Flash Smelting Matte Sulfurization to Suppress Metallic Cu Phase
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Solution Overview
Problem
The increasing use of recycled raw materials in copper smelting leads to an increase in metallic Cu, which exceeds its solubility in matte, causing the formation of metallic Cu phase, leading to impurity concentration, brick degradation, and operational risks such as metal discharge and high-impurity metal supply to converters.
Innovation Solution
Adding an S-source, such as FeS2 or pyrite, to the matte generated in the reaction shaft of a flash smelting furnace to convert excess metallic Cu into matte by mixing it with smelting feed or injecting it with an inert gas, ensuring a specific surface area and sufficient amount to completely convert metallic Cu into matte.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If recycled raw materials are increased to improve copper recovery, then copper smelting efficiency is improved, but metallic Cu phase forms when exceeding solubility limit causing operational problems
Solution Approach 1:
The invention changes the chemical parameters of the smelting system by introducing S-source materials (FeS2, pyrite, or CuFeS2) to alter the sulfur activity and copper solubility in the matte. This parameter change enables the system to accommodate higher copper concentrations without forming metallic Cu phase, thus maintaining operational stability while improving copper recovery from recycled materials.
Solution Approach 2:
The S-source materials act as intermediaries between the metallic Cu and the matte phase. These intermediaries facilitate the dissolution of excess metallic Cu into the matte by providing additional sulfur, preventing direct metal accumulation and the formation of separate metallic Cu phase, thereby resolving the contradiction between copper recovery and operational stability.
2Quantity of substance
If metallic Cu is added to increase copper content, then copper production is improved, but metal accumulates at bottom causing brick degradation and impurity concentration
Solution Approach 1:
By adding S-source materials, the invention changes the chemical environment to increase sulfur activity, which enhances the solubility of copper in the matte phase. This parameter change allows copper to remain dissolved in the liquid matte rather than accumulating as solid metal at the bottom, preventing brick degradation while maintaining high copper content.
Solution Approach 2:
The invention converts the potentially harmful effect of excess metallic Cu into a beneficial process by using S-source materials to promote sulfurization. The excess copper that would normally accumulate and cause damage is instead converted into sulfurized copper compounds that dissolve in the matte, transforming a harmful accumulation problem into a beneficial copper recovery process.
3Reliability
If S-source is added to convert metallic Cu to matte, then metallic Cu phase is reduced, but additional material handling is required
Solution Approach 1:
The invention merges the S-source addition process with the existing smelting feed delivery system. The S-source materials are introduced through the same feeders and injection nozzles used for delivering copper concentrate and other raw materials, combining multiple functions into a single operational framework and avoiding additional complex handling infrastructure.
Solution Approach 2:
The S-source materials serve dual purposes: they provide sulfur for matte formation and simultaneously act as the agent that converts excess metallic Cu into dissolved copper in the matte. This self-service approach eliminates the need for separate conversion processes or additional reagents, simplifying the overall material handling while achieving metallic Cu phase reduction.
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
Reduces the formation of metallic Cu phase, preventing impurity concentration and brick degradation, and minimizing operational risks by ensuring metallic Cu is fully converted into matte.
Implementation Method 1
adding an S-source to a matte generated by a reaction of a smelting feed containing a copper concentrate and a raw material containing metallic Cu with a reaction gas in a reaction shaft of a flash smelting furnace, when a metallic phase of a metallic Cu is formed in the matte
Implementation Method 2
The copper concentrate undergoes an oxidation reaction due to the reaction gas, producing matte and slag at a bottom of the reaction shaft
Data Source
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AI summary
An operation method of copper smelting is characterized by comprising adding an S-source to a matte generated by a reaction of a smelting feed containing a copper concentrate and a raw material containing metallic Cu with a reaction gas in a reaction shaft of a flash smelting furnace, when a metallic phase of a metallic Cu is formed in the matte.