WO2022227180A1 - 一种铜熔炼—热态涡流贫化一体化方法 - Google Patents

一种铜熔炼—热态涡流贫化一体化方法 Download PDF

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WO2022227180A1
WO2022227180A1 PCT/CN2021/096794 CN2021096794W WO2022227180A1 WO 2022227180 A1 WO2022227180 A1 WO 2022227180A1 CN 2021096794 W CN2021096794 W CN 2021096794W WO 2022227180 A1 WO2022227180 A1 WO 2022227180A1
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copper
slag
smelting
depletion
matte
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PCT/CN2021/096794
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English (en)
French (fr)
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张廷安
豆志河
吕国志
李小龙
刘燕
张子木
赫冀成
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东北大学
东大有色固废技术研究院(辽宁)有限公司
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Publication of WO2022227180A1 publication Critical patent/WO2022227180A1/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
    • C22B15/00—Obtaining copper
    • C22B15/0026—Pyrometallurgy
    • C22B15/0028—Smelting or converting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B4/00—Electrothermal treatment of ores or metallurgical products for obtaining metals or alloys
    • C22B4/04—Heavy metals
    • 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 relates to the field of copper concentrate smelting, in particular to an integrated method for copper smelting and thermal eddy current dilution.
  • copper slag dilution can be divided into two categories: slow cooling beneficiation and pyrolytic dilution smelting.
  • the pyrolysis smelting can theoretically reduce the copper content of the slag to the slag-matte equilibrium level.
  • the hot slag is directly electrothermally depleted, and the copper-containing slag is put into the depletion furnace for sedimentation and slag-matte separation and reduction.
  • the addition of the depleting agent has serious volatilization and serious environmental pollution.
  • the residual copper content in the depleted slag is more than 0.5%, and the copper recovery rate is low.
  • the matte and slag flow into the depletion electric furnace continuously through the chute, and the waste heat is recovered from the high-temperature flue gas and then sent to acid production; the slag is overheated by the electrode and the copper matte is clarified and separated to obtain depleted slag and copper matte, and the copper matte is sent to the continuous blowing furnace through the chute; Under the action of compressed air, copper matte reacts with quartz sand to obtain blister copper, which is processed by blowing and smelting slag, and the flue gas is sent to acid.
  • a production process and special equipment for smelting blister copper in an oxygen-enriched side-blown molten pool authorization number: CN101275185B
  • Tan Ronghe et al. discloses a production process and special equipment for smelting blister copper in an oxygen-enriched side-blown molten pool , that is, the charge is blown into the oxygen-enriched side-blown furnace and the oxygen-enriched air is blown into the tuyere on both sides of the furnace body for oxygen-enriched molten pool smelting, and the low matte or nickel obtained from the smelting settles on the bottom of the furnace and is discharged from the siphon at the furnace end.
  • the slag with lower nickel is in the upper layer of the furnace melt and is discharged from the slag port; the low nickel matte and slag produced in the smelting process flow into the depletion electric furnace through the chute for reduction, clarification and separation, and crushed coal is added as a reducing agent, and the melt is depleted. After sufficient clarification and separation in the electric furnace, the upper layer is depleted slag, which is released through the slag port and released by low-grade nickel matte siphon.
  • the present invention proposes a copper smelting-thermal eddy current depletion An integrated method, through which the copper content in the depleted slag can be reduced to less than 0.25%.
  • An integrated method for copper smelting and thermal eddy current depletion comprising the following steps:
  • the oxygen-enriched air is blown to the slag layer or the slag-copper matte interface position in the smelting zone to carry out smelting;
  • the smelting temperature is controlled at 1150°C ⁇ 1250°C, and the smelting time is 0.5 ⁇ 1.5h to complete the slag and matte making.
  • the chemical reaction process generates the lower layer of matte and the upper layer of molten copper slag;
  • the copper matte is discharged and used as a raw material for copper smelting for copper smelting, and the depleted slag can be directly used for comprehensive utilization of reduction and iron extraction after discharge.
  • the mass percentage of copper is less than or equal to 0.25%.
  • the added amount of slag and flux is according to the ratio requirements of conventional copper smelting raw materials.
  • the fuel is preferably coal or natural gas.
  • the oxygen-enriched air is blown to the slag layer or the slag-copper matte interface position in the smelting zone by side blowing or bottom blowing, and in the oxygen-enriched air, the volume percentage of oxygen is 40-65%.
  • the molten copper slag is heated to 1250-1350° C., and the method of electrode heating and/or the method of spraying oxygen-enriched fuel is adopted;
  • the oxygen-enriched fuel is selected from fuel and oxygen-containing gas.
  • the fuel is carbonaceous fuel and/or combustible gas;
  • the carbonaceous fuel is preferably one or more of pulverized coal, coke, anthracite, and bituminous coal;
  • the combustible gas is natural gas, coal gas, and water gas.
  • the oxygen-containing gas is preferably oxygen and oxygen-enriched air.
  • the depleting agent is selected from one or more of FeS, FeS 2 , pyrite, copper concentrate or carbon depleting agent, and the quality of the depleting agent is 10% of the quality of the molten copper slag. 2% ⁇ 15%.
  • step (2) calcium oxide or calcium fluoride is selected as the slag-forming agent, and the quality of the slag-forming agent is 3% to 12% of the quality of the molten copper slag.
  • stirring to form a stable vortex is selected from mechanical stirring to form a stable vortex or gas injection stirring to form a stable vortex. Adjust the stirring paddle or the gas injection port to insert it to 1/3 ⁇ 1/2 of the depth of the molten copper slag layer, and perform central stirring.
  • the central stirring speed is 50 ⁇ 200r/min, and the stirring speed is set to ensure the characteristic rotation of the eddy current in the molten pool.
  • the speed is 5rpm ⁇ 100rpm, and continuous stirring ensures that the hot slag forms a stable eddy current structure, improves the entrainment and dispersion effect of the hot copper slag on the depleting agent, and strengthens the depletion effect of the hot copper slag.
  • the depletion reaction of the molten copper slag obtained after smelting is mainly carried out according to the following reaction formulas (1) and (2).
  • the invention realizes the integration of oxygen-enriched smelting of copper sulfide concentrate and copper slag depletion, effectively utilizes the waste heat of copper smelting slag, reduces energy consumption, and shortens the smelting cycle.
  • the depleted slag can be directly used for comprehensive utilization of reduction and iron extraction, which lays the foundation for the high-value and large-scale treatment of copper smelting without slag.
  • Fig. 1 is a schematic diagram of the device structure adopted by the copper smelting-hot state eddy current depletion integration method of the present invention
  • the main components of the copper sulfide concentrate used in the embodiment of the present invention are: Cu is 26.43%, Fe is 23.45%, S is 33.28%, Al is 1.67%, Si is 9.72%, and the total amount of other impurities is 5.45%.
  • the fuel used in the embodiment of the present invention is coal, and the main components of coal are: fixed carbon 69.17%, ash content 11.13%, and volatile matter 19.42%.
  • the depleting agent used in the embodiment of the present invention is FeS, and the mass purity of FeS is: FeS 89%.
  • the content of the present invention is not limited to the use of such raw materials, for example, the fuel can also be replaced by natural gas and the like.
  • FeS is used as the depleting agent, and a depleting agent such as pyrite, copper concentrate or carbon-based depleting agent can also be used.
  • the schematic structural diagram of the copper smelting-thermal eddy current depletion integrated furnace is shown in Fig. 1, including the copper smelting furnace main body 1, and the copper smelting furnace main body 1 is divided into a smelting furnace body and a depletion furnace body, respectively corresponding to copper
  • the concentrate smelting system and the molten copper slag depletion system, the copper concentrate smelting system and the molten copper slag depletion system are connected in series, and are separated by a retaining wall 5; one end of the retaining wall 5 is connected to the top of the copper smelting furnace main body 1, and the retaining wall 5 The other end extends into the matte layer, and the matte inlet of the molten copper slag depletion system is left between the bottom and the bottom; where the retaining wall is located in the molten copper slag layer, three channels are set for the molten copper slag depletion system.
  • the copper concentrate smelting system includes a smelting furnace body, a material feeding port is arranged on the upper part of the smelting furnace body, a plurality of oxygen-enriched air tuyere 3 are arranged on both sides of the smelting furnace body, and smelting smoke is also arranged on the upper part of the smelting furnace body. air vent;
  • the molten copper slag depletion system also includes a depletion furnace body, a heating electrode 7, a mechanical stirring 9, a depletion agent feeding port 8, a slag discharge port 11, a matte discharge port 12, and a depleted flue gas discharge port 10.
  • the heating end of the heating electrode 7 extends into the upper layer of molten copper slag
  • the stirring paddle of the mechanical stirring 9 extends into the upper layer of molten copper slag
  • the depletion agent feeding port 8 and the depletion flue gas discharge port 10 are arranged in the depletion furnace body.
  • the slag discharge port 11 is provided in the depleted slag layer
  • the matte discharge port 12 is provided in the matte layer.
  • the heating electrode 7 can also be replaced by a fuel combustion device; the mechanical stirring 9 can also be replaced by a gas injection device.
  • An integrated method for copper smelting and thermal eddy current depletion comprising the following steps:
  • the volume concentration of oxygen in the oxygen-enriched air is controlled at 45%, the temperature of the melt is controlled at 1160°C, and the smelting time is 1h, the chemical reaction process of slag and matte formation is completed, and the lower layer of matte and the upper layer of molten copper slag are generated.
  • the upper layer of molten copper slag overflows to the depletion zone, and the lower layer of matte flows into the depletion zone of the matte zone; the molten copper slag is heated to 1250 ⁇ 1350°C by electrode heating to obtain a high-temperature molten copper slag melt;
  • the depleting agent FeS and the slagging agent limestone are continuously added into the high-temperature molten copper slag melt through the depleting agent feeding port, wherein the quality of the depleting agent is 8% of the mass of the high-temperature molten copper slag.
  • the mass of the slag-forming agent is 2% of the mass of the high-temperature molten copper slag;
  • An integrated method for copper smelting and thermal eddy current depletion comprising the following steps:
  • the raw materials such as copper concentrate, slag, and flux are mixed with fuel (coal), of which 280kg per ton of blister copper is blended.
  • the mixed material is continuously fed into the smelting zone from the material feeding port, and at the same time, oxygen-enriched air is sprayed to the slag-copper matte interface position of the smelting zone through the submerged tuyere by means of double-side injection.
  • the oxygen volume concentration of the oxygen-enriched air is controlled at 55%
  • the temperature of the melt is controlled at 1170°C
  • the smelting time is 1.5h
  • the chemical reaction process of slag and matte formation is completed, and the lower layer of matte and the upper layer of molten copper slag are generated.
  • the upper layer of molten copper slag overflows to the depletion zone, and the lower layer of matte flows into the depletion zone of the matte zone; the molten copper slag is heated to 1250 ⁇ 1350°C by electrode heating to obtain a high-temperature molten copper slag melt;
  • the depleting agent FeS and the slag-forming agent limestone are continuously added into the high-temperature molten copper slag melt through the depleting agent feeding port, wherein the quality of the depleting agent is 10% of the mass of the high-temperature molten copper slag, and the quality of the slag-forming agent is 10%. It is 2% of the mass of high temperature molten copper slag.
  • An integrated method for copper smelting and thermal eddy current depletion comprising the following steps:
  • oxygen-enriched air is injected to carry out the smelting matte-making reaction, and the temperature of the smelting zone is maintained at 1200°C, and the smelting time is 1.2h;
  • the depletion area adopts mechanical agitation to spray and stir the melt to form a stable vortex
  • the vortex stirring speed is 80rpm
  • the depletion time is 45min
  • the depletion agent and the slag-forming agent are quickly entrained into the molten copper slag melt , and fully disperse to complete the eddy current depletion process to obtain depleted slag and matte;
  • the matte is discharged from the matte outlet into the blowing process for blowing; the depleted slag is continuously discharged from the slag outlet, and the copper content in the depleted slag is ⁇ 0.25%.
  • An integrated method for copper smelting-hot eddy current depletion adopts a copper smelting-hot eddy current depletion integrated furnace, and gas injection equipment is also arranged in the depletion zone, and the steps include:
  • the temperature of the depletion zone is increased from 1250°C in the smelting zone to 1350°C by electrode heating;
  • the matte is discharged from the matte outlet into the blowing process for blowing; the depleted slag is continuously discharged from the slag outlet, and the copper content in the depleted slag is ⁇ 0.25%.
  • a kind of copper smelting-hot state eddy current depletion integrated method with the embodiment 1, the difference is:
  • the depletion time was 0.3h, and the mass percentage of copper in the depleted slag was 0.5%. It shows that the depletion time has an effect on the copper content of the final depleted slag.
  • a kind of copper smelting-hot state eddy current depletion integrated method with the embodiment 1, the difference is:
  • a copper smelting-hot eddy current depletion method comprising the following steps:
  • Example 2 Compared with Example 1, the difference is that after the single copper smelting is adopted, the obtained molten copper slag is further depleted. With eccentric stirring, no vortex is formed. First, the heat energy is wasted seriously. Second, because the matte is not separated again in the subsequent depletion process, the recovery rate of copper is low.

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Abstract

一种铜熔炼—热态涡流贫化一体化方法，属于铜精矿冶炼领域。该方法为：将铜熔炼原料经过高温烟气脱水干燥后，持续落入熔炼区的熔池内；同时，将富氧空气通过喷吹到熔炼区的渣层或渣-铜锍界面位置，在1150℃~1250℃进行熔炼0.5~1.5h，生成下层冰铜和上层熔融铜渣；将上层熔融铜渣溢流至贫化区，下层冰铜流入贫化区的冰铜区；将熔融铜渣升温至1250~1350℃，加入贫化剂和造渣剂，搅拌形成稳定涡流，进行涡流贫化0.5h~2h，得到贫化渣和冰铜；冰铜排出，作为铜冶炼的原料进行炼铜，贫化渣排出后可以直接进行还原提铁综合利用。该方法能够使得贫化渣中铜含量降低至0.25%以下，提高铜的回收率。

Description

一种铜熔炼—热态涡流贫化一体化方法 技术领域
本发明涉及铜精矿冶炼领域，具体涉及一种铜熔炼—热态涡流贫化一体化方法。
 背景技术
现代铜冶炼技术向节约能耗、减少污染物生成、控制污染物排放、资源全流程循环利用等绿色化趋势发展。火法炼铜仍然是铜冶炼的主要工艺。火法炼铜的熔炼过程依据氧枪位置的不同可分为：顶吹熔炼、侧吹熔炼、底吹熔炼过程。其中，侧吹熔炼过程具有良好的节能、绿色环保、设备投资较小等优势被逐渐推广使用。但是，在铜精矿富氧吹炼强化冶炼强度的同时，不可避免地带来了冶炼渣中铜残留量的急剧增加，所以现代炼铜工艺都对铜渣进行了贫化回收铜的处理。目前，铜渣贫化可分为两类：缓冷选矿和火法贫化熔炼。其中，火法贫化熔炼在理论上能够将渣含铜降低到渣—锍平衡水平。热态炉渣直接进行电热贫化将含铜炉渣放入贫化炉进行沉降和渣—锍分离还原。然而，火法贫化熔炼过程中贫化剂加入过程挥发严重，严重污染环境，贫化剂浮于熔渣表面，难以与熔池充分接触，从而制约了贫化剂的高效利用。综合来看，现有的火法贫化熔炼工艺，贫化渣中铜残留含量多在0.5%以上，铜回收率低。
为实现铜渣中铜等组分的回收，国内相关科研人员进行了大量的工作，如孙林权等发明的“一种富氧侧吹熔池熔炼粗铜的生产工艺及其专用设备，授权号：CN101275185B”公开一种富氧侧吹熔池熔炼粗铜的生产工艺及其专用设备，即将含铜物料，石英石，石灰石，粉煤加入熔池炉内，鼓入高压富氧空气，形成的铜锍、炉渣经溜槽不间断流入贫化电炉，高温烟气回收余热后送制酸；炉渣经过电极过热与铜锍澄清分离得到贫化渣和铜锍，铜锍经溜槽送入连续吹炼炉；铜锍在压缩空气的作用下，与石英砂反应得到粗铜，吹炼渣选矿处理，烟气送制酸。
谭荣和等发明的“一种富氧侧吹熔池熔炼粗铜的生产工艺及其专用设备，授权号：CN101275185B”公开一种富氧侧吹熔池熔炼粗铜的生产工艺及其专用设备，即将炉料在富氧侧吹炉内与从炉体两侧的风口鼓入富氧空气进行富氧熔池熔炼，熔炼所得低冰铜或镍沉降在炉膛底层由炉端的虹吸口排出，含铜镍较低的渣在炉膛熔体上层，由渣口排出；将熔炼过程产生的低冰镍和渣通过溜槽流入贫化电炉进行还原澄清分离，并加入碎煤作还原剂，熔体在贫化电炉内经充分的澄清分离后，上层为贫化渣，经渣口放出，低冰镍虹吸放出。
上述专利虽然可以实现粗铜的生产，但是多存在贫化渣中铜含量较高，铜的回收率低(基本上都在0.5%以上)的问题。
 技术解决方案
针对现有炼铜技术中的不足以及选矿贫化渣无法再利用等问题，为了大幅降低贫化渣中铜含量，提高铜的回收率，本发明提出了一种铜熔炼—热态涡流贫化一体化方法，通过该方法能够使得贫化渣中铜含量降低至0.25%以下。
为了实现上述目的，本发明采用如下技术方案：
一种铜熔炼—热态涡流贫化一体化方法，包括以下步骤：
(1)将硫化铜精矿、返渣、熔剂、燃料由物料加料口加入，并经过高温烟气脱水干燥后，持续落入熔炼区的熔池内；其中，按质量比，燃料：硫化铜精矿=150~400kg：1t；
同时，将富氧空气通过喷吹到熔炼区的渣层或渣-铜锍界面位置，进行熔炼；熔炼温度控制在1150℃~1250℃，熔炼时间为0.5~1.5h，完成造渣、造锍化学反应过程，生成下层冰铜和上层熔融铜渣；
(2)上层熔融铜渣溢流至贫化区，下层冰铜流入贫化区的冰铜区；将熔融铜渣升温至1250~1350℃，加入贫化剂和造渣剂，搅拌形成稳定涡流，贫化剂和造渣剂卷吸到熔融铜渣中，充分弥散，进行涡流贫化过程，贫化时间为0.5h~2h，得到贫化渣和冰铜；
所述的冰铜排出，作为铜冶炼的原料进行炼铜，所述的贫化渣排出后可以直接进行还原提铁综合利用。
所述的贫化渣中，铜的质量百分含量≤0.25%。
所述的步骤(1)中，返渣、熔剂的加入量按常规铜熔炼原料配比要求。
所述的步骤(1)中，燃料优选为煤或天然气。
所述的步骤(1)中，富氧空气通过侧吹或底吹到熔炼区的渣层或渣-铜锍界面位置，富氧空气中，氧的体积百分比为40~65%。
所述的步骤(2)中，将熔融铜渣升温至1250~1350℃，采用经过电极加热的方式和/或喷吹富氧燃料的方式；所述的富氧燃料选用燃料与含氧气体的混合物；燃料为碳质燃料和/或可燃气体；所述的碳质燃料优选为煤粉、焦炭、无烟煤、烟煤中的一种或几种；所述的可燃气体为天然气，煤气、水煤气中的一种；含氧气体优选为氧气和富氧空气。
所述的步骤(2)中，贫化剂选用FeS、FeS 2、硫铁矿、铜精矿或炭质贫化剂中的一种或几种，贫化剂的质量为熔融铜渣质量的2%~15%。
所述的步骤(2)中，造渣剂选用氧化钙或氟化钙，造渣剂的质量为熔融铜渣质量的3%~12%。
所述的步骤(2)中，搅拌形成稳定涡流选用机械搅拌形成稳定涡流或气体喷吹搅拌形成稳定涡流。调整搅拌桨或气体喷吹口插入至熔融铜渣层深度的1/3～1/2处，进行中心搅拌，中心搅拌速度为50～200r/min，搅拌转速设定要保证熔池内涡流的特征旋转速度为5rpm~100rpm，并持续搅拌，确保热态熔渣形成稳定的涡流结构，提升热态铜渣对贫化剂的卷吸和分散效果，强化热态铜渣的贫化效果。
本发明的一种铜熔炼—热态涡流贫化一体化方法，熔炼后得到的熔融铜渣的贫化反应主要按照如下反应式(1)和(2)进行。
Cu 2O+FeS=Cu 2S+FeO                   (1)
3Fe 3O 4+FeS+5SiO 2=5(2FeO∙SiO 2)+SO 2                (2)
有益效果
与现有的铜冶炼技术相比，本发明的特点和有益效果是：
(1)该发明实现了硫化铜精矿富氧熔炼和铜渣贫化一体化，有效利用了铜熔炼渣余热，降低了能耗，缩短了冶炼周期。
(2)熔融铜渣直接涡流搅拌贫化实现了贫化剂高效利用和绿色贫化，同时极大提升了贫化效果，贫化渣中铜的质量百分含量降至0.25%以下。
(3)贫化渣可直接进行还原提铁综合利用，为铜冶炼无渣化高值化规模化处理奠定了基础。
 附图说明
图1为本发明铜熔炼—热态涡流贫化一体化方法采用的装置结构示意图；
图中：1-铜冶炼炉主体；2-物料加料口；3-富氧空气风口；4-熔炼烟气排出口；5-挡墙；6-熔融铜渣通道；7-加热电极；8-贫化剂加料口；9-机械搅拌；10-贫化烟气排放口；11-排渣口；12-冰铜排出口。
 本发明的实施方式
下面结合实施例对本发明作进一步的详细说明。
本发明实施例所采用的硫化铜精矿的主要成分为：Cu为26.43%，Fe为23.45%，S为33.28%，Al为1.67%，Si为9.72%，其他杂质总量为5.45%。
本发明实施例所采用的燃料为煤，煤的主要成分为：固定碳69.17%，灰分11.13%，挥发分19.42%。
本发明实施例所采用的贫化剂为FeS，FeS的质量纯度为：FeS 89%。
本发明内容不局限于采用该类原料，如燃料还可以采用天然气等代替。此实施例中贫化剂采用FeS，同样可以采用硫铁矿、铜精矿或者炭质贫化剂等贫化剂。
以下实施例中，采用的铜熔炼—热态涡流贫化一体炉的结构示意图见图1，包括铜冶炼炉主体1，铜冶炼炉主体1分为熔炼炉体和贫化炉体，分别对应铜精矿熔炼系统和熔融铜渣贫化系统，铜精矿熔炼系统和熔融铜渣贫化系统串联，并且通过挡墙5分隔；挡墙5的一端和铜冶炼炉主体1顶部连接，挡墙5的另一端延伸至冰铜层中，并和底部之间留有熔融铜渣贫化系统的冰铜入口；在挡墙位于熔融铜渣层的位置，设置3个通道为熔融铜渣贫化系统的熔融铜渣通道6；
所述的铜精矿熔炼系统包括熔炼炉体，在熔炼炉体上部设置有物料加料口、在熔炼炉体的两侧设置有多个富氧空气风口3，熔炼炉体上部还设置有熔炼烟气排放口；
所述的熔融铜渣贫化系统还包括贫化炉体、加热电极7、机械搅拌9、贫化剂加料口8、排渣口11、冰铜排出口12、贫化烟气排放口10。其中，加热电极7的加热端延伸至上层熔融铜渣中，机械搅拌9的搅拌桨延伸至上层熔融铜渣中，贫化剂加料口8和贫化烟气排放口10设置在贫化炉体上部，排渣口11设置在贫化渣层，冰铜排出口12设置在冰铜层。
采用的铜熔炼—热态涡流贫化一体炉的结构示意图加热电极7还可以采用燃料燃烧装置替换；机械搅拌9还可以选用气体喷吹装置进行替换。
实施例1
一种铜熔炼—热态涡流贫化一体化方法，包括以下步骤：
首先，将铜精矿、返渣、熔剂等原料和燃料(煤)混合，其中每吨粗铜配煤200kg。将混合后的物料由物料加料口加入，并经过高温烟气脱水干燥后，连续加入到熔炼区，同时将富氧空气通过浸没式风口以双侧喷吹的方式喷到熔炼区中渣层。富氧空气的氧的体积浓度控制在45%，熔体的温度控制在1160℃，熔炼时间为1h，完成造渣、造锍化学反应过程，生成下层冰铜和上层熔融铜渣。
上层熔融铜渣溢流至贫化区，下层冰铜流入贫化区的冰铜区；将熔融铜渣采用电极加热升温至1250~1350℃，得到高温熔融铜渣熔体；
然后，将贫化剂FeS和造渣剂石灰石通过贫化剂加料口连续加入到高温熔融铜渣熔体中，其中，贫化剂的质量为高温熔融铜渣质量的8%。造渣剂的质量为高温熔融铜渣质量的2%；
同时采用机械搅拌控制涡流的旋转速度为15rpm，实现对熔融铜渣的高效涡流贫化。贫化时间为35min。最后将高温贫化渣从排渣口排出，将冰铜从出口排出。贫化渣中铜的质量百分含量为0.25%。
实施例2
一种铜熔炼—热态涡流贫化一体化方法，包括以下步骤：
首先，将铜精矿、返渣、熔剂等原料和燃料(煤)混合，其中每吨粗铜配煤280kg。将混合后的物料由物料加料口连续加入到熔炼区，同时将富氧空气通过浸没式风口以双侧喷吹的方式喷到熔炼区的渣-铜锍界面位置。富氧空气的氧气体积浓度控制在55%，熔体的温度控制在1170℃，熔炼时间为1.5h，完成造渣、造锍化学反应过程，生成下层冰铜和上层熔融铜渣。
上层熔融铜渣溢流至贫化区，下层冰铜流入贫化区的冰铜区；将熔融铜渣采用电极加热升温至1250~1350℃，得到高温熔融铜渣熔体；
然后，将贫化剂FeS和造渣剂石灰石通过贫化剂加料口连续加入到高温熔融铜渣熔体中，其中贫化剂的质量为高温熔融铜渣质量的10%，造渣剂的质量为高温熔融铜渣质量的2%。
同时采用机械搅拌控制涡流的旋转速度为35rpm，实现对熔融铜渣的高效涡流贫化。贫化时间为50min。最后将高温贫化渣从排渣口排出，将冰铜从出口排出。贫化渣中铜的质量百分含量为0.22%。
实施例3
一种铜熔炼—热态涡流贫化一体化方法，包括以下步骤：
(1)将硫化铜精矿、返渣、熔剂等原料和燃料(煤粉)按比例充分混合，持续加入到熔炼区域的熔池中；
(2)同时喷入富氧空气，进行熔炼造锍反应，并维持熔炼区的温度在1200℃，熔炼时间为1.2h；
(3)经熔炼获得铜渣和冰铜，高温熔融铜渣通过挡墙内部的熔融铜渣通道流入挡墙另一侧串联的贫化区，冰铜从挡墙下方留设的冰铜入口流入贫化区冰铜层；
(4)将贫化剂和造渣剂加入到贫化区，贫化区经电极加热将温度由熔炼区的1200℃提升至1350℃；
(5)同时贫化区域采用机械搅拌喷吹搅拌熔体形成稳定的涡流，涡流搅拌速度为80rpm，贫化时间为45min，将贫化剂和造渣剂迅速卷吸到熔融铜渣熔体中，充分弥散完成涡流贫化过程，得到贫化渣和冰铜；
(6)冰铜由冰铜出口排出进入吹炼流程进行吹炼；贫化渣由出渣口连续排出，贫化渣中铜含量≤0.25%。
实施例4
一种铜熔炼—热态涡流贫化一体化方法，采用的一种铜熔炼—热态涡流贫化一体炉，在贫化区还设置有气体喷吹设备，其步骤包括：
(1)将硫化铜精矿、返渣、熔剂等原料和燃料(煤粉)按比例充分混合，持续加入到熔炼区域的熔池中；
(2)同时喷入富氧空气，进行熔炼造锍反应，并维持熔炼区的温度为1250℃；
(3)经熔炼获得熔融铜渣和冰铜，高温熔融铜渣通过挡墙内部通道流入挡墙另一侧串联的贫化区，冰铜从挡墙下方流入贫化区冰铜层；
(4)贫化区经电极加热将温度由熔炼区的1250℃提升至1350℃；
(5)同时将贫化剂和造渣剂加入到贫化区，采用机械搅拌和气体喷吹搅拌熔体形成稳定的涡流，涡流搅拌速度为100rpm，贫化时间为0.5h，将贫化剂和造渣剂迅速卷吸到熔融铜渣熔体中，充分弥散完成涡流贫化过程，得到贫化渣和冰铜；
(6)冰铜由冰铜出口排出进入吹炼流程进行吹炼；贫化渣由出渣口连续排出，贫化渣中铜含量≤0.25%。
对比例1
一种铜熔炼—热态涡流贫化一体化方法，同实施例1，不同之处在于：
贫化时间为0.3h，贫化渣中铜的质量百分含量为0.5%。说明贫化时间对最终贫化渣的铜的含量有影响。
对比例2
一种铜熔炼—热态涡流贫化一体化方法，同实施例1，不同之处在于：
增加贫化时间为3h，贫化渣中铜的质量百分含量为0.24%，说明超时贫化不仅没有显著的降低效果，还增加了能耗。
对比例3
一种铜熔炼—热态涡流贫化方法，包括以下步骤：
和实施例1相比，区别在于采用的是单独铜熔炼后，得到的熔融铜渣再进行贫化的过程。采用偏心搅拌，并没有形成涡流，第一其热能浪费严重，第二因为冰铜没有在后续的贫化过程中，再次分离，因此，铜的回收率低。

Claims (10)

  1. 一种铜熔炼—热态涡流贫化一体化方法，其特征在于，包括以下步骤：
    (1)将铜熔炼原料由物料加料口加入，经过高温烟气脱水干燥后，持续落入熔炼区的熔池内；
    同时，将富氧空气通过喷吹到熔炼区的渣层或渣-铜锍界面位置，进行熔炼；熔炼温度控制在1150℃~1250℃，熔炼时间为0.5~1.5h，完成造渣、造锍化学反应过程，生成下层冰铜和上层熔融铜渣；
    (2)上层熔融铜渣溢流至贫化区，下层冰铜流入贫化区的冰铜区；将熔融铜渣升温至1250~1350℃，加入贫化剂和造渣剂，搅拌形成稳定涡流，贫化剂和造渣剂卷吸到熔融铜渣中，充分弥散，进行涡流贫化过程，贫化时间为0.5h~2h，得到贫化渣和冰铜；
    所述的冰铜排出，作为铜冶炼的原料进行炼铜，所述的贫化渣排出后直接进行还原提铁综合利用。
  2. 根据权利要求1所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的贫化渣中，铜的质量百分含量≤0.25%。
  3. 根据权利要求1所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的步骤(1)中，铜熔炼原料为硫化铜精矿、返渣、熔剂和燃料，其中，按质量比，燃料：硫化铜精矿=150~400kg：1t；燃料为煤或天然气。
  4. 根据权利要求1所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的步骤(1)中，富氧空气通过侧吹或底吹到熔炼区的渣层或渣-铜锍界面位置，富氧空气中，氧的体积百分比为40~65%。
  5. 根据权利要求1所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的步骤(2)中，将熔融铜渣升温至1250~1350℃，采用经过电极加热的方式和/或喷吹富氧燃料的方式。
  6. 根据权利要求5所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的富氧燃料选用燃料与含氧气体的混合物；燃料为碳质燃料和/或可燃气体；所述的碳质燃料为煤粉、焦炭、无烟煤、烟煤中的一种或几种；所述的可燃气体为天然气，煤气、水煤气中的一种；含氧气体为氧气和富氧空气。
  7. 根据权利要求1所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的步骤(2)中，贫化剂选用FeS、FeS 2、硫铁矿、铜精矿或炭质贫化剂中的一种或几种，贫化剂的质量为熔融铜渣质量的2%~15%。
  8. 根据权利要求1所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的步骤(2)中，造渣剂选用氧化钙或氟化钙，造渣剂的质量为熔融铜渣质量的3%~12%。
  9. 根据权利要求1所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，所述的步骤(2)中，搅拌形成稳定涡流选用机械搅拌形成稳定涡流或气体喷吹搅拌形成稳定涡流。
  10. 根据权利要求9所述的铜熔炼—热态涡流贫化一体化方法，其特征在于，通过调整搅拌桨或气体喷吹口插入至熔融铜渣层深度的1/3～1/2处，进行中心搅拌，中心搅拌速度为50～200r/min，搅拌转速设定要保证熔池内涡流的特征旋转速度为5rpm~100rpm。
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