Suspension smelting furnace

Abstract

The present invention relates to a suspension smelting furnace, which comprises a reaction shaft (5) equipped with a burner (4), a settler (8) communicating with the lower end of the reaction shaft (5), a first tap (15) positioned for discharging slag (14) from a layer of slag (11) in the internal space (9) of the settler (8), and a second tap (17) for discharging matte or metal alloy (16) from a layer of matte or metal alloy (10) in the internal space (9) of the settler (8). The present invention also relates to a method for producing matte or metal alloy in a suspension smelting furnace.

Description

Technical Field

[0001] The present invention relates to a suspension smelting furnace. The present invention also relates to a method of using the suspension smelting furnace.

Background Art

[0002] Conventional processes for converting metal-containing concentrates typically include flash smelting and flash conversion.

[0003] This process usually oxidizes the concentrate in a flash smelting furnace (FSF) to produce matte. The matte is then fed to a flash conversion furnace (FCF) or a Peirce Smith converter, where the matte is further oxidized. In this process, slag is formed in both the FSF and the FCF or Peirce Smith converter. Since slag typically contains a significant amount of metal, in order to improve the yield of the process, it should be recycled back to one or more furnaces for further processing. In one embodiment, the slag from the FCF or Peirce Smith converter should be recycled to the FSF.

[0004] Recycling of slag consumes a lot of resources because the slag is usually granulated by water spraying, stored in bins, sent to a dryer and then returned to the furnace. Consuming a lot of water for slag granulation is because water is mainly used to cool the slag and break it into smaller particles. This results in steam loss and particle contamination of the granulation water, and further treatment is required to make the water reusable. When the slag is fed to the furnace where it is recycled, energy is required to reheat the slag to a temperature sufficient to melt it. The slag granulation water needs to be cooled by a secondary cooling water circuit, which also consumes more energy and water.

[0005] Furthermore, to maximize the exchange of metals from slag to the furnace products, it is crucial that the recycled slag is thoroughly mixed with the reaction mixture in the furnace.

[0006] Therefore, improved furnaces and methods are needed to enable the recycling of molten material between furnaces. Improved furnaces and methods are also needed to enable good mixing of slag and furnace products. [Overview of the Initiative]

[0007] In the first embodiment, a suspension smelting furnace is provided according to the figure, and the suspension smelting furnace is, i. A reaction shaft (5) equipped with a burner, wherein the burner burns concentrate or matte (4) and supplies concentrate or matte (1) to the reaction shaft (5) to form a jet of at least partially oxidized suspension (6) within the reaction shaft (5), ii. A settler (8) communicating with the lower end of the reaction shaft (5), the settler (8) having an internal space (9), a first end wall structure (27) at one end of the settler (8), a second end wall structure (28) at the opposite end of the settler (8), and a landing zone (7) below the lower end of the reaction shaft (5) for the jet of the oxidized suspension (6) in the internal space (9) of the settler (8), the settler (8) extending in two opposite directions from the landing zone (7) The settler (8) comprises a first settler section (18) on the first side of the landing zone (7) and a second settler section (19) on the second side opposite the landing zone (7), wherein the settler (8) receives the suspension (6) which has been at least partially oxidized from the reaction shaft (5) in the landing zone (7), and is configured to form a layer (10) of mat or metal alloy and a layer (11) of slag on the mat or metal alloy layer (10) within the internal space (9) of the settler (8), iii. In order to discharge the slag (14) from the slag layer (11) in the internal space (9) of the settler (8), the first tapping port (15) is located in the second settler section (19), iv. To discharge the mat or metal alloy (16) from the mat or metal alloy layer (10) in the internal space (9) of the settler (8), a second tapping port (17) is provided in the second settler section (19), Equipped with, The first taphole (15) is positioned vertically at a level above the second taphole (17), and the suspension smelting furnace is, v. A supply means (30) for supplying molten material (31) to the suspension smelting furnace, wherein the supply means (30) is in communication with the settler (8) in the first settler section (18) above the slag layer (11) when in use. To further prepare.

[0008] According to a second aspect, a method is provided for producing matte or a metal alloy in a suspension smelting furnace, the method being: i. Using a burner for burning concentrate or matte (4), supply concentrate or matte (1) to the reaction shaft (5) of the suspension smelting furnace to form a jet of at least partially oxidized suspension (6) within the reaction shaft (5), ii. A step of receiving the jet of at least partially oxidized suspension (6) in a landing zone (7) of a settler (8) communicating with the lower end of the reaction shaft (5), wherein the settler (8) has an internal space (9), a first end wall structure (27) at one end of the settler (8), and a second end wall structure (28) at the opposite end of the settler (8), and the settler (8) extends in two opposite directions from the landing zone (7), with the settler (8) comprising a first settler portion (18) on the first side of the landing zone (7) and a second settler portion (19) on the second side opposite the landing zone (7), iii. The steps of forming a layer (10) of mat or metal alloy and a layer (11) of slag on top of the mat or metal alloy layer (10) within the internal space (9) of the settler (8), iv. Discharging the slag (14) from the slag layer (11) in the settler (8) through the first tapping port (15) located in the second settler section (19), v. Discharging the mat or metal alloy (16) from the layer (10) of the mat or metal alloy in the settler (8) through the second tapping port (17) located in the second settler section (19), Includes, The first tapping port (15) is positioned vertically at a level above the second tapping port (17), and the method is as follows: vi. A step of supplying molten material (31) to the suspension smelting furnace via a supply means (30), wherein the supply means (30) is in communication with the settler (8) in the first settler section (18), and the molten material (31) is supplied to the first settler section (18) above the slag layer (11). It also includes. [Brief explanation of the drawing]

[0009] The accompanying drawings, included to provide a further understanding of the present invention and to constitute part of this specification, illustrate embodiments of the invention and, together with the description, help to illustrate the principles of the invention.

[0010] [Figure 1] This is a schematic diagram of a suspension smelting furnace according to a first embodiment of the present invention, in which the supply means (30) is located at the first distal end of the first settler section (18), and the first tapping port (15) and the second tapping port (17) are located at the second distal end of the second settler section (19). [Figure 2] This is a schematic diagram of a suspension smelting furnace according to a first embodiment of the present invention, wherein the supply means (30) is located on the roof of the settler in the first settler section (18), and the first tapping port (15) and the second tapping port (17) are located at the second distal end of the second settler section (19). [Figure 3] This is a schematic diagram of a suspension smelting furnace according to a first embodiment of the present invention, wherein the supply means (30) is located on the side wall of the settler in the first settler section (18), and the first tapping port (15) and the second tapping port (17) are located at the second distal end of the second settler section (19). [Figure 4] This is a schematic diagram of a suspension smelting furnace according to a first embodiment of the present invention, wherein the supply means (30) is located at the first distal end of the first settler section (18), the first tapping port (15) is located at the second distal end of the second settler section (19), and the second tapping port (17) is located on the side wall of the second settler section (19). [Figure 5] This is a schematic diagram of a suspension smelting furnace according to a first embodiment of the present invention, wherein the supply means (30) is located at the first distal end of the first settler section (18), the second tapping port (17) is located at the second distal end of the second settler section (19), and the first tapping port (15) is located on the side wall of the second settler section (19). [Modes for carrying out the invention]

[0011] Those skilled in the art will see that, with advances in technology, the basic idea of ​​the present invention can be implemented in various ways. Therefore, the present invention and its embodiments are not limited to the examples described below, but rather may vary within the scope of the claims.

[0012] Suspension smelting furnace In the first embodiment, a suspension smelting furnace is provided according to the figure, and the suspension smelting furnace is, i. A reaction shaft (5) equipped with a burner, wherein the burner (4) burns concentrate or matte and supplies concentrate or matte (1) to the reaction shaft (5) to form a jet of at least partially oxidized suspension (6) within the reaction shaft (5), ii. A settler (8) communicating with the lower end of the reaction shaft (5), the settler (8) having an internal space (9), a first end wall structure (27) at one end of the settler (8), a second end wall structure (28) at the opposite end of the settler (8), and a landing zone (7) below the lower end of the reaction shaft (5) for the jet of the oxidized suspension (6) in the internal space (9) of the settler (8), the settler (8) extending in two opposite directions from the landing zone (7) The settler (8) comprises a first settler section (18) on the first side of the landing zone (7) and a second settler section (19) on the second side opposite the landing zone (7), wherein the settler (8) receives the suspension (6) which has been at least partially oxidized from the reaction shaft (5) in the landing zone (7), and is configured to form a layer (10) of mat or metal alloy and a layer (11) of slag on the mat or metal alloy layer (10) within the internal space (9) of the settler (8), iii. In order to discharge the slag (14) from the slag layer (11) in the internal space (9) of the settler (8), the first tapping port (15) is located in the second settler section (19), iv. To discharge the mat or metal alloy (16) from the mat or metal alloy layer (10) in the internal space (9) of the settler (8), a second tapping port (17) is provided in the second settler section (19), Equipped with, The first taphole (15) is positioned vertically at a level above the second taphole (17), and the suspension smelting furnace is, v. A supply means (30) for supplying molten material (31) to the suspension smelting furnace, wherein the supply means (30) is in communication with the settler (8) in the first settler section (18) above the slag layer (11) when in use. To further prepare.

[0013] Before supplying the concentrate or matte (1) to the concentrate or matte burner (4), it may be preferably dried in a steam dryer, a rotary dryer or a matte grinding mill until the moisture content reaches 0 to 1%. This consumes steam or fuel in the form of natural gas or fuel oil.

[0014] The burner (4) for burning the concentrate or matte may be designed to symmetrically mix the feedstock and the oxygen-enriched gas. The oxygen-enriched gas may be air or oxygen-enriched air. In one embodiment, the reaction shaft (5) provides means for delivering natural gas or fuel oil to the reaction shaft fuel burner. When natural gas or fuel oil is burned within the reaction shaft (5), it provides additional heat and promotes the melting of the concentrate or matte (1) supplied thereto.

[0015] The suspension smelting furnace may be a flash smelting furnace (FSF) or a flash converting furnace (FCF). When the suspension smelting furnace is an FSF, the concentrate may be supplied to the furnace. When the suspension smelting furnace is an FCF, the matte may be supplied to the furnace. However, some low-grade matte may be supplied to the FSF for further processing. Similarly, when the suspension smelting furnace is an FSF, the settler (8) may be configured to receive the at least partially oxidized suspension (6) from the reaction shaft (5) in the landing zone (7) and form a matte layer (10) and a slag layer (11) above the matte layer (10) within the internal space (9) of the settler (8). Conversely, when the suspension smelting furnace is an FCF, the settler (8) may be configured to receive the at least partially oxidized suspension (6) from the reaction shaft (5) in the landing zone (7) and form a metal alloy layer (10) and a slag layer (11) above the metal alloy layer (10) within the internal space (9) of the settler (8).

[0016] A jet of at least partially oxidized suspension may be formed within a burner and guided to a settler through a reaction shaft. In one embodiment, the jet of at least partially oxidized suspension (6) is heated to a temperature sufficient to completely melt the concentrate or matte. The jet of at least partially oxidized suspension (6) is preferably heated to a temperature of 1100 - 1600 °C, or 1250 - 1450 °C, for example, 1300 °C. By heating the jet of at least partially oxidized suspension (6) to these temperatures, it has been found that the suspension (6) is completely melted and is suitable for separating the slag viscosity into two phases, namely, slag and matte or metal alloy.

[0017] The concentrate may refer to ore concentrate, which is a product in a metal ore mine. Specifically, the concentrate may include copper or nickel concentrate containing copper and iron or nickel and iron in the form of copper or nickel iron sulfide. The exact composition of the concentrate may vary depending on the geographical origin of the metal ore. In one embodiment, the concentrate is supplied to the reaction shaft in a solid state as fine particles.

[0018] When using copper concentrate, the suspension smelting furnace may be FSF and / or FCF, and the metal alloy may include copper blister. In one embodiment, the metal alloy contains at least 60 wt%, or at least 80 wt% or 100 wt% of copper blister.

[0019] Copper blister may contain copper, iron and sulfur. In one embodiment, copper blister contains 96 - 99.5 wt% of copper and 0.01 - 0.5 wt% of iron.

[0020] When using nickel concentrate, the suspension smelting furnace may be FSF. FSF may be used in combination with a Peirce Smith converter to produce high-grade nickel matte. FSF may be used in combination with a Peirce Smith converter to produce high-grade nickel matte.

[0021] High-grade nickel matte may contain nickel, iron, and sulfur. In one embodiment, the high-grade nickel matte contains 96 to 99.5% by weight of nickel and 0.01 to 0.5% by weight of iron.

[0022] Conventional Peirce-Smith converters are disclosed in Davenport et al., 2002, Extractive Metallurgy of Copper, ELSEVIER SCIENCE Ltd, ISBN: 0-08-044029-0.

[0023] To be at least partially oxidized may mean that at least 60%, 70%, 80%, 90%, or 100% by weight of the iron present in the furnace feed is in an oxidized state. The oxidized state may also mean that the iron element is in the form of an oxide compound, and the weight percentage may refer to the proportion of iron present in the furnace feed that is in an oxidized state. Forming a jet in which at least 70% by weight of the iron is in an oxidized state is particularly advantageous because it reduces the need for oxidation that would otherwise be carried out further downstream in the process line.

[0024] The slag may contain copper oxide and iron oxide, as well as a flux, when using copper concentrate, and nickel oxide and iron oxide, as well as a flux, when using nickel concentrate. The flux may be a compound containing silica and / or calcium. In one embodiment, if the suspension smelting furnace is FSF, silicon dioxide is used as the flux, and if the suspension smelting furnace is FCF, lime, calcium carbonate, or calcium oxide is used as the flux. The flux may be supplied to the reaction shaft. The flux reduces the viscosity of the slag, facilitates the discharge of the slag from the suspension smelting furnace, and minimizes the formation of material to be reverted. Preferably, the weight ratio of iron to silicon dioxide in the FSF slag is 0.9 to 2.0, or 0.7 to 1.8, for example, 1.0 to 1.5. Silicon dioxide, lime, calcium carbonate, or calcium oxide are particularly useful as fluxes because they are relatively inexpensive and provide the desirable result of reducing the viscosity of the slag.

[0025] The term "to communicate with" refers to the existence of available open space between the components discussed, such that the components share open space and materials can be freely exchanged between them.

[0026] The settler (8) may further comprise two side walls, a bottom, and a roof extending between a first end wall structure (27) and a second end wall structure (28). The end wall structures (27, 28) may be square or rectangular in shape, so that the side walls, bottom, and roof extend from around the first end wall (27) to around the second end wall (28), thereby forming a closed space between the end walls (27, 28), bottom, roof, and side walls. The reaction shaft (5) may be located on the roof, and layers of slag and mat or metal alloy (10, 11) may be placed on the bottom when the device is in use. The bottom may be inclined and / or curved downward, for example, toward the first and second tapholes (15, 17), to facilitate the discharge of slag and mat or metal alloy.

[0027] In one embodiment, the supply means (30) for supplying the molten material (31) to the suspension smelting furnace comprises a trough or opening for introducing the molten material (31) continuously or in batches. Alternatively, the supply means (30) for supplying the molten material (31) to the suspension smelting furnace may comprise a pot or ladle for supplying the molten material (31) in batches. The molten material (31) may also be supplied to the suspension smelting furnace by gravity. This has the additional advantage of not requiring energy to transport the molten material (31). The temperature of the molten material (31) is preferably 1000°C to 1450°C, or 1220°C to 1320°C, for example, 1270°C. These temperatures have been found to be high enough to maintain the slag, for example as molten metal, in liquid form, but low enough not to damage the equipment used.

[0028] The suspension smelting furnace according to the first embodiment may be equipped with an uptake shaft (13) through which process gas (12) is introduced from the suspension smelting furnace, and the uptake shaft (13) has an end that communicates with the settler (8) of the second settler section (19).

[0029] The process gas (12) may include sulfur dioxide, carbon dioxide, water, metal-containing vapor, nitrogen, and several reaction shaft products in the form of unsettled suspended particles. Specifically, the unsettled suspended particles, which are dust, may include copper compounds or nickel compounds, depending on whether copper concentrate or nickel concentrate was used in one embodiment.

[0030] The process gas (12) may be led to a heat exchanger to cool the process gas and subsequently separate the gas and solids. The heat exchanger is typically, but not necessarily, a steam boiler that cools the gas by evaporating water into steam. Dust may be separated from the gas during the separation of the gas and solids. The gas and solid separator may be an electrostatic precipitator that collects and separates dust from the gas. In one embodiment, the dust is recycled by being returned to the burner (4) of the reaction shaft (5) of the suspension smelting furnace. The heat obtained from cooling may be recovered and used as electricity.

[0031] The dust may be recycled from the intake shaft (13) of a suspension smelting furnace (FSF or FCF) to the burner (4) of the same suspension smelting furnace via a heat exchanger and solid separation. Alternatively, the dust may be recycled from the intake shaft (13) of one suspension smelting furnace, e.g., an FCF, to the burner (4) of another suspension smelting furnace, e.g., an FSF, via a heat exchanger and solid separation. Recycling the dust improves the yield of copper or nickel in the final product because some copper or nickel is still present in the dust. To avoid misunderstanding, the yield of copper may improve when using copper concentrate, and the yield of nickel may improve when using nickel concentrate.

[0032] A burner (4) according to the first embodiment is more suitable for supplying a flux (1), an oxygen-containing reaction gas (1), solidified slag (1), dust (1), and / or material to be returned (1).

[0033] The dust may be recycled and processed as described above. The flux may also be as described above.

[0034] The reaction gas containing oxygen promotes the oxidation of the concentrate / matte in the reaction shaft (5).

[0035] The returned material may be supplied to both the FSF and FCF, and recycled from the output of the suspension smelter to the input of the same suspension smelter, or from another suspension smelter to the input of another suspension smelter.

[0036] In one embodiment, solidified slag refers to slag produced in a suspension smelting furnace, discharged through a first taphole, and solidified. The slag may, for example, be discharged from the FCF and recycled to the FSF when copper concentrate is used. The slag may be recycled to the FSF from the Peirce-Smith converter when nickel concentrate is used. The slag may also be discharged from the same suspension smelting furnace from which it is recycled, regardless of whether copper concentrate or nickel concentrate was used. The slag may be solidified and granulated using water and / or air and / or nitrogen before being supplied to the suspension smelting furnace.

[0037] The returned material may refer to any reaction shaft products accumulated from the off-gas line, trough or ladle, and furnace. The returned material may be supplied to the suspension smelting furnace by mixing it with the main feed material or through a separate feeder.

[0038] Solidified slag and returned materials typically contain a significant amount of metal, and the remaining metal may be recovered by recycling them into a suspension smelter (either the same suspension smelter from which they originated or a different suspension smelter).

[0039] Alternatively, if the suspension smelting furnace is FCF and copper concentrate is used, no flux is supplied to the burner (4). The copper present in the matte may be oxidized, and some of the copper may be converted into copper oxide. The presence of copper oxide in the slag promotes the liquefaction of the slag. It may be desirable to oxidize the copper to achieve at least 30 wt% copper oxide in the slag by weight of the total weight of the slag. The desired ratio may be achieved by injecting an oxygen-containing reaction gas through the burner to reach partial pressures (pO2) of 1 to 100 Pa, or 2 to 70 Pa, or 10 to 30 Pa. In one embodiment, the concentration of copper oxide in the slag is 30 to 90 wt%, or 35 to 70 wt%, or 40 to 60 wt% of the total weight of the slag. Thus, it may be possible to convert copper-containing material into blister copper without using conventional flux. The desired burner temperature may depend on the desired concentration of copper oxide in the converter slag. The temperature is typically at least 1200°C to ensure the slag is in the molten phase and to achieve an acceptable yield of copper. If the concentration of copper oxide present in the slag is low, a higher temperature may be required. The temperature may be, for example, 1220–1450°C, 1250–1400°C, or 1300–1380°C.

[0040] When using a flux and copper concentrate, the copper oxide concentration in the FCF slag may be 5 to 30% by weight.

[0041] The mat according to the first embodiment may include a copper mat, the metal alloy may include blistered copper, or the mat may include a nickel mat.

[0042] The mat according to the first embodiment may include a copper mat or a nickel mat, depending on whether copper concentrate or nickel concentrate is used. In one embodiment, the mat includes at least 60% by weight, or at least 80% by weight, or 100% by weight of copper mat or nickel mat.

[0043] Matte can refer to the product of FSF supplied with concentrate and oxygen. Specifically, matte may contain iron and copper sulfide, and the copper content of matte may be 40-75% by weight when copper concentrate is used. In contrast, matte may contain iron and nickel sulfide, and the nickel content of matte may be 13-72% by weight when nickel concentrate is used.

[0044] In one embodiment, when copper concentrate is used, the matte is supplied to the reaction shaft (5) of the FCF in a solid state as fine granules. Therefore, it may be necessary to cool and granulate the matte derived from the FSF before supplying it to the FCF. The matte is usually cooled and granulated with water and / or air and / or nitrogen and then ground into fine particles using a grinding mill. The grinding mill may use natural gas or steam as fuel. In one embodiment, when nickel concentrate is used, the matte is supplied to the Peirce-Smith converter in a liquid state.

[0045] The molten material (31) according to the first embodiment may contain slag, preferably the slag contains iron oxide and copper oxide and a flux, or the slag contains iron oxide and nickel oxide and a flux.

[0046] The molten material (31) may contain at least 60% by weight, or at least 80% by weight or 100% by weight of slag. In one embodiment, when copper concentrate is used, the slag contains iron oxide and copper oxide, as well as a flux. The slag may contain 0.4 to 40% by weight of copper and 5 to 55% by weight of iron. In one embodiment, when nickel concentrate is used, the slag contains iron oxide and nickel oxide, as well as a flux. The slag may contain 0.3 to 30% by weight of nickel and 25 to 60% by weight of iron.

[0047] The slag may be recycled from the discharge of a suspension smelting furnace to a feed system of the same suspension smelting furnace or to another suspension smelting furnace. For example, FSF may be used to produce copper matte, the copper matte may be fed into an FCF, and then, if copper concentrate is used, the slag from the FCF may be recycled into FSF in molten form. For example, FSF may be used to produce nickel matte, the nickel matte may be fed into a Peirce Smith converter, and then, if nickel concentrate is used, the slag from the Peirce Smith converter may be recycled into FSF in molten form.

[0048] The inventors have found, surprisingly, that many advantages can be obtained by recycling molten material, particularly slag, in its molten form from one suspension smelting furnace to another, or from a Peirce-Smith converter to a suspension smelting furnace, via the supply means (30) described herein. Firstly, energy can be saved because there is no need to cool, granulate, and reheat the material between furnaces. Water and / or air and / or nitrogen used for granulation can also be saved. Furthermore, by enabling the material to be supplied in liquid form between furnaces, the material, such as slag, can be continuously withdrawn and supplied between furnaces.

[0049] The supply means (30) in the first embodiment may be located closer to the first end wall structure (27) within the first settler portion (18) than to the center of the settler (8).

[0050] It has been found that when molten material (31), particularly slag, is supplied to the settler (8) above the slag layer (11) and in the first settler section (1), the slag is forced to move through the suspension coming from the reaction shaft (5). This is because the reaction shaft products are discharged out of the furnace from the settler (8) on the opposite side of the supply means (30). As a result, the molten material, such as slag, mixes with the reaction shaft output material, which contributes to the oxidation of the molten material, producing a homogeneous mixture and having a positive effect on the yield of metal recovered from the process.

[0051] In the first embodiment, the internal space (9) of the settler (8) may communicate with the lower end of the reaction shaft (5) at a point in the settler (8) that is closer to the center of the settler (8) than one of the ends of the settler (8).

[0052] The settler (8) according to the first embodiment may have an elongated structure. In one embodiment, the settler has the shape of a rectangular parallelepiped, and the rectangular parallelepiped rests on its base in a horizontal position. The settler may be 12 to 30 m in length, 4 to 12 m in width, and 1 to 3 m in height.

[0053] The inventors have found that the configuration of the settler (8) has many advantages. For example, the dust content of the first settler section (18) is low because the gas and dust are drawn together with the off-gas through the gas phase of the second settler section (19) toward the intake shaft (13). The low dust content creates a relatively dust-free atmosphere for the supply means (30). This relatively dust-free atmosphere is beneficial in minimizing dust emissions from the furnace through the supply means (30). Also, the pressure in the first settler section (18) is lower than that of the second settler section (19) because the gas and dust are drawn together with the off-gas through the gas phase of the second settler section (19) toward the intake shaft (13). This lower pressure is beneficial in minimizing SO2 emissions from the furnace through the supply means (30).

[0054] The suspension smelting furnace may be equipped with a baffle to prevent oxidized dust generated in the suspension smelting furnace from entering at least a portion of the first settler section (18). The baffle may extend downward into the first settler section (18) from the roof of the first settler section (18). The baffle can further minimize dust content and reduce pressure within the first settler section (18).

[0055] In conventional suspension smelting furnaces, such as the one disclosed in Finnish Patent No. 22694, the end of the settler wall closest to the reaction shaft experiences significant wear because it is in close proximity to the reaction shaft, which is the hottest part of the settler. In the suspension smelting furnace according to the present invention, the end wall of the settler is located away from this hottest part of the settler, so wear is not a problem.

[0056] In one embodiment, the suspension smelting furnace includes reducing agent supply means for supplying a reducing agent to at least one of the mat or metal alloy layer and slag layer (10, 11) in the first settler section (18). The first settler section (18) may also include a burner for generating a reducing atmosphere in at least a portion of the first settler section (18). A reducing atmosphere may be generated in at least a portion of the first settler section (18) by using the burner, for example, by consuming oxygen present in the first settler section (18) in a combustion process. This further reduces the oxygen oxide content in the first settler section (18).

[0057] The first settler portion (18) according to the first embodiment may have a first proximal end in the landing zone (7) and a first distal end at the opposite end of the first settler portion (18), the first distal end being the first end wall structure (27) of the settler (8), and the supply means (30) is positioned at the first distal end of the first settler portion (18).

[0058] Alternatively, the supply means (30) may be located on the side wall of the settler within the first settler section (18). This is shown in Figure 3. Alternatively, the supply means (30) may be located on the roof of the settler within the first settler section (18). This is shown in Figure 2. The supply means (30) may be located at a distance of 0.2 to 2 m, 0.4 to 1.8 m, or 0.6 to 1.6 m from the first end wall structure (27).

[0059] The supply means (30) may include a trough extending from the end wall structure (27) or side wall or roof of the settler (8) to guide the molten material into the internal space of the settler (9). The trough can guide the molten material so that it does not come into direct contact with the end wall structure (27) or the side wall or roof of the settler (8). In this way, the internal structure of the settler does not wear down by constantly being in contact with the newly introduced high-temperature molten material.

[0060] The position of the supply means (30) has the advantage of maximizing the distance between the inlet of the supply means (30) and the reaction shaft (5), thereby maximizing the contact time between the molten material and the furnace products. This is beneficial because it maximizes the amount of mass exchange between the molten material, particularly the slag, and the reaction shaft products.

[0061] The second settler section (19) according to the first embodiment may have a second proximal end in the landing zone (7) and a second distal end at the opposite end of the second settler section (19), the second distal end being the second end wall structure (28) of the settler (8), and the first tapping port (15) and the second tapping port (17) are located at the second distal end of the second settler section (19).

[0062] Alternatively, the first tapping port (15) may be located on the side wall of the settler (8) of the second settler section (19), preferably at a distance of less than 2 m from the end wall (28). This is shown in Figure 5. Alternatively, the second tapping port (17) may be located on the side wall of the settler (8) of the second settler section (19), preferably at a distance of less than 2 m from the end wall (28). This is shown in Figure 4. Both the first and second tapping ports (15, 17) may be located on the side wall, or one of the first or second tapping ports (15, 17) may be located on the side wall, or one of the first or second tapping ports (15, 17) may be located on the end wall (28).

[0063] The positions of the first and second tapping ports (15, 17) offer the advantage of moving the molten material from the supply means (30) through the reaction shaft output material before it enters the tapping ports.

[0064] The suspension smelting furnace according to the first embodiment may be equipped with suction means for introducing process gas (12) from the suspension smelting furnace.

[0065] In one embodiment, the suction means is a blower located further down the process gas line.

[0066] method The above description of the suspension smelting furnace applies to the suspension smelting furnace in the following description of the method.

[0067] According to a second aspect, a method is provided for producing matte or a metal alloy in a suspension smelting furnace, the method being: i. Using a burner (4) for burning concentrate or matte, supply concentrate or matte (1) to the reaction shaft (5) of the suspension smelting furnace to form a jet of at least partially oxidized suspension (6) within the reaction shaft (5), ii. A step of receiving the jet of at least partially oxidized suspension (6) in a landing zone (7) of a settler (8) communicating with the lower end of the reaction shaft (5), wherein the settler (8) has an internal space (9), a first end wall structure (27) at one end of the settler (8), and a second end wall structure (28) at the opposite end of the settler (8), and the settler (8) extends in two opposite directions from the landing zone (7), with the settler (8) comprising a first settler portion (18) on the first side of the landing zone (7) and a second settler portion (19) on the second side opposite the landing zone (7), iii. The steps of forming a layer (10) of mat or metal alloy and a layer (11) of slag on top of the mat or metal alloy layer (10) within the internal space (9) of the settler (8), iv. Discharging the slag (14) from the slag layer (11) in the settler (8) through the first tapping port (15) located in the second settler section (19), v. The step of discharging the mat or metal alloy (16) from the layer (10) of the mat or metal alloy in the settler (8) through the second tapping port (17) located in the second settler section (19), Includes, The first tapping port (15) is positioned vertically at a level above the second tapping port (17), and the method is as follows: vi. A step of supplying molten material (31) to the suspension smelting furnace via a supply means (30), wherein the supply means (30) is in communication with the settler (8) in the first settler section (18), and the molten material (31) is supplied to the first settler section (18) above the slag layer (11). It also includes.

[0068] If the suspension smelting furnace is FSF, concentrate (1) may be supplied to the burner (4), and if the suspension smelting furnace is FCF, matte (1) may be supplied to the burner (4). If the suspension smelting furnace is FSF, the method may include the step of forming a layer of matte (10) below the layer of slag (11), and if the suspension smelting furnace is FCF, the method may include the step of forming a layer of metal alloy (10) below the layer of slag (11). If the suspension smelting furnace is FSF, copper or nickel concentrate may be supplied to the burner.

[0069] The method according to the second embodiment may further include the step of introducing a process gas (12) from the suspension smelting furnace via an intake shaft (13) having a lower end that communicates with a settler (8) in a second settler section (19).

[0070] A method according to a second embodiment may further include the step of supplying a flux (1), an oxygen-containing reaction gas (1), solidified slag (1), dust (1), and / or returned material (1) using a concentrate burner or matt burner (4).

[0071] According to the second embodiment, the mat may include a copper mat, the metal alloy may include blistered copper, or the mat may include a nickel mat.

[0072] The mat according to the second embodiment may include a copper mat or a nickel mat, depending on whether copper concentrate or nickel concentrate was used. The metal alloy according to the second embodiment may include blister copper.

[0073] The molten material (31) according to the second embodiment may contain slag, and the slag may contain iron oxide and copper oxide and a flux, or the slag may contain iron oxide and nickel oxide and a flux.

[0074] The supply means (30) in the second embodiment may be located closer to the first end wall structure (27) within the first settler portion (18) than to the center of the settler (8).

[0075] The molten material (31) according to the second embodiment may be recycled to the supply means (30) from the second suspension smelting furnace or Peirce Smith converter.

[0076] The molten material may be recycled from FCF to FSF when using copper concentrate, or from the Peirce Smith converter to FSF when using nickel concentrate. In one embodiment, when using copper concentrate, the matte is supplied from the FSF to the FCF, from where the slag is recycled back to the FSF. In another embodiment, when using nickel concentrate, the matte is supplied from the FSF to the Peirce Smith converter, from where the slag is recycled back to the FSF.

[0077] In the second embodiment, the internal space (9) of the settler (8) may communicate with the lower end of the reaction shaft (5) at a point in the settler (8) that is closer to the center of the settler (8) than one of the ends of the settler (8).

[0078] The settler (8) according to the second embodiment may have an elongated configuration.

[0079] The first settler section (18) according to the second embodiment may have a first proximal end in the landing zone (7) and a first distal end at the opposite end of the first settler section (18), the first distal end being the first end wall structure (27) of the settler (8), and the supply means (30) may be located at the first distal end of the first settler section (18).

[0080] The second settler section according to the second embodiment may have a second proximal end in the landing zone (7) and a second distal end at the opposite end of the second settler section (18), the second distal end being the second end wall structure (28) of the settler (8), and the first tapping port (15) and the second tapping port (17) may be located at the second distal end of the second settler section (19).

[0081] In the second embodiment, the process gas (12) from the suspension smelting furnace may be guided through the intake shaft (13) by suction. [Examples]

[0082] The following examples illustrate two processes in which copper blisters were produced in processes comprising FSF and FCF according to the present invention. In this process, copper concentrate was fed into the FSF, where copper matte and slag were produced. The copper matte was then fed into the FCF, where copper blisters and slag were produced. In process 1, the slag was not recycled from the FCF to the FSF in molten form. However, some of the slag was recycled from the FCF to the FSF in solid form. In process 2, the slag was recycled from the FCF to the FSF in molten form, and some of the slag was recycled in solid form.

[0083] The following process was evaluated using examples. [Table 1]

[0084] The process details and results are shown in the table below. [Table 2]

[0085] As can be seen in the table above, Process 2 resulted in several reductions in OPEX. The most significant OPEX reductions are listed in the table below. [Table 3]

[0086] Furthermore, in process 2, water consumption was reduced by approximately -3 m3 / h compared to process 1.

[0087] Thus, Process 2 saved some OPEX and reduced water consumption compared to Process 1. This has a significant positive impact on both the environment and economics.

Claims

1. It is a suspension smelting furnace, i. A reaction shaft (5) equipped with a burner (4), wherein the burner (4) burns concentrate or matte and supplies concentrate or matte (1) to the reaction shaft (5) to form a jet of at least partially oxidized suspension (6) within the reaction shaft (5), ii. A settler (8) communicating with the lower end of the reaction shaft (5), the settler (8) having an internal space (9), a first end wall structure (27) at one end of the settler (8), a second end wall structure (28) at the opposite end of the settler (8), and a landing zone (7) below the lower end of the reaction shaft (5) for the jet of the oxidized suspension (6) in the internal space (9) of the settler (8), the settler (8) extending in two opposite directions from the landing zone (7), the settler (8) The landing zone (7) comprises a first settler section (18) on the first side and a second settler section (19) on the second side opposite the landing zone (7), wherein the settler (8) receives the suspension (6) which has been at least partially oxidized from the reaction shaft (5) in the landing zone (7), and is configured to form a layer (10) of mat or metal alloy and a layer (11) of slag on the mat or metal alloy layer (10) within the internal space (9) of the settler (8), iii. In order to discharge the slag (14) from the slag layer (11) in the internal space (9) of the settler (8), the first tapping port (15) is located in the second settler section (19), iv. In order to discharge the mat or metal alloy (16) from the layer (10) of mat or metal alloy (16) in the internal space (9) of the settler (8), a second tapping port (17) is provided in the second settler section (19), Equipped with, The first taphole (15) is positioned vertically at a level above the second taphole (17), and the suspension smelting furnace is, v. A supply means (30) for supplying molten material (31) to the suspension smelting furnace, wherein the supply means (30) is in communication with the settler (8) in the first settler section (18) above the slag layer (11) when in use. A suspension smelting furnace, further equipped with additional features.

2. The suspension smelting furnace according to claim 1, further comprising an intake shaft (13), the intake shaft (13) guides process gas (12) from the suspension smelting furnace via the intake shaft (13), and the lower end of the intake shaft (13) is in communication with the settler (8) of the second settler section (19).

3. The suspension smelting furnace according to claim 1 or 2, wherein the burner (4) is further suitable for supplying a flux (1), an oxygen-containing reaction gas (1), a solidified slag (1), dust (1), and / or material to be returned (1).

4. The suspension smelting furnace according to any one of claims 1 to 3, wherein the mat includes a copper mat, the metal alloy includes blistered copper, or the mat includes a nickel mat.

5. The suspension smelting furnace according to any one of claims 1 to 4, wherein the molten material (31) includes slag, preferably the slag includes iron oxide and copper oxide and a flux, or the slag includes iron oxide and nickel oxide and a flux.

6. The suspension smelting furnace according to any one of claims 1 to 5, wherein the supply means (30) is located closer to the first end wall structure (27) in the first settler section (18) than to the center of the settler (8).

7. The suspension smelting furnace according to any one of claims 1 to 6, wherein the internal space (9) of the settler (8) communicates with the lower end of the reaction shaft (5) at a point on the settler (8) that is closer to the center of the settler (8) than one of the ends of the settler (8).

8. The settler (8) has an elongated configuration, as described in any one of claims 1 to 7.

9. The suspension smelting furnace according to any one of claims 1 to 8, wherein the first settler portion (18) has a first proximal end in the landing zone (7) and a first distal end at the opposite end of the first settler portion (18), the first distal end is also the first end wall structure (27) of the settler (8), and the supply means (30) is positioned at the first distal end of the first settler portion (18).

10. The suspension smelting furnace according to any one of claims 1 to 9, wherein the second settler section (19) has a second proximal end in the landing zone (7) and a second distal end at the opposite end of the second settler section (19), the second distal end being the second end wall structure (28) of the settler (8), and the first tapping port (15) and the second tapping port (17) are located at the second distal end of the second settler section (19).

11. The suspension smelting furnace according to any one of claims 2 to 10, wherein the suspension smelting furnace is equipped with a suction means for introducing a process gas (12) from the suspension smelting furnace.

12. A method for producing matte or a metal alloy in a suspension smelting furnace, i. Using a burner (4) for burning concentrate or matte, supply concentrate or matte (1) to the reaction shaft (5) of the suspension smelting furnace to form a jet of at least partially oxidized suspension (6) within the reaction shaft (5), ii. A step of receiving the jet of at least partially oxidized suspension (6) in a landing zone (7) of a settler (8) communicating with the lower end of the reaction shaft (5), wherein the settler (8) has an internal space (9), a first end wall structure (27) at one end of the settler (8), and a second end wall structure (28) at the opposite end of the settler (8), and the settler (8) extends in two opposite directions from the landing zone (7), with the settler (8) comprising a first settler portion (18) on the first side of the landing zone (7) and a second settler portion (19) on the second side opposite the landing zone (7), iii. The step of forming a layer (10) of mat or metal alloy and a layer (11) of slag on the mat or metal alloy layer (10) within the internal space (9) of the settler (8), iv. Discharging the slag (14) from the slag layer (11) in the settler (8) through the first tapping port (15) located in the second settler section (19), v. The step of discharging the mat or metal alloy (16) from the layer (10) of the mat or metal alloy in the settler (8) through the second tapping port (17) located in the second settler section (19), Includes, The first tapping port (15) is positioned vertically at a level above the second tapping port (17), and the method is as follows: vi. A step of supplying molten material (31) to the suspension smelting furnace via a supply means (30), wherein the supply means (30) is in communication with the settler (8) in the first settler section (18), and the molten material (31) is supplied to the first settler section (18) above the slag layer (11). Methods that further include the above.

13. The method according to claim 12, further comprising the step of introducing a process gas (12) from the suspension smelting furnace via an intake shaft (13) having a lower end that communicates with the settler (8) in the second settler section (19).

14. The method according to claim 12 or 13, further comprising the step of supplying a flux (1), an oxygen-containing reaction gas (1) and / or solidified slag (1), dust (1) and / or returned material (1) using the concentrate burner or mat burner (4).

15. The method according to any one of claims 12 to 14, wherein the mat comprises a copper mat, the metal alloy comprises blistered copper, or the mat comprises a nickel mat.

16. The method according to any one of claims 12 to 15, wherein the molten material (31) includes slag, preferably the slag includes iron oxide and copper oxide and a flux, or iron oxide and nickel oxide and a flux.

17. The method according to any one of claims 12 to 16, wherein the supply means (30) is located closer to the first end wall structure (27) in the first settler portion (18) than to the center of the settler (8).

18. The method according to any one of claims 12 to 17, wherein the molten material (31) is recycled from a second suspension smelting furnace or a Peirce Smith converter to the supply means (30).

19. The method according to any one of claims 12 to 18, wherein the internal space (9) of the settler (8) communicates with the lower end of the reaction shaft (5) at a point of the settler (8) that is closer to the center of the settler (8) than one of the ends of the settler (8).

20. The method according to any one of claims 12 to 19, wherein the settler (8) has an elongated configuration.

21. The method according to any one of claims 12 to 20, wherein the first settler portion (18) has a first proximal end in the landing zone (7) and a first distal end at the opposite end of the first settler portion (18), the first distal end is also the first end wall structure (27) of the settler (8), and the supply means (30) is positioned at the first distal end of the first settler portion (18).

22. The method according to any one of claims 12 to 21, wherein the second settler portion has a second proximal end in the landing zone (7) and a second distal end at the opposite end of the second settler portion (18), the second distal end being the second end wall structure (28) of the settler (8), and the first tapping port (15) and the second tapping port (17) are located at the second distal end of the second settler portion (19).

23. The method according to any one of claims 13 to 22, wherein the process gas (12) from the suspension smelting furnace is guided through the intake shaft (13) by suction.

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