Fluxless Copper Converting via Controlled Oxidation
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Solution Overview
Problem
The existing pyrometallurgic copper production processes require the use of fluxes during the converting step, which increases energy consumption and necessitates additional sulfur removal steps, limiting efficiency and optimizing copper yield.
Innovation Solution
Converting copper containing materials with high copper content in the absence of flux by controlling oxidation levels to produce copper oxide, which liquefies the slag, allowing for molten phase operation without conventional fluxes, using oxygen-enriched gases to achieve desired copper and sulfur concentrations in the slag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If flux is used during converting, then the slag becomes more liquid and operating temperature can be lowered, but energy consumption increases
Solution Approach 1:
The invention extracts and eliminates the flux component from the conventional converting process. By removing flux entirely and operating without it, the process avoids the energy consumption associated with flux heating and melting, while maintaining liquid slag through higher operating temperatures and copper oxide formation
Solution Approach 2:
The invention changes the operating parameters by eliminating flux and adjusting the oxidation level to produce copper oxide. This parameter change transforms the slag composition and liquidus temperature characteristics, allowing the process to operate at higher temperatures without flux-related energy penalties
2Stability of the object's composition
If flux is used during converting, then slag liquidity is improved, but additional sulfur removal steps are required
Solution Approach 1:
The invention removes flux from the process and replaces its slag-liquifying function with copper oxide formed through controlled oxidation. This elimination of flux simplifies the process by removing the need for separate sulfur removal steps associated with flux-based slag systems
Solution Approach 2:
The copper-containing material itself serves dual purposes: as the feed material and as the source of copper oxide that provides the slag-liquifying effect normally achieved by flux. The copper oxide forms in-situ during oxidation, eliminating the need for external flux additives
3Ease of manufacture
If oxidation level is increased to produce copper oxide, then flux becomes unnecessary, but copper content in slag increases
Solution Approach 1:
The invention optimizes the oxidation level parameter to achieve a balance where sufficient copper oxide is formed to eliminate flux requirements, while controlling the oxidation extent to limit excessive copper transfer to the slag phase. This parameter optimization resolves the contradiction between process simplification and copper recovery
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
This method reduces energy consumption by eliminating flux-related energy use and enhances copper yield by producing fluxless slag that acts as a better coolant, enabling higher concentrate feeding and reducing sulfur content in blister copper.
Implementation Method 1
converting the matte yields a high-grade 'blister' copper, with 97.5 to 99.5% copper. Matte from the smelting furnace is charged to converters, where the molten material is oxidized in the presence of air to remove iron and sulfur impurities
Implementation Method 2
flash furnaces use the heat generated from partial oxidation of their sulfide charge to provide much or all of the required heat
Implementation Method 3
the resulting converter slag is in molten phase to obtain blister copper and converter slag
Data Source
AI summary
The present invention provides a method of converting copper containing material to blister copper comprising: (a) providing copper containing material comprising copper sulfides and iron sulfides, whereby the copper containing material comprises at least 35 wt % copper of the total weight of the copper containing material; (b) reacting the copper containing material in a furnace with an oxygen containing gas, in the absence of flux, to effect oxidation of iron sulfide and copper sulfide, and controlling injection of the oxygen containing gas and the temperature so that the resulting converter slag is in a molten phase to obtain blister copper and converter slag.