为自然混合与搅拌混合，所述搅拌混合的方式为氩气搅拌、氮气搅拌、氮气-氩气混合气搅拌、还原性气体搅拌、氧化性气体搅拌、电磁搅拌或机械搅拌中的一种或几种；
在所述步骤S2中，所述沉降为自然沉降或旋转沉降或离心沉降；进行冷却沉降时的冷却方式为自然冷却或旋转冷却或离心冷却，所述分离时，用重力分选法是摇床分选、溜槽分选或者二者相结合。
混合熔渣生产的方法，与现有技术相比，本发明的特点是：
(1)本发明的由含镍与铁的混合熔渣生产的方法，既可以处理热态熔渣，充分利用熔融镍冶炼渣与熔融冶金渣(铅冶炼渣、熔融高炉渣、熔融钢渣、熔融铁合金渣)中的一种或几种)物理热资源和热态冶金熔剂，又可以处理冷态炉渣，通过熔渣混合或冷态混合，实现了熔渣冶金改性；(2)混合熔渣中的熔渣冶金反应，铁橄榄石解体，铁氧化物充分释放出来，实现长大与沉降，混合熔渣中的金属铁组分聚集、长大与沉降，富铁相包括金属铁、FeO相、铁橄榄石相中的多种，作为高炉炼铁或直接还原或熔融还原炼铁的原料；(3)混合熔渣中的铜组分、镍钴组分、金银组分分别富集于富铜镍相，并实现长大与沉降；其中，富铜镍相包括有铜、白冰铜、铜冰镍、富铜镍钴相、含铁组分中的多种，或部分铜组分进入富铁相；(4)混合熔渣中的锌组分、铅组分分别富集于烟灰，加以回收；部分含铟组分、铋组分、含钾组分、含钠组分挥发进入烟尘进行回收；(5)混合熔渣中的硅、钙与磷组分迁移、富集于硅酸盐矿物相，上浮；(6)混合熔渣中自由氧化钙与氧化镁消失，混合熔渣实现调质；(7)采用人工分拣、磁选、重选与渣金分离结合的方法，分离沉降在不同部位的富铜镍相、铁氧化物与上部的硅酸盐矿物相，实现混合熔渣中铜组分、镍钴组分、金银组分、铁组分、铟组分、铋组分、钠组分与钾组分的高效回收，渣含铜<0.1wt％，低铜硅酸盐相与富铁组分可以通过熔融还原炼铁，获得铁精矿或金属铁；(8)可以处理固态含铜、铁物料，达到资源高效综合利用；(9)熔渣实现调质，上部尾渣利用限制因素消失，可作为水泥原料或建筑材料或代替碎石作骨料和路材或作为高炉炼铁与直接还原炼 铁与熔融还原炼铁的原料或磷肥；(10)本工艺采用混合熔渣，整个过程无需加热或少量补偿热量；本工艺采用混合熔渣，整个过程无需冶金熔剂或少量补偿冶金熔剂，可以处理冷态物料。本发明方法可连续或间断的进行，满足工业生产需要。
(三)有益效果
本发明的有益效果是：
(1)本发明实现有色冶金炉渣与钢铁冶金炉渣中铜组分、铁组分、锌组分、铅组分、镍组分、钴组分、金组分、银组分、铋组分、钠组分、钾组分、有价组分的综合利用，解决目前炉渣大量堆积，环境污染问题。
(2)本发明不仅可以大规模处理铁合金炉渣、钢渣、高炉渣、铅冶炼渣、含铜炉渣，而且可以处理氧化铜矿物、硫化铜矿物、含铜物料。
(3)本发明可以处理冷态含铜、含铁物料。
(4)本发明的原料可以是出渣口中流出的液态熔融镍冶炼渣(≥1200℃)和熔融冶金渣(熔融铅冶炼渣、熔融高炉渣、熔融钢渣、熔融铁合金渣中的一种或几种，≥1050℃)，具有高温度、高热量的特点，充分利用了熔渣物理热资源；混合熔渣中含有大量的热态冶金熔剂，都是物理化学性质优良的熔渣体系，实现了冶金资源与热资源的高效利用；充分利用了混合熔渣高反应化学活性的特点，实现了熔渣冶金。
(5)本发明通过熔渣混合，保温或喷吹气体，使熔渣中铜组、镍钴组分、金组分与银组分富集到富铜镍相；其中，富铜镍相还包括铜相、白冰铜、铜冰镍、富铜镍钴相、含铁组分中的多种，实现聚集、长大与沉降，或部分铜组分进入富铁相，实现聚集、长大与沉降，富铁相包括金属铁、FeO相、铁橄榄石相中的多种，作为高炉炼铁或直接还原或熔融还原炼铁的原料；铅组分与锌组分富集到烟尘中加以回收；铟组分、铋组分、钠组分、钾组分挥发，进入烟尘加以回收。
(6)本发明方法中，加入冷态物料与熔融镍渣避免了熔渣温度过高，提高保温装置的寿命；加入冷态物料与熔融镍渣提高了原料处理量，不仅可以处理液态熔渣，而且可以处理少量冷态物料，原料适应性强；加入冷态物料实现了熔渣冶金反应释放的化学热与熔渣物理热的高效利用。
(7)本发明方法自然冷却过程中，熔渣中铜组分、镍钴组分、金银组分分别富集于富铜镍相，并实现聚集、长大与沉降，熔渣中铁组分富集于富铁相，并实现聚集、长大与沉降；装有熔渣的保温装置置于旋转平台上旋转，加速富铜镍相、富铁相的聚集、长大与沉降；含氟物料的加入，加速富铜镍相、富铁相的聚集、长大与沉降；
(8)本发明方法硅酸盐矿物相中，自由氧化钙与自由氧化镁消失，矿物可磨性增加，熔渣实现调质。
(9)本发明方法采用人工分拣、磁选、重选或渣-金分离的方法，分别对分布在上部、中部与底部的低铁硅酸盐矿物相、富铁相、富铜镍相进行分离，实现熔渣中铜组分、镍组分、钴组分、金银组分、铟组分、铋组分、铁组分的高效回收，获得的含铁硅酸盐相与富铁组分的渣含铜<0.1wt％，由于富铜镍相、富铁相沉降在中、下部，因此，需分选炉渣量小，矿物可磨性增加，磨矿、磁选与重选成本低；后续的分离过程采用磁选或重选，分离的介质为水，分离过程中不会产生环境污染；尾矿作为水泥原料、建筑材料、代替碎石作骨料、路材使用。
(10)本发明通过富铜镍相沉降，含铁硅酸盐相与富铁组分的含铜量小于0.1％，作为高炉炼铁或直接还原或熔融还原的原料,获得金属铁与铁水。
(11)本发明既充分利用熔融渣物理热资源和热态冶金熔剂，又可以处理冷态炉渣，实现了熔渣冶金，熔渣中铜组分、镍组分、钴组分、金银组分富集于富铜镍相， 并实现聚集、长大与沉降，铁组分富集于富铁相，实现聚集、长大与沉降，分离沉降在不同部位的富铜镍相和富铁相，实现熔渣中有价组分的高效回收；可以处理固态含铜物料，该方法工艺流程短、金属回收率高、生产成本低、原料适应性强、处理量大、环境友好、经济收益高、可解决冶金资源与热能高效回收利用问题。
具体实施方式
本发明提供一种由含镍与铁的混合熔渣生产的方法，具体包括以下步骤：
步骤1，炉渣混合：
将镍冶炼渣，加入保温转置中或熔渣可流出的熔炼反应装置中，并加入铅冶炼渣(烟化炉炉渣和/或含铅熔炼渣)、高炉渣、钢渣和铁合金渣中的一种或多种，形成混合熔渣；同时加入氧化铜矿物、硫化铜矿物、氧化镍矿物、硫化镍矿物、含铜物料中的一种或两种；混合均匀作为含镍与铁反应熔渣，并实时监测反应熔渣，通过调控同时保证如下(a)和(b)两个参数，获得反应完成后的熔渣，或将反应完成后的熔渣倒入保温装置；(a)含镍与铁反应熔渣的温度为1050～1450℃；
(b)含镍与铁反应熔渣的碱度CaO/SiO2比值＝0.15～1.5；
调控方法为：
对应(a)：控制含镍与铁的反应熔渣的温度在设定温度范围的方法为：
当含镍与铁的反应熔渣的温度＜设定温度范围下限时，通过反应装置自身的加热功能，或向熔渣中加入燃料或熔融镍冶炼渣、熔融铅冶炼渣、熔融高炉渣、熔融钢渣或熔融铁合金渣的一种或多种，喷入燃料时，同时喷入预热的氧化性气体，使反应熔渣的温度达到设定温度范围内；
当含镍与铁的反应熔渣的温度＞设定温度范围上限时，向含铜与铁的反应熔渣中加入镍冶炼渣、氧化铜矿物、硫化铜矿物、硫化镍矿物、氧化镍矿物、含铜物料、高炉渣、钢渣、铁合金渣、冶金熔剂、含铁物料或含氟物料中的一种或几种，使混合熔渣的温度达到设定温度范围内；
对应(b)：
当含镍与铁的反应熔渣中碱度CaO/SiO2比值<0.15时，向反应熔渣中加入碱性物料和/或碱性含铁物料；
当含镍与铁的反应熔渣中碱度CaO/SiO2比值>1.5时，向反应熔渣中加入酸性物料和/或酸性含铁物料；
步骤2，分离回收：
保温5～50min，反应完成后的熔渣，沉降，渣-金分离，获得底部熔融态富的铜镍、中下部熔融态的富铁相与中上部熔融态的含铁硅酸盐矿物相，同时生成含锌组分与含铅组分，其中，铟、铋、镍、钴、金、银组分迁移到所述富铜镍相，部分镍钴组分迁移到富铁相；对各项进行回收处理。
采用以下方法中的一种进行回收处理：
方法一：采用熔渣可流出熔炼反应装置时，反应完成后的熔渣进行如下步骤：
(1)熔融态含铁硅酸盐矿物相，进行熔渣处理；
(2)熔融态富铜镍，送往转炉或吹炼炉或作为铜钴镍分离的原料；
(3)部分铅组分、锌组分、铟组分、铋组分、钠组分、钾组分挥发进入烟灰回收氧化物氧化物进入烟尘；
(4)富铁相进行水淬或空冷或倒入保温装置缓冷或经人工分拣与重选结合获得，作为高炉炼铁原料或直接还原炼镍铁原料或熔融还原炼镍铁原料或浮选提铜镍原料；浮选产物为铜精矿、镍精矿、含镍合金与铁精矿，铁精矿作为高炉炼铁原料或 直接还原炼铁原料或熔融还原炼铁原料；所述直接还原过程采用转底炉、隧道窑、车底路、竖炉、回转窑或感应炉作为还原设备，利用气基或煤基还原技术，气基还原采用天然气和/或煤气，煤基还原采用无烟煤、烟煤、褐煤、焦煤、焦粉或焦炭中的一种或几种，控制还原温度为900～1400℃，控制碱度CaO/SiO2比值＝0.8～1.5。
其中，所述(1)熔融态含铁硅酸盐矿物相，进行如下方法A-G中的任一种处理；
方法A：含铁硅酸盐矿物相作为水泥原料：
含铁硅酸盐矿物相水淬或空冷直接作为水泥原料或进一步处理成高附加值的水泥原料；
方法B：部分或全部含铁硅酸盐矿物相返回到含铜反应熔渣：
部分或全部含铁硅酸盐矿物相返回到含铜反应熔渣，作为热态冶金熔剂，调整含铜反应熔渣成分，控制含铜反应熔渣温度；方法C：含铁硅酸盐矿物相浇筑微晶玻璃或作为矿渣棉；
方法D：含铁硅酸盐熔渣氧化后空冷或水淬：
(1)向熔炼反应装置内的含铁硅酸盐熔渣中，吹入预热的氧化性气体，当熔渣氧化亚铁含量<1％，完成熔渣的氧化，获得氧化后的熔渣，其中，氧化性气体的预热温度为0～1200℃；并在整个过程中，保证(c)硅酸盐熔渣温度>1450℃；
对应(c)采用的控制方法：
当含铁硅酸盐熔渣温度<1450℃，喷入预热燃料与预热的氧化性气体，燃烧放热、补充热量，或装置自身加热，使硅酸盐熔渣温度>1450℃；
(2)氧化后的熔渣直接空冷或水淬，用作矿渣水泥、水泥调整剂、水泥生产中的添加剂或水泥熟料；
方法E：含铁硅酸盐熔渣处理生产高附加值的水泥熟料：
E-1、向熔炼反应装置内的含铁硅酸盐熔渣中，加入熔融钢渣、石灰、石灰石、铁合金炉渣、粉煤灰、碱性铁贫矿、铝土矿、熔融高炉渣、赤泥、脱钠后赤泥或电石渣中的一种或几种，充分混合，获得熔渣混合物料；
E-2、向熔渣混合物料中吹入预热的氧化性气体，当氧化亚铁含量<1％，完成熔渣的氧化，获得氧化后的熔渣，其中，氧化性气体的预热温度为0～1200℃；并在整个过程中，保证(d)熔渣混合物料温度>1450℃；温度控制方法同方法D步骤(1)中的硅酸盐熔渣温度控制方法；
E-3、氧化后的熔渣，进行空冷或水淬，制得高附加值的水泥熟料；
方法F：含铁硅酸盐矿物相熔渣作为高炉炼铁原料或直接还原炼铁原料：将含铁硅酸盐矿物相的熔渣空冷、水淬或缓冷后，用作高炉炼铁或直接还原炼铁原料，直接还原后，采用磁选分离或电炉熔分，磁选产物为金属铁与尾矿，电炉熔分，产物为铁水与熔渣；
或将所述含铁硅酸盐矿物相的熔渣倒入保温装置后，采用以下方法进行分离：熔渣改性后磁选分离：向保温装置中的熔渣，吹入0～1200℃的预热的氧化性气体，并保证其熔渣温度>1250℃，完成熔渣中磁铁矿的转化；将上述氧化后的熔渣缓冷至室温，破碎、磁选，产物为磁铁矿精矿与尾矿，尾矿作为建筑材料；
还原过程中，含锌组分与含铅组分挥发，以氧化物形式进入烟尘；
方法G：含铁硅酸盐熔渣熔融还原炼铁：
G-1熔炼反应装置内的含铁硅酸盐熔渣，或加入含铁物料，熔渣中加入还原剂，进行熔融还原，实时监测反应熔渣，通过调控同时保证如下(a)和(b)两个参数，获得反应完成后的熔渣；
(a)反应熔渣的温度为1350～1640℃；
(b)反应熔渣的碱度CaO/SiO2比值＝0.6～2.4；
调控方法为：
对应(a)：
控制反应熔渣的温度在设定温度范围的方法为：
当反应熔渣的温度＜设定温度范围下限时，通过反应装置自身的加热功能，或向熔渣中加入燃料与预热的氧化性气体，使反应熔渣的温度达到设定温度范围内；
当反应熔渣的温度＞设定温度范围上限时，向反应熔渣中加入冶金熔剂、含铁物料或含氟物料中的一种或几种，使反应熔渣的温度达到设定温度范围内；
对应(b)：
当反应熔渣中碱度CaO/SiO2比值<0.6时，向熔渣中加入碱性物料和/或碱性含铁物料；
当反应熔渣中碱度CaO/SiO2比值>2.4时，向熔渣中加入酸性物料和/或酸性含铁物料；
G-2向熔渣中喷吹预热后的氧化性气体进行熔融还原，形成还原后的熔渣，其中：氧化性气体的预热温度为0～1200℃，并在喷吹过程中，通过调控同时保证(a)和(b)两个参数：
(a)反应完成后的熔渣的温度为1350～1640℃；
(b)反应完成后的熔渣的碱度CaO/SiO2比值＝0.6～2.4；
其中，设定温度范围和碱度调控方法同方法G步骤(1)；
G-3分离回收：
采用以下方法中的一种：
方法Ⅰ：进行如下步骤：
(a)冷却：将还原后的混合熔渣倒入保温渣罐，冷却至室温，获得缓冷渣；
(b)分离：金属铁沉降到反应装置的底部，形成铁坨，人工取出铁坨；将剩余缓冷渣中含金属铁层，破碎至粒度20～400μm，磨矿，磁选分离出剩余金属铁与尾矿；
(c)尾矿的回收利用，作为水泥原料、建筑材料、代替碎石作骨料、路材或磷肥使用；
方法Ⅱ：进行如下步骤：
(a)还原后的混合熔渣，冷却沉降，渣-金分离，获得铁水与还原后的熔渣；
(b)还原后的熔渣，进行炉外熔渣处理，具体方式为：采用步骤2的分离回收方法一中的方法A～E中的一种或几种，进行炉外熔渣处理；
(c)铁水，送往转炉或电炉炼钢；
(d)含锌组分与含铅组分挥发，以氧化物形式进入烟尘回收；
(e)部分金银组分、铟组分、铋组分、钠组分、钾组分挥发进入烟尘；
(f)还原产生的煤气在熔渣表面二次燃烧，提供了热量，而且由炉内流出的煤气可以作为烘干炉料与保温装置的热源；
方法二：采用熔渣可流出的熔炼反应装置时，反应完成后的熔渣进行如下步骤：
(1)熔融态富铜镍相，送往转炉或吹炼炉或作为铜钴镍分离的原料；
(2)熔融态富铁相层与含铁硅酸盐矿物相采用处理方法用方法一中所述方法A～G中一种或几种进行处理；
(3)部分含锌组分与含铅组分挥发，以氧化物形式进入烟尘回收；
(4)部分铟组分、铋组分、钠组分、钾组分挥发进入烟尘。
方法三：采用熔渣可转动的转炉与反应渣罐时，反应完成后的熔渣进行如下步骤：
(1)熔融态含铁硅酸盐矿物相，进行熔渣处理，具体处理方式为：采用步骤2的分离回收方法一中的方法A～G中的一种或几种进行熔渣处理；或含有所述富铁相采用方法一中的步骤(4)进行处理；
(2)熔融态富铜镍相或倒入保温装置缓冷后，送往转炉或吹炼炉或作为铜钴镍分离的原料；
(3)部分铟组分、铋组分、钠组分、钾组分挥发进入烟尘回收；
方法四：采用熔渣可转动的转炉与反应渣罐时，反应完成后的熔渣进行如下步骤：
(1)熔融态含铁硅酸盐矿物相与富铁相，进行熔渣处理，具体方式为：采用步骤2的分离回收方法一中的方法A～G中的一种或几种进行处理；
(2)熔融态富铜镍相，送往转炉或吹炼炉或作为铜钴镍分离的原料；
(3)部分铅锌组分、铟组分、铋组分、钠组分、钾组分以氧化物挥发进入烟尘；
方法五：采用保温装置时，或采用熔渣可流出的熔炼反应装置，将熔渣倒入保温装置时，反应完成后的熔渣进行如下步骤：
(1)沉降冷却：反应完成后的熔渣冷却至室温，获得缓冷渣；富铜镍相沉降到反应装置的底部，形成富铜坨；含铁硅酸盐矿物相上浮；富铜镍相金属坨和含铁硅酸盐矿物中间的缓冷渣为富铁相，同时生成含锌组分与含铅组分；金银组分迁移到富铜镍相；
(2)分离：人工取出沉降在底部的富铜镍坨，往转炉或吹炼炉或作为铜钴镍分离的原料；中部的富铁相层作为高炉炼镍铁原料或直接还原炼镍铁原料或熔融还原炼镍铁原料或浮选提铜原料；在浮选过程中，浮选产物为铜精矿、镍精矿、镍合金与铁精矿，铁精矿作为高炉炼铁原料或直接还原炼铁原料或熔融还原炼铁原料；
所述直接还原过程采用转底炉、隧道窑、车底路、竖炉、回转窑或感应炉作为还原设备，利用气基或煤基还原技术，气基还原为天然气和/或煤气，煤基还原为无烟煤、烟煤、褐煤、焦煤、焦粉或焦炭中的一种或几种，还原温度为900～1400℃，碱度CaO/SiO2比值＝0.8～1.5；
(3)部分铅锌组分、铟组分、铋组分、钠组分、钾组分挥发进入烟尘。
如上所述的方法中，优选地，所述的步骤1与2中，镍冶炼渣为熔融态或冷态，其中：熔融镍冶炼渣由镍冶炼炉出渣口获得，或将镍冶炼渣加热至熔融状态；镍冶炼渣是“造锍熔炼”工艺产生的镍熔炼渣、铜冰镍吹炼”工艺吹炼后的吹炼渣、“铜冰镍吹炼”工艺吹炼后的吹炼渣经贫化产生的贫化炉渣、顶吹熔炼产生的镍熔炼渣、顶吹熔炼产生的镍熔炼渣经沉降产生的沉降渣中一种或多种；
所述的步骤1中铜物料是粗铜火法精炼渣、铜渣、选铜尾矿、锌冶炼渣、锌冶炼烟灰与尘泥、铅冶炼炉渣、铅锌尾矿、铅冰铜、砷冰铜、粗铅火法精炼渣、铅冶炼烟灰与尘泥、铅酸电池、铜冶炼烟灰与尘泥、杂铜、含铜垃圾、含铜电路板、锡冶炼渣、锡尾矿中的一种或几种；锌冶炼渣为湿法炼锌与火法炼锌产生的锌冶炼渣，包括浸出渣、铁矾渣、铜镉渣、针铁矿渣、赤铁矿渣、挥发窑渣、竖罐炼锌渣、鼓风炉渣、烟化炉渣、旋涡炉渣、电炉炼锌渣；铅冶炼渣为烟化炉炉渣与含铅熔炼渣，“ISP铅锌鼓风炉还原”或“烧结矿鼓风炉还原”或“固态高铅渣还原”或“液态高铅渣还原工艺”还原工艺产生含铅熔炼渣，含铅熔炼渣通过烟化炉冶炼产生含铅烟化炉渣；
所述的步骤1与2中，铜渣是含铜熔炼渣、含铜吹炼渣、贫化弃渣、浮选尾渣、 湿法炼铜渣中的一种或多种，含铜熔炼渣产生于铜的火法冶炼工艺的“造锍熔炼”过程；含铜吹炼渣产生于铜的火法冶炼工艺的“铜锍吹炼”过程；贫化弃渣为含铜熔炼渣与含铜吹炼渣贫化后弃渣，浮选尾渣为含铜熔炼渣与含铜吹炼渣选矿后尾渣；高炉渣、钢渣与铁合金渣为熔融态，或冷态，其中：熔融态炉渣(铅冶炼渣、高炉渣、钢渣与铁合金渣)由出渣口获得，或将冷态炉渣(铅冶炼渣、高炉渣、钢渣与铁合金渣)加热至熔融状态；所属钢渣为铁水预脱硫渣(脱硫渣、脱硅渣、脱磷渣)、转炉渣、电炉渣、VOD/VAD渣、VD渣、中间包弃渣；所述铁合金炉渣为铁合金生产过程中产生的炉渣，包括冶炼碳素锰铁产生的炉渣、冶炼铬铁产生的炉渣、冶炼镍铁产生的炉渣、冶炼钒铁产生的炉渣、冶炼硅铁产生的炉渣、冶炼铌铁产生的炉渣、冶炼钼铁产生的炉渣。
如上所述的方法中，优选地，所述的步骤1中，氧化铜矿物包括赤铜矿、黑铜矿、孔雀石、蓝铜矿、硅孔雀石、胆矾中的一种或多种；硫化铜矿物包括辉铜矿、铜蓝、黄铜矿、斑铜矿、硫砷铜矿、黝铜矿的一种或多种。
如上所述的方法中，优选地，所述的步骤1与2中，熔渣可流出的熔炼反应装置为可转动的熔炼反应装置或带有渣口或铁口的熔炼反应装置；其中：
所述的保温装置为可倾倒的熔炼反应渣灌、保温地坑；
所述的可转动的熔炼反应装置为转炉、熔炼反应渣罐；
所述的带有渣口或铁口熔渣可流出的熔炼反应装置为等离子炉、直流电弧炉、交流电弧炉、矿热炉、鼓风炉、高炉、感应炉、冲天炉、侧吹熔池熔炼炉、底吹熔池熔炼炉、顶吹熔池熔炼炉、反射炉、奥斯麦特炉、艾萨炉、瓦钮可夫熔池熔炼炉、侧吹回转炉、底吹回转炉、顶吹回转炉。
所述的步骤1中，通过调控同时保证如下(a)和(b)两个参数，同时保证熔渣中铜氧化物、镍氧化物、钴氧化物和铁氧化物还原为金属铜、金属镍、金属钴和FeO，熔渣中金属铁含量<3％。可通过加入还原剂、含碳的含铁物料中的一种或两种进行调控，其中，所述还原剂和/或含碳的含铁物料的用量为熔渣中铜氧化物、镍氧化物、钴氧化物和铁氧化物还原为金属铜、镍、钴和FeO的理论量110～140％；所述含碳的含铁物料为钢铁尘泥与烟灰、铁精矿含碳预还原球团、铁精矿含碳金属化球团、湿法炼锌挥发窑渣、焦炭炉尘泥与烟灰。
所述的步骤1与2中，所述的燃料与还原剂为固体、液体或气体中的一种或多种，以喷吹的方式喷入，载入气体为氧化性气体、氮气、氩气中的一种或几种，载入气体的预热温度是0～1200℃；所述的喷吹方式为采用耐火喷枪插入熔渣或置于含铜与铁的反应熔渣上部或侧面吹入；固体燃料与还原剂为煤粉、粉煤灰、焦粉、焦炭、烟煤或无烟煤中的一种或多种，形状为粒状或粉状或块状，粒状物料的粒度为5～25μm，粉状物料的粒度为≤150μm，液体燃料与还原剂为重油，气体燃料与还原剂为煤气和/或天然气中的一种或两种；所述的冶金熔剂为含CaO或SiO2的矿物，具体为石英砂、含金银石英砂、赤泥、脱钠后高钙赤泥、电石渣、白云石或石灰石中的一种或几种；
所述含铁物料是普通铁精矿、普通铁精矿直接还原铁，普通铁精矿烧结矿、普通铁精矿球团矿、普通铁精矿金属化球团、普通铁精矿含碳预还原球团、钢渣、锌冶炼渣、焦炭冶炼烟尘与尘泥、钢铁烟尘与尘泥、含镍冶炼渣、铜渣、铅冶炼渣、锌冶炼渣、锡冶炼渣、赤泥、脱钠后高钙赤泥、煤粉灰、硫酸烧渣中的一种或几种；所述钢铁烟尘与尘泥包括高炉瓦斯泥、转炉尘泥、电炉尘泥、热(冷)轧污泥、烧结粉尘、球团粉尘、出铁厂集尘、高炉瓦斯灰、电炉除尘灰、轧钢氧化铁皮。
所述含氟物料是萤石、CaF2或含氟高炉渣中的一种或几种。
如上所述的方法中，优选地，所述的步骤1与2中，控制混合熔渣的温度在设定温度范围的方法中：
含铜物料、含铁物料和含氟物料均为球团或粉状物料或制粒；其中，粒状物料的粒度为5～25μm，粉状物料的粒度为≤150μm，粉状物料以喷吹的方式喷入，载入气体为氩气、氮气还原性气体(煤气和/或天然气)、氧化性气体中的一种或多种，载入气体的预热温度是0～1200℃，所述的喷吹方式为采用耐火喷枪插入熔渣或置于含铜与铁的反应熔渣上部或侧面吹入；
含铜物料与含铁物料为热态或冷态，所述的热态物料是从冶金炉中直接产出的热态物料，热态物料温度为200～1550℃。
所述湿法炼锌渣与尘泥需经脱水、干燥。
在上述的原料中，锌冶炼渣与烟灰、铅冶炼渣与烟灰含有铟与铋、铅、银、锌、铋；赤泥中含有钠与钾，钢铁烟尘与尘泥含有铟、铋、银、钠与钾，以上物料都有铁，铅冶炼渣与锌冶炼渣都含有铜，铜烟灰与尘泥含有铟与铋，因此在发明的方法中，铟、铋、钠、钾、锌、铅会以氧化物的形式进入烟尘，从而进行回收。
如上所述的方法中，优选地，所述的步骤1中，控制混合熔渣的温度在设定温度范围的方法中：
当混合熔渣的温度＞设定温度上限时，加入镍冶炼渣、含铜物料、含铁物料、高炉渣、钢渣、铁合金渣、冶金熔剂或含氟物料中的一种或几种，目的是避免温度过高，保护耐火材料；加入含氟物料的另一个作用是降低粘度，加速熔渣中富铜镍相、富铁相聚集、长大与沉降，有利于硅酸盐上浮；
所述的步骤1中，熔渣反应过程中，熔渣中铜组分、镍钴组分、金银组分富集于富铜镍相，并实现聚集、长大与沉降，铁组分从橄榄石释放出来，富集于富铁相，实现聚集、长大与沉降，熔渣中锌组分、铅组分、铟组分、铋组分分别进入烟尘，其中烟灰中以氧化物形式回收，富铜镍相为铜、白冰铜、铜冰镍、富铜镍钴、含铁组分中的多种，或部分镍钴组分进入富铁相，富铁相包括金属铁、FeO相、铁橄榄石相中的多种；
所述步骤1与2中，调整碱度时，所述的碱性物料可为石灰粉、赤泥、脱钠后赤泥、电石渣、白云石粉或生石灰粉中一种或几种；所述的碱性含铁物料为CaO/SiO2>1的碱性烧结矿、钢渣、铁合金渣、碱性铁精矿、碱性预还原球团、碱性金属化球团、钢渣或高炉渣中的一种或几种；
所述步骤1与2中，调整碱度时，所述的酸性物料可为硅石、粉煤灰、煤矸石中的一种或多种；所述的酸性含铁物料为CaO/SiO2≤1的含铁物料、酸性烧结矿、酸性铁精矿、酸性预还原球团、酸性金属化球团、铜渣、铅冶炼渣、锌冶炼渣、镍冶炼渣、锡冶炼渣、铁合金渣、高炉渣含铜火法贫化渣、含铜尾矿的一种或几种；
所述的步骤1与2中，熔渣中富铜镍相、富铁相聚集、长大与沉降，有利于硅酸盐上浮。
在上述的原料中，锌冶炼渣与烟灰、铅冶炼渣与烟灰含有铟与铋、铅、银、锌、铋；赤泥中含有钠与钾，钢铁烟尘与尘泥含有铟、铋、银、钠与钾，以上物料都有铁，铅冶炼渣与锌冶炼渣都含有铜，铜烟灰与尘泥含有铟与铋，因此在发明的方法中，铟、铋、钠、钾、锌、铅会以氧化物的形式进入烟尘，从而进行回收。
所述的步骤1中，保证(a)和(b)两个参数的同时，使混合熔渣充分混合，混合方式为自然混合或搅拌混合，搅拌方式为以下方式中的一种：氩气搅拌、氮气搅拌、 氩气-氮气混合气、还原性气体搅拌、氧化性气体搅拌、电磁搅拌、机械搅拌中的一种或多种，气体预热温度为0～1200℃；
所述的步骤1与2中，氧化性气体为空气、氧气、富氧空气、氮气-氧气、氩气-氧气中的一种，氧化性气体预热温度为0～1200℃，喷吹方式为采用耐火喷枪插入熔渣或置于反应熔渣上部或侧面或底部吹入中的一种或几种。
如上所述的方法中，优选地，直接还原过程采用转底炉、隧道窑、车底路、竖炉、回转窑、感应炉作为还原设备，利用气基或煤基还原技术，气基为天然气和/或煤气，煤基还原为无烟煤、烟煤、褐煤、焦煤、焦粉、焦炭中的一种或几种，还原温度为900～1400℃，碱度CaO/SiO2比值＝0.7～1.9；
所述的步骤1与2中，含铜物料与含铁物料为热态或冷态，所述的热态物料是从冶金炉中直接产出的热态物料，热态物料温度为200～1750℃。
如上所述的方法中，优选地，所述的步骤2中，冷却方式为自然冷却或旋转冷却或离心冷却，沉降方式为自然沉降或旋转沉降或离心冷却；
进一步地，旋转与离心冷却的具体操作为：装有反应完成后的熔渣的装置置于旋转平台上，按照一定速度进行旋转，旋转速度依熔渣质量与保温装置高度或深度而定，旋转时间依熔渣质量与熔渣凝固情况而定；将装有反应完成后的熔渣的装置置于旋转平台上旋转，目的是加速富铜镍相、富铁相聚集、长大与沉降，有利于硅酸盐上浮，缩短沉降时间，改善沉降效果，提高生产效率。
所述的步骤2中，反应完成后的熔渣冷却过程中，由于密度不同与矿物大小不同，大部分富铜镍相、富铁相沉降于中下部；
反应完成后的熔渣中铜组分、镍钴组分金银组分继续富集于富铜镍相，并实现长大与沉降，或部分富集于富铁相；混合熔渣中铁组分分别继续富集于富铁相，并实现长大与沉降。
采用如上所述，最后获得的渣含铜≤0.1％，最后铁的回收率为≥89％，锌的回收率为≥91％，铅的回收率为≥92％，镍的富集率为≥91％，钴的富集率为≥91％，金的富集率为≥94％，银的富集率为≥94％。
为了更好的解释本发明，以便于理解，通过具体实施方式，对本发明作详细描述。其中，以下实施例中所用检测方法与原料未明确指出的，均可采用本领域常规技术，除非另有说明，本发明中所用的百分数均为重量百分数。
以下实施例1～10中的步骤(1)熔渣混合时，通过调控保证的(a)和(b)两个参数具体为：
(a)含铜与铁的反应熔渣的温度为1050～1450℃；
(b)含铜与铁的反应熔渣碱度CaO/SiO2比值＝0.15～1.5。
实施例1
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由“造锍工艺”工艺熔炼炉出渣口获得的熔融镍冶炼渣与由“铜冰镍吹炼”工艺吹炼炉出渣口加入直流电弧炉，同时加入冷态高炉渣、VOD/VAD渣和冶炼碳素锰铁产生的铁合金炉渣，液态高铅渣还原炉的含铅熔炼渣，形成混合熔渣，同时加入硫化铜精矿、氧化镍精矿；将混合熔渣加热至熔融状态，形成含铜与铁的反应熔渣，并使反应熔渣电磁搅拌，实现自然混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；对应(a)：含铜与铁的反应熔渣的温度为1660℃，采用耐火喷枪插入反应熔渣中，以氮气为载入气，喷入常温粉状粒度≤150μm的铜渣、含铜烟灰、杂铜和含铜垃圾和含铜电路板，同时加入 高炉瓦斯泥、电炉尘泥、转炉尘泥普通铁精矿直接还原铁和高炉瓦斯灰，使温度降至1380℃；(b)：含铜与铁的反应熔渣的碱度CaO/SiO2比值＝2.8，向反应熔渣中加入硅石、粉煤灰和煤矸石混合物，使含铜与铁的反应熔渣碱度比值降至1.4；熔渣中金属铁含量1.1％；
步骤2，分离回收采用方法一：
保温50min，熔渣自然沉降，渣-金分离，获得熔融态富铜镍相层、富铁相层与含铁硅酸盐矿物相，同时生成锌组分与铅组分，进行如下步骤：(1)熔融态含铁硅酸盐矿物相，进行炉外熔渣处理，采用方法F，硅酸盐熔渣空冷后，用作直接还原炼铁原料，采用回转窑进行直接还原，利用气基还原技术，气基还原剂为天然气和煤气，还原温度为900℃，碱度CaO/SiO2比值为0.8，还原后采用磁电炉熔分获得金属铁与熔渣，熔分温度为1550℃；(2)熔融态富铜镍相，送往转炉；(3)富铁相层倒入保温装置，空冷后作为高炉炼镍铁原料；(4)锌组分、铟组分、铅组分、铋组分、钾组分、钠组分挥发，以氧化物形式进入烟尘回收，最后获得的渣含铜<0.1％，锌回收率为92％，铅回收率为92％，铁回收率为92％，铟回收率为92％，铋回收率为94％，钠回收率为95％，钾回收率为96％，铁回收率为96％，镍的富集率为93％，钴的富集率为95％，金的富集率为96％，银的富集率为94％。其中，在本发明的所有实施例中，渣含铜是指富镍铜相分离后的渣相，具体为富铁相与硅酸盐矿物相中的含铜量，镍、钴的富集率是指在富铜镍相中镍、钴的含量占原料中对应镍、钴总量的百分比，金、银的富集率是指富铜镍相中金、银的含量占原料中金、银总量的百分比。
实施例2
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由“造锍工艺”工艺熔炼炉出渣口获得的熔融镍冶炼渣与由“铜冰镍吹炼”工艺吹炼渣经贫化炉出渣口获得的熔融镍冶炼渣加入可倾倒的熔炼反应渣灌，同时加入由出渣口获得的熔融态冶炼铬铁产生的铁合金炉渣，形成混合熔渣，同时加入氧化铜精矿与硫化镍精矿；用预热温度为800℃的富氧空气，粒度为20mm无烟煤与焦粒，并喷吹天然气，将混合熔渣加热至熔融状态，形成含铜与铁的反应熔渣，并使反应熔渣电磁搅拌，实现混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后熔渣；
对应(a)含铜与铁反应熔渣温度1660℃，采用耐火喷枪插入反应熔渣中，以氩气为载气，喷入常温粉状粒度≤150μm的铜渣、含铜烟灰、杂铜、钢铁烧结粉尘、烧结球团粉尘、出铁厂粉尘、普通铁精矿、普通铁精矿直接还原铁和普通铁精矿烧结矿，使温度降至1430℃；(b)含铜与铁反应熔渣碱度CaO/SiO2比值为2.7，向反应熔渣中加入酸性烧结矿、酸性铁精矿和酸性预还原球团，使含铜与铁反应熔渣碱度比值降至1.3；熔渣中金属铁含量为3％；
步骤2，分离回收采用方法二：保温15min，反应完成后的熔渣旋转沉降，渣-金分离，获得熔融态富铜镍相层、富铁相层与含铁硅酸盐矿物相，同时生成锌组分、铅组分与铟组分，进入烟尘，以氧化物形式加以回收，进行如下步骤：(1)熔融态硅酸盐矿物相与富铁相层，采用方法G进行炉外熔渣处理，熔渣熔融还原炼镍铁，步骤如下：(1-1)熔渣倒入可倾倒的转炉中，向熔渣中加入粒度为20mm无烟煤与烟煤，进行熔融还原，实时监测反应熔渣，通过调控保证如下(a)反应熔渣的温度为1350～1640℃，和(b)反应熔渣碱度CaO/SiO2比值＝0.6～2.4两个参数，获得反应完成后的熔渣；对应(a)：熔渣的温度为1480，在温度范围内；对应(b)：反应熔渣中碱度CaO/SiO2比值为0.8时，在碱度范围内；(1-2)向反应完成后熔渣中喷吹预热200℃富 氧空气进行熔融还原，形成还原后混合熔渣，并在喷吹过程中，通过调控同时保证(a)反应熔渣温度为1350～1640℃，和(b)反应熔渣碱度CaO/SiO2比值＝0.6～2.4两个参数；(1-3)分离回收：(a)还原后熔渣，沉降渣-金分离，获得含镍铁水与还原后熔渣；(b)还原后熔渣，采用步骤2方法一中法A处理做成高附加值水泥原料；(c)铁水送往转炉或电炉炼钢；(d)含锌组分、含铅组分、铋组分与铟组分挥发，以Z氧化物形式进入烟尘回收；(e)含钠组分、含钾组分挥发，进入烟尘回收；(2)熔融态富铜镍相，送往转炉；(3)富铁相倒入保温装置，空冷后作为高炉炼铁原料；(4)锌组分与铅组分挥发，以氧化物形式进入烟尘回收，最后获得的渣含铜<0.1％，锌回收率为92％，铅回收率为92％，铁回收率为91％，铟回收率为96％，铋回收率为96％，钠回收率为97％，钾回收率为98％，镍的富集率为92％，钴的富集率为96％，金的富集率为94％，银的富集率为95％。
实施例3
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由“造锍工艺”工艺熔炼炉出渣口获得的熔融镍冶炼渣与由顶吹熔池熔炼产生熔炼渣经沉降电炉出渣口获得的熔融镍冶炼渣加入直流电弧炉，同时加入由转炉炼钢出渣口获得的钢渣，形成混合熔渣，同时加入硫化铜精矿与氧化铜精矿；用预热温度为800℃的氧气，喷吹粒度为20mm无烟煤、焦粒与煤粉，将混合熔渣加热至熔融状态，形成含铜与铁的反应熔渣，并使熔渣实现混合；实时监测熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；对应(a)：含铜与铁的反应熔渣的温度为1685℃，向反应熔渣中加入石英砂、赤泥、白云石和石灰石，同时加入含铜烟灰、含铅物料、普通铁精矿球团矿、轧钢氧化铁鳞和普通铁精矿含碳预还原球团，使温度降至1340℃；(b)：含铜与铁的反应熔渣的碱度CaO/SiO2比值＝3.0，向反应熔渣中加入酸性金属化球团、含铜熔炼渣和含铜吹炼渣的混合物，使含铜与铁的反应熔渣的碱度比值降至1.2；熔渣中金属铁含量为2.4％；
步骤2，分离回收采用方法二：保温12min，熔渣自然沉降，渣-金分离，获得熔融态富铜镍相、富铁相层与含铁硅酸盐矿物相，同时生成含锌组分与含铅组分，进行如下步骤：(1)熔融态富铜镍相，送往转炉；(2)富铁相层与硅酸盐矿物相作为直接还原炼镍铁原料；还原过程中，锌组分、铅组分、铋组分与铟组分挥发，进入烟尘；直接还原过程中，采用转底炉，还原温度为1200℃，碱度CaO/SiO2比值＝1.0，粒度为≤150μm的无烟煤与煤粉；(3)含锌组分、铟组分、铋组分与含铅组分挥发，进入烟尘回收，渣含铜<0.1％，铁的回收率为89％，锌的回收率为93％，铅的回收率为92％铟回收率为93％，铋回收率为94％；镍的富集率为93％，钴的富集率为97％，金的富集率为95％，银的富集率为96％。
实施例4
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将冷态的由顶吹熔池熔炼产生熔炼渣经沉降电炉出渣口获得的熔融镍冶炼渣加入等离子炉，同时加入由出渣口获得的转炉钢渣、电炉钢渣与冶炼镍铁获得的铁合金炉渣，形成混合熔渣，同时加入氧化铜精矿与含铜物料(湿法炼锌浸出渣、湿法炼锌挥发窑渣)；将混合熔渣加热至熔融状态，形成含铜与铁反应熔渣，喷吹预热温度为700℃的氩气，并使反应熔渣实现混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；对应(a)含铜与铁的反应熔渣的温度为1670℃，向反应熔渣中加入赤泥、硫酸烧渣、萤石、铅冰铜、含铅烟灰、含锌烟灰、砷冰铜和湿法炼锌渣，使温度降至1320℃；(b)含铜与铁的反应熔 渣碱度CaO/SiO2比值为2.9，向反应熔渣中加入含铜吹炼渣，使含铜与铁反应熔渣碱度比值降至1.1；喷吹天然气，并用空气喷吹粒度为20mm的焦粒，熔渣中金属铁含量为2.5％；
步骤2，分离回收采用方法四：保温42min，反应完成后熔渣倒入自然冷却沉降，渣-金分离，获得熔融态富铜镍相、富铁铜相层与含铁硅酸盐矿物相，进行如下步骤：(1)熔融态富铜镍相，送往转炉；(2)熔融态富铁相层与含铁硅酸盐矿物相步骤2分离回收方法一中方法F，氧化改性磁选分离：①将熔渣倒入保温渣罐，向熔渣中喷入预热温度为900℃的富氧空气，实现磁铁矿的转化；②缓冷至室温，磁选分离，获得铁精矿与尾矿；(3)部分含锌组分、铋组分、铟组分与与含铅组分挥发，进入烟尘回收，渣含铜<0.1％，铁的回收率为90％，锌的回收率为92％，铅的回收率为92％，铟回收率为94％，铋回收率为94％；镍的富集率为95％，钴的富集率为94％，金的富集率为95％，银的富集率为96％。
实施例5
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由“造锍工艺”工艺熔炼炉出渣口获得的熔融镍冶炼渣、由“铜冰镍吹炼”工艺吹炼炉出渣口获得的熔融镍冶炼渣加入反射炉，同时加入由出渣口获得的转炉熔融钢渣，形成混合熔渣，氧化铜精矿与含铜物料(含铅熔炼渣、烟化炉渣、铅冰铜与砷冰铜)；用预热温度为800℃的空气，喷吹粒度为20mm烟煤与煤粉，将混合熔渣加热至熔融状态，形成含铜与铁的反应熔渣，并使反应熔渣实现混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；对应(a)：含铜与铁的反应熔渣温度为1310℃；(b)：含铜与铁反应熔渣碱度CaO/SiO2比值为1.5，均在要求范围内；熔渣中金属铁含量为1.6％；
步骤2，分离回收采用方法五：将反应完成后的熔渣倒入保温地坑中，进行炉外熔渣处理，进行如下步骤：(1)沉降冷却：保温42min，反应完成后的熔渣自然冷却至室温，获得缓冷渣；富铜镍相沉降到反应装置的底部，形成富铜镍坨；含铁硅酸盐矿物相上浮；富铜镍相金属坨和硅酸盐矿物中间缓冷渣为富铁相，同时生成含锌与含铅组分；(2)分离：人工取出沉降在底部的富铜镍坨，产物作为铜镍铬分离的原料；中部的富铁相层作为高炉炼镍铁的原料；(3)人工取出上部的含铁硅酸盐矿物相，获得硅酸盐尾矿，作为水泥原料使用；(4)部分锌组分与铅组分挥发，以氧化物形式进入烟尘回收，渣含铜<0.1％，铁的回收率为90％，锌的回收率为92％，铅的回收率为92％。
实施例6
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由“造锍工艺”工艺获得的冷态镍冶炼渣、由“铜冰镍吹炼”工艺吹炼渣经贫化炉获得的冷态镍冶炼渣加入交流电弧炉，同时加入冷态冶炼钒铁产生的铁合金炉渣和冶炼硅铁产生的铁合金炉渣，形成混合熔渣，同时加入硫化铜精矿、氧化镍精矿、硫化镍精矿与含铜物料(含铜熔炼渣、含铜吹炼渣与铜火法精炼渣)；将混合熔渣加热至熔融状态，形成含铜与铁反应熔渣，喷吹预热温度为1100℃的氩气-氮气混合气并使反应熔渣混合；实时监测反应熔渣，通过调控同时保证(a)(b)两参数，获得反应完成后熔渣；对应(a)：含铜与铁反应熔渣温度为1040℃，向反应熔渣中喷入预热温度为800℃的富氧空气、重油，加入熔融含铜吹炼渣，使温度升至1330℃；(b)：含铜与铁反应熔渣碱度CaO/SiO2比值为0.1，向反应熔渣中加入碱性铁精矿和碱性预还原球团，使含铜与铁反应熔渣碱度CaO/SiO2比值升至0.5；熔渣中 金属铁含量为0.5％；
步骤2，分离回收采用方法一：保温19min，反应完成后的熔渣自然沉降，渣-金分离，获得熔融态富铜镍相、富铁相层和硅酸盐矿物相，以及含锌与含铅组分，进行如下步骤：(1)熔融态含铁硅酸盐矿物相采用步骤2分离回收方法一法A，水淬直接作水泥原料；(2)熔融态富铜镍相，送往转炉；(3)富铁层倒入保温装置冷却，直接还原炼镍铁；(4)部分含锌与含铅组分挥发，以氧化物形式进入烟尘回收，渣含铜<0.1％，铁的回收率为91％，锌的回收率为92％，铅的回收率为92％，镍的富集率为95％，钴的富集率为93％，金的富集率为94％，银的富集率为96％。
实施例7
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由“造锍工艺”工艺熔炼炉出渣口获得的熔融镍冶炼渣、由“铜冰镍吹炼”工艺吹炼炉出渣口获得的熔融镍冶炼渣加入矿热炉，同时加入出渣口获得的冶炼铌铁产生的炉渣和冶炼钼铁产生的炉渣，形成混合熔渣，同时加入氧化铜精矿(铜火法贫化弃渣、铜渣浮选尾矿、含铜尾矿)；将混合熔渣加热至熔融状态，形成含铜与铁的反应熔渣，并使反应熔渣喷吹氮气，实现混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；对应(a)：含铜与铁的反应熔渣的温度为1320℃；(b)：含铜与铁的反应熔渣的碱度CaO/SiO2比值为0.8，均在要求范围内；喷入天然气，熔渣中金属铁含量为1.7％；
步骤2，分离回收采用方法三：保温35min，将反应完成后熔渣自然沉降，渣-金分离得熔融态富铜镍相、富铁相、含铁硅酸盐矿物相及锌组分与铅组分，进行如下步骤：(1)富铜镍相，送转炉；(2)富铁相层与硅酸盐矿物具体采用步骤2的分离回收方法一中的方法F，水淬后，作为直接还原炼镍铁的原料；(3)部分含锌组分与含铅组分挥发，以氧化物形式进入烟尘回收，最后获得的渣含铜<0.1％，铁的回收率为91％，锌的回收率为93％，铅的回收率为92％，镍的富集率为91％，钴的富集率为97％，金的富集率为98％，银的富集率为96％。
实施例8
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由“造锍工艺”工艺熔炼炉出渣口获得的熔融镍冶炼渣、由“铜冰镍吹炼”工艺吹炼渣经贫化炉出渣口获得的熔融镍冶炼渣加入鼓风炉，同时加入由出渣口获得的高炉渣与电炉钢渣，形成混合熔渣，同时加入硫化铜精矿与含铜物料(含铜烟灰、含铜垃圾与杂铜)；用预热温度为600℃的空气，喷吹粒度为20mm烟煤与煤粉，将混合熔渣加热至熔融状态，形成含铜与铁的反应熔渣，并使反应熔渣实现混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；对应(a)：含铜与铁的反应熔渣的温度为1330℃；(b)：含铜与铁的反应熔渣的碱度CaO/SiO2比值为1.0，均在要求范围内；熔渣中金属铁含量为2.1％；
步骤2，分离回收采用方法三：保温14min，将反应完成后熔渣自然沉降，渣-金分离，获得富铜镍相与中上部含铁硅酸盐矿物相，同时生成含锌与含铅组分，进行如下步骤：(1)含铁硅酸盐矿物相，倒入熔炼装置，进行炉外熔渣处理，具体采用步骤2分离回收方法一法B，将中上部熔渣全部返回到含铜与铁反应熔渣，作为热态冶金熔剂，调整含铜与铁反应熔渣成分，控制其温度；(2)富铜镍相送往转炉或吹炼炉，富铁相作为直接还原炼镍铁的原料；(3)部分含锌组分与含铅组分挥发，以氧化物形式富集进入烟尘回收，最后获得的渣含铜<0.1％，铁的回收率为90％，锌的回收率为92％，铅的回收率为92％，镍的富集率为97％，钴的富集率为93％，金的富集 率为94％，银的富集率为96％。
实施例9
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：将由顶吹熔池熔炼产生熔炼渣经沉降电炉出渣口获得的熔融镍冶炼渣与“铜冰镍吹炼”工艺吹炼渣经贫化炉出渣口获得的熔融镍冶炼渣加入侧吹回转炉，同时加入由出渣口获得的熔融态高炉渣和VD渣，形成混合熔渣，同时加入硫化铜与含铜物料(铜精炼铜渣)；将混合熔渣加热至熔融状态，形成含铜与铁的反应熔渣，并使反应熔渣实现喷吹氩气混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；对应(a)：含铜与铁的反应熔渣温度为1340℃；(b)：含铜与铁的反应熔渣碱度CaO/SiO2比值为1.2，均符合要求；用预热温度为900℃的空气喷吹粒度为20mm的焦粒，熔渣中金属铁含量为2.4％；
步骤2，分离回收采用方法四：保温29min，将反应完成后熔渣自然沉降，渣-金分离，获得富铜镍相与中上部含铁硅酸盐矿物相，以及含锌与含铅组分，进行如下步骤：(1)熔融态含铁硅酸盐矿物相倒入熔炼装置，采用步骤2分离回收方法一中法C，含铁硅酸盐矿物相熔渣浇筑微晶玻璃；(2)下部熔融态富铜镍相送往转炉处理，富铁相作为高炉炼镍铁的原料；(3)部分含锌与含铅组分，以氧化锌和氧化铅形式进入烟尘回收，最后获得渣含铜<0.1％，铁的回收率为90％，锌的回收率为92％，铅的回收率为92％，镍的富集率为96％，钴的富集率为97％，金的富集率为95％，银的富集率为96％。
实施例10
一种由含镍与铁的混合熔渣生产的方法，包括以下步骤：
步骤1，炉渣混合：
将由顶吹熔池熔炼产生熔炼渣经沉降电炉出渣口获得的熔融镍冶炼渣、“铜冰镍吹炼”工艺吹炼渣经贫化炉出渣口获得的熔融镍冶炼渣与由顶吹熔池熔炼产生熔炼渣经沉降电炉出渣口获得的熔融镍冶炼渣加入保温地坑，同时加入冷态钢渣，形成混合熔渣，同时加入氧化铜精矿；用富氧空气，喷吹粒度≤150μm烟煤，将混合熔渣加热至熔融状态，形成含铜反应熔渣，并使反应熔渣实现混合；实时监测反应熔渣，通过调控同时保证(a)和(b)两个参数，获得反应完成后的熔渣；
对应(a)：含铜与铁反应熔渣的温度为1430℃；
(b)：含铜与铁反应熔渣的碱度CaO/SiO2比值为1.5，均在要求范围内；熔渣中金属铁含量为1.6％；
步骤2，分离回收采用方法五：
将反应完成后的熔渣进行如下步骤：
(1)沉降冷却：保温48min，反应完成后的熔渣自然冷却至室温，获得缓冷渣；富铜镍相沉降到反应装置的底部，形成富铜镍坨；含铁硅酸盐矿物相上浮；富铜镍相金属坨和硅酸盐矿物中间缓冷渣为富铁相，同时生成含锌组分与含铅组分；
(2)分离：人工取出沉降在底部的富铜镍坨，作为铜镍钴分离的原料；中部的富铁相层直接还原后，磁选分离金属镍铁；
(3)人工取出上部的硅酸盐矿物相，获得硅酸盐尾矿，作为水泥原料使用；
(4)部分锌组分与铅组分挥发，以氧化物形式进入烟尘回收，最后获得的渣含铜<0.1％，铁的回收率为90％，锌的回收率为92％，铅的回收率为92％，镍的富集率为95％，钴的富集率为96％，金的富集率为95％，银的富集率为97％。

Claims (10)

  1. 一种由含镍与铁的混合熔渣生产的方法，其特征在于，其包括如下步骤：
    S1、炉渣混合：将镍冶炼渣加入反应装置中，加入铅冶炼渣、高炉渣、钢渣和铁合金渣中的一种或多种形成混合熔渣；将混合熔渣加热至熔融状态，同时加入氧化铜矿物、硫化铜矿物、硫化镍矿物、氧化镍矿物、含铜物料中的一种或几种；混合均匀作为反应熔渣，并实时监测反应熔渣，同时通过调控使混合后的反应熔渣同时满足条件a和条件b，获得反应后的熔渣，或将反应后的熔渣倒入保温装置；
    其中，所述条件a为控制反应熔渣温度为1050～1450℃；
    所述条件b为控制反应熔渣的碱度CaO/SiO2比值＝0.15～1.5；
    S2、分离回收：所述步骤S1反应后的熔渣，保温5～50min，分离获得底部的富铜镍相、中下部的富铁相与中上部的含铁硅酸盐矿物相，同时生成含锌组分与含铅组分的烟尘；金银组分迁移、富集进入富镍铜相；含镍组分、含钴组分迁移进入富铜镍相与富铁相。
  2. 如权利要求1所述的方法，其特征在于，在所述步骤S1中，所述条件a调控的方法为：
    当所述反应熔渣的温度＜1050℃，利用反应装置自身的加热，或向熔渣中加入燃料或熔融镍冶炼渣、熔融铅冶炼渣、熔融高炉渣、熔融钢渣或熔融铁合金渣的一种或多种，喷入燃料时，同时喷入预热的氧化性气体，使反应熔渣的温度达到1050～1450℃；
    当所述反应熔渣的温度＞1450℃，向反应熔渣中加入镍冶炼渣、氧化铜矿物、硫化铜矿物、氧化镍矿物、硫化镍矿物、含铜物料、高炉渣、钢渣、铁合金渣、冶金熔剂、含铁物料或含氟物料中的一种或几种，使混合的反应熔渣温度达到1050～1450℃；
    所述条件b调控的方法为：
    当所述反应熔渣中碱度CaO/SiO2比值<0.15时，向反应熔渣中加入碱性物料和/或碱性含铁物料；
    当所述反应熔渣中碱度CaO/SiO2比值>1.5时，向反应熔渣中加入酸性物料和/或酸性含铁物料。
  3. 如权利要求1所述的方法，其特征在于，所述反应装置为保温装置或可转动的熔炼反应装置或带有渣口或铁口熔渣可流出的熔炼反应装置；其中，所述保温装置为可倾倒的熔炼反应渣灌或保温地坑；
    所述可转动的熔炼反应装置为转炉、熔炼反应渣罐；
    所述带有渣口或铁口熔渣可流出的熔炼反应装置为等离子炉、直流电弧炉、交流电弧炉、矿热炉、鼓风炉、高炉、感应炉、冲天炉、侧吹熔池熔炼炉、底吹熔池熔炼炉、顶吹熔池熔炼炉、反射炉、奥斯麦特炉、艾萨炉、瓦钮可夫熔池熔炼炉、侧吹回转炉、底吹回转炉、顶吹回转炉。
  4. 如权利要求1所述的方法，其特征在于，在所述步骤S1中，满足所述条件a和b的同时，应同时满足，控制所述反应熔渣中铜氧化物、镍氧化物、钴氧化物和铁氧化物分别还原为金属铜、金属镍、金属钴和FeO，熔渣中金属铁含量<3％。
  5. 如权利要求1所述的方法，其特征在于，所述镍冶炼渣是“造锍熔炼”工艺产生的镍熔炼渣、“铜冰镍吹炼”工艺吹炼后的吹炼渣、“铜冰镍吹炼”工艺吹炼后的吹炼渣经贫化产生的贫化炉渣、顶吹熔炼产生的镍熔炼渣、顶吹熔炼产生的镍熔炼渣经电炉沉降产生的沉降渣中一种或多种；所述镍冶炼渣为熔融态或冷态，其中：熔融镍冶炼渣由镍冶炼炉出渣口获得，或将镍冶炼渣加热至熔融状态；
    所述高炉渣、钢渣与铁合金渣为熔融态，或冷态，其中：熔融态炉渣由出渣口 获得，或将冷态炉渣加热至熔融状态；所属钢渣为铁水预脱硫渣、转炉渣、电炉渣、VOD/VAD渣、VD渣、中间包弃渣；所述铁合金炉渣为铁合金生产过程中产生的炉渣，包括冶炼碳素锰铁产生的炉渣、冶炼铬铁产生的炉渣、冶炼镍铁产生的炉渣、冶炼钒铁产生的炉渣、冶炼硅铁产生的炉渣、冶炼铌铁产生的炉渣、冶炼钼铁产生的炉渣；
    所述氧化铜矿物包括赤铜矿、黑铜矿、孔雀石、蓝铜矿、硅孔雀石、胆矾中的一种或多种；硫化铜矿物包括辉铜矿、铜蓝、黄铜矿、斑铜矿、硫砷铜矿、黝铜矿的一种或多种；
    所述含铜物料为粗铜铜火法精炼渣、选铜尾矿、铜渣、锌冶炼渣、锌冶炼烟灰与尘泥、铅锌尾矿、铅冶炼渣、铅冰铜、砷冰铜、粗铅火法精炼渣、铅冶炼烟灰与尘泥、铅酸电池、铜冶炼烟灰与尘泥、杂铜、含铜垃圾、含铜电路板、锡冶炼渣、锡尾矿中的一种或几种；其中，所述锌冶炼渣为湿法炼锌与火法炼锌产生的锌冶炼渣，包括浸出渣、铁矾渣、铜镉渣、针铁矿渣、赤铁矿渣、挥发窑渣、烟化炉渣、鼓风炉渣、旋涡炉渣、竖罐炼锌渣、电炉炼锌渣；含铅冶炼渣为烟化炉炉渣与含铅熔炼渣，或“ISP铅锌鼓风炉还原”或“烧结矿鼓风炉还原”或“固态高铅渣还原”或“液态高铅渣还原工艺”还原工艺产生的含铅熔炼渣，含铅熔炼渣通过烟化炉冶炼产生含铅烟化炉渣；所述铜渣是含铜熔炼渣、含铜吹炼渣、贫化弃渣、浮选尾渣、湿法炼铜渣中的一种或多种，含铜熔炼渣产生于铜的火法冶炼工艺的“造锍熔炼”过程；所述含铜吹炼渣产生于铜的火法冶炼工艺的“铜锍吹炼”过程；贫化弃渣为含铜熔炼渣与含铜吹炼渣贫化后弃渣，浮选尾渣为含铜熔炼渣与含铜吹炼渣选矿后尾渣。
  6. 如权利要求2所述的方法，其特征在于，所述含铁物料为普通铁精矿、普通铁精矿直接还原铁，普通铁精矿烧结矿、普通铁精矿球团矿、普通铁精矿金属化球团、普通铁精矿含碳预还原球团、钢渣、锌冶炼渣、焦炭冶炼烟尘与尘泥、钢铁烟尘与尘泥、含镍冶炼渣、铜渣、铅冶炼渣、锌冶炼渣、锡冶炼渣、赤泥、脱钠后高钙赤泥、煤粉灰、硫酸烧渣中的一种或几种；所述钢铁烟尘与尘泥包括高炉瓦斯泥、转炉尘泥、电炉尘泥、热或冷轧污泥、烧结粉尘、球团粉尘、出铁厂集尘、高炉瓦斯灰、电炉除尘灰、轧钢氧化铁皮；
    所述含铜物料与含铁物料为热态或冷态，其中热态物料由冶金炉出料口或出渣口直接获得；湿法的炼锌渣与尘泥需经脱水、干燥；
    所述燃料为固体、液体或气体燃料中的一种或多种；所述燃料以喷吹或投料的方式加入，所述喷吹时，采用载入气体为预热的氧化性气体，所述预热的温度为0～1200℃；所述冶金熔剂为含CaO或SiO2的矿物与炉渣；所述含氟物料为萤石、CaF2或含氟高炉渣中的一种或几种；
    所述的碱性物料为石灰粉、赤泥、脱钠后高钙赤泥、电石渣、白云石粉或生石灰粉中的一种或几种；所述的碱性含铁物料为CaO/SiO2>1的碱性烧结矿、碱性铁精矿、碱性预还原球团、碱性金属化球团、钢渣或高炉渣中的一种或几种；所述酸性物料为硅石、含金银硅石、粉煤灰、煤矸石中的一种或多种；所述酸性含铁物料为CaO/SiO2≤1的含铁物料、酸性烧结矿、酸性铁精矿、酸性预还原球团、酸性金属化球团、铜渣、铅冶炼渣、锌冶炼渣、镍冶炼渣、锡冶炼渣、铁合金渣、高炉渣中的一种或几种。
  7. 如权利要求1或2所述的方法，其特征在于，所述高炉渣、钢渣与铁合金渣为熔融态，或冷态，其中：熔融态炉渣包括高炉渣、钢渣与铁合金渣，由出渣口获得，或将冷态炉渣包括高炉渣、钢渣与铁合金渣，加热至熔融状态；所属钢渣为包括脱硫渣、脱硅渣、脱磷渣的铁水预脱硫渣、转炉渣、电炉渣、VOD/VAD渣、VD 渣、中间包弃渣；所述铁合金炉渣为铁合金生产过程中产生的炉渣，包括冶炼碳素锰铁产生的炉渣、冶炼铬铁产生的炉渣、冶炼镍铁产生的炉渣、冶炼钒铁产生的炉渣、冶炼硅铁产生的炉渣、冶炼铌铁产生的炉渣、冶炼钼铁产生的炉渣；
    所述氧化铜矿物包括赤铜矿、黑铜矿、孔雀石、蓝铜矿、硅孔雀石、胆矾中的一种或多种；所述硫化铜矿物包括辉铜矿、铜蓝、黄铜矿、斑铜矿、硫砷铜矿、黝铜矿的一种或多种。
  8. 如权利要求1-7中任一项所述的方法，其特征在于，所述步骤S2中分离回收，进行如下处理：
    含有热态或冷态所述富铜镍相，送往转炉或吹炼炉吹炼或作为铜钴镍分离的原料；
    所述含锌组分与含铅组分挥发，以氧化物形式进入烟尘；
    镍、钴组分分别进入富铜镍相与富铁相；
    含有所述含铁硅酸盐矿物相和/或所述富铁相，进行如下方法A-G中的任一种处理；
    方法A：水淬或空冷后，直接作为水泥原料；
    方法B部分或全部返回到所述反应熔渣中作为热态冶金熔剂；
    方法C：用于浇筑微晶玻璃或作为矿渣棉；
    方法D：所述含铁硅酸盐矿物相和/或所述富铁相保留在熔炼反应装置内或将其倒入保温装置，向熔渣中吹入温度为0～1200℃的预热氧化性气体，并保证熔渣温度>1450℃；当熔渣氧化亚铁重量百分比含量<1％，获得氧化后的熔渣；所述氧化后的熔渣直接空冷或水淬，用作矿渣水泥、水泥调整剂、水泥生产中的添加剂或水泥熟料；
    方法E：用于生产高附加值的水泥熟料，方法如下:
    E-1、向所述含铁硅酸盐矿物相和/或所述富铁相的熔渣中，加入熔融钢渣、石灰、石灰石、铁合金炉渣、粉煤灰、碱性铁贫矿、铝土矿、熔融高炉渣、赤泥、脱钠后赤泥或电石渣中的一种或几种，充分混合，获得熔渣混合物料；
    E-2、向上熔渣混合物料中吹入预热温度为0～1200℃的氧化性气体，并保证熔渣混合物料温度>1450℃；当氧化亚铁重量百分比含量<1％，获得氧化后的熔渣；
    E-3、对所述氧化后的熔渣，进行空冷或水淬，制得高附加值的水泥熟料；
    方法F：所述含铁硅酸盐矿物相和/或所述富铁相熔渣作为高炉炼铁原料或直接还原炼铁原料：将含铁硅酸盐矿物相和/或所述富铁相的熔渣空冷、水淬或缓冷后，用作高炉炼铁或直接还原炼铁原料，直接还原后，采用磁选分离或电炉熔分，磁选产物为金属铁与尾矿，电炉熔分，产物为铁水与熔渣；
    或将所述含铁硅酸盐矿物相和/或所述富铁相的熔渣倒入保温装置后，采用以下方法进行分离：熔渣改性后磁选分离：向保温装置中的熔渣，吹入0～1200℃的预热的氧化性气体，并保证其熔渣温度>1250℃，完成熔渣中磁铁矿的转化；将上述氧化后的熔渣缓冷至室温，破碎、磁选，产物为磁铁矿精矿与尾矿，尾矿作为建筑材料；
    方法G：所述熔融态含铁硅酸盐矿物相和/或所述富铁相进行还原炼铁，包括如下步骤：
    G-1、将所述含铁硅酸盐矿物相和/或所述富铁相的熔渣保留在熔炼反应装置内或将熔渣倒入保温装置，向熔融态熔渣中加入含铁物料、还原剂，进行熔融还原，实时监测反应熔渣，通过调控同时满足条件：反应熔渣的温度为1350～1640℃和反应熔渣的碱度CaO/SiO2比值＝0.6～2.4，获得反应完成后的熔渣；
    其中，控制反应熔渣的温度的方法为：
    当反应熔渣的温度＜1350℃，通过反应装置自身的加热，或向熔渣中加入燃料与预热的氧化性气体，使反应熔渣的温度达到1350～1640℃；
    当反应熔渣的温度＞1640℃，向反应熔渣中加入冶金熔剂、含铁物料或含氟物料中的一种或几种，使反应熔渣的温度达到1350～1640℃；其中，所述冶金熔剂为含CaO或SiO2的矿物；
    控制反应熔渣的碱度的方法为：
    当反应熔渣中碱度CaO/SiO2比值<0.6时，向熔渣中加入碱性物料和/或碱性含铁物料；
    当反应熔渣中碱度CaO/SiO2比值>2.4时，向熔渣中加入酸性物料和/或酸性含铁物料；
    G-2、所述G-1中熔融还原时还需向熔渣中喷吹0～1200℃预热后的氧化性气体进行熔融还原，形成还原后的熔渣；
    G-3、分离回收：采用以下方法中的一种：
    方法Ⅰ：将还原后的混合熔渣倒入保温渣罐，冷却至室温，获得缓冷渣；其中，金属铁沉降到反应装置的底部，形成铁坨，将剩余缓冷渣中含金属铁层，破碎至粒度20～400μm，磨矿，磁选分离出剩余金属铁与尾矿；
    方法Ⅱ：还原后的混合熔渣，冷却沉降，渣-金分离，获得铁水与还原后的熔渣；所述还原后的熔渣，按照方法A～E中的一种或几种方法进行熔渣处理；所述铁水，送往转炉或电炉炼钢；
    所述富铁相层进行水淬或空冷或倒入保温装置缓冷后，作为高炉炼铁原料或直接还原炼铁原料或熔融还原炼铁原料或浮选提铜原料；浮选过程中，浮选产物为铜精矿、镍精矿、含镍合金与铁精矿，铁精矿作为高炉炼铁原料或直接还原炼铁原料或熔融还原炼铁原料；所述直接还原过程采用转底炉、隧道窑、车底路、竖炉、回转窑或感应炉作为还原设备，利用气基或煤基还原，气基还原采用天然气和/或煤气，煤基还原采用无烟煤、烟煤、褐煤、焦煤、焦粉或焦炭中的一种或几种，控制还原温度为900～1400℃，控制碱度CaO/SiO2比值＝0.8～1.5；还原产生的煤气在熔渣表面二次燃烧，提供了热量，而且由炉内流出的煤气可以作为烘干炉料与保温装置的热源。
  9. 如权利要求8的方法，其特征在于，所述氧化性气体为预热的空气、氧气、富氧空气、氮气-空气、氩气-空气、氧气-氮气、氧气-氩气中的一种，所述预热的温度为0-1200℃；
    所述燃料与还原剂为固体、液体或气体燃料中的一种或多种，以喷吹或投料的方式喷入，所述喷吹载入气体为预热的氧化性气体、氮气或氩气中的一种或多种，所述预热的温度为0-1200℃；所述固体燃料与还原剂为煤粉、焦粉、焦炭、粉煤灰、烟煤或无烟煤中的一种或多种，形状为粒状或粉状，粒状物料粒度为5～25mm，粉状物料粒度为≤150μm，所述液体燃料与还原剂为重油，所述气体燃料与还原剂为煤气和/或天然气。
  10. 如权利要求1所述的方法，其特征在于，在所述步骤S1中，所述混合均匀为自然混合或搅拌混合，搅拌方式为氩气搅拌、氮气搅拌、氮气-氩气混合气搅拌、还原性气体搅拌、氧化性气体搅拌、电磁搅拌或机械搅拌中的一种或几种；
    在所述步骤S2中，所述沉降为自然沉降或旋转沉降或离心沉降；进行冷却沉降时的冷却方式为自然冷却或旋转冷却或离心冷却，所述分离时，用重力分选法是摇床分选、溜槽分选或者二者相结合。
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CN106191344A (zh) * 2016-07-18 2016-12-07 东北大学 一种混合熔渣熔融还原生产与调质处理的方法

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