Copper-Solder Separation Process for Nickel-Rich Secondary Feedstocks
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Solution Overview
Problem
Current pyrometallurgical processes for producing copper and solder streams from secondary feedstocks suffer from poor separation efficiency, leading to high losses of tin and lead, and are burdened by contaminants like nickel, which impede the production of high-purity copper and solder products.
Innovation Solution
A process involving multiple oxidation and separation steps to produce a dilute copper metal composition with specific metal ratios, allowing for better separation of copper from tin and lead, and enabling the removal of nickel into other product streams, thereby improving the purity and yield of copper and solder products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional pyrometallurgical processes are used for producing copper and solder streams, then copper production is achieved, but separation efficiency is poor leading to high losses of tin and lead
Solution Approach 1:
The invention divides the conventional single-step pyrometallurgical process into multiple sequential steps: (1) initial smelting to produce matte, (2) conversion to produce intermediate copper product, (3) final refining to produce high-purity copper. Each step is optimized for specific separation functions, with the conversion step specifically designed to enhance tin-lead separation from copper through controlled chemical reactions and phase separation.
Solution Approach 2:
The invention introduces intermediate product streams between the initial smelting and final refining stages. The matte stream serves as an intermediary that concentrates copper while retaining tin and lead, which are then selectively separated during the conversion step. This intermediary stage enables more efficient separation than direct single-step processing.
2Manufacturing precision
If conventional processes are used, then copper production is achieved, but nickel content in copper product is high impeding high-purity production
Solution Approach 1:
The invention extracts nickel from the copper product stream during the conversion step. The conversion process selectively removes nickel through chemical reactions that form nickel-containing slag or intermediate phases, which are then separated from the copper. This extraction step specifically targets nickel removal while preserving copper and other valuable metals.
Solution Approach 2:
The invention changes process parameters during the conversion step, including temperature control, oxygen potential, and chemical composition adjustments, to optimize nickel separation. By controlling these parameters, the process selectively promotes nickel oxidation and transfer to slag phases while maintaining copper in the metal phase.
3Manufacturing precision
If strict limits on nickel in raw materials are imposed, then copper quality is maintained, but flexibility in accepting secondary feedstocks is reduced
Solution Approach 1:
The invention converts the harmful effect of nickel present in secondary feedstocks into a beneficial separation process. Rather than preventing nickel-containing materials from entering the process, the conversion step is designed to actively remove nickel through controlled chemical reactions, transforming the potential contaminant into a separable component that ends up in slag or intermediate phases.
Solution Approach 2:
The invention changes the chemical and physical parameters during processing to enable nickel removal regardless of initial feedstock composition. By controlling oxygen potential, temperature, and chemical additives during the conversion step, the process can handle variable nickel levels in feedstocks while consistently producing high-purity copper product.
4Manufacturing precision
If multiple oxidation and separation steps are implemented, then separation efficiency and purity are improved, but process complexity increases
Solution Approach 1:
The invention combines multiple separation functions into integrated process steps. The conversion step, for example, simultaneously performs oxidation reactions, phase separation, and selective metal concentration. By merging these functions into fewer operational units rather than using separate steps for each function, the process achieves high separation efficiency while limiting overall complexity.
Solution Approach 2:
The invention designs process steps that perform multiple functions simultaneously. The conversion step serves as a multi-functional unit that: (1) oxidizes sulfides to oxides, (2) separates copper from tin and lead through phase differentiation, (3) removes nickel through selective oxidation and slag formation, and (4) produces an intermediate product ready for final refining. This multi-functionality reduces the number of separate equipment units needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a clear separation between copper and solder streams, reduces nickel content in the copper product, and allows for the acceptance of more nickel in raw materials without compromising copper quality, resulting in higher purity and yield of copper and solder products.
Implementation Method 1
A process involving multiple oxidation and separation steps to produce a dilute copper metal composition with specific metal ratios
Data Source
AI summary
A dilute copper metal composition includes 57-85% wt Cu, ≥3.0% wt Ni, ≤0.8% wt Fe, 7-25% wt Sn and 3-15% wt Pb. A process includes the steps of partially oxidizing a black copper composition to obtain a first copper refining slag and a first enriched copper metal, partially oxidizing the first enriched copper metal to obtain a second copper refining slag, whereby at least 37.0% wt of the amount of tin and lead processed is retrieved in the first and second copper refining slags together; and partially reducing the first copper refining slag to form a first lead-tin based metal composition and a first spent slag. The process further includes the steps of adding the second copper refining slag to the first lead-tin based metal composition, thereby forming a first liquid bath; and partially oxidizing the first liquid bath, thereby obtaining the dilute copper metal composition.