Frontmatter

Numerical Simulation and “Post-mortem” Studies: The Holistic Approach for Optimized Lining Concepts in the Copper Smelting Furnaces

Dean Gregurek, Ulrich Marschall, Thomas Prietl, Jürgen Schmidl

This chapter delves into the critical wear phenomena affecting magnesia-chromite bricks in copper anode furnaces, focusing on slag corrosion and copper infiltration. Through detailed microstructural analysis, it examines how these processes degrade the brick's microstructure, leading to reduced lining lifespan. The study employs finite element analysis (FEA) to model the thermal and thermo-mechanical behavior of furnace linings under various conditions, including virgin, worn, and infiltrated states. Key findings reveal that infiltrated materials exhibit significantly higher thermal conductivity, impacting temperature fields and mechanical stability. The research concludes that numerical simulations, such as FEA, can realistically describe in-service lining performance, paving the way for optimized solutions tailored to specific process situations. Professionals will gain insights into the intricate interplay between material properties, wear mechanisms, and furnace performance, highlighting the importance of advanced modeling techniques in enhancing industrial processes.

AI Generated

This summary of the content was generated with the help of AI.

Robotic Application to Olympic Dam Tapping Practices

Michael Hill, Rodrigo Madariaga, John Barbante, John O’Sullivan, Randall Fernando, Jared Hoog, Ian Fellows

This chapter explores the integration of robotic technology into the smelting processes at Olympic Dam, focusing on managing copper skull build-up during blister tapping. The project, a collaboration between Olympic Dam smelter, BHP innovation team, MIRS Robotics, and Vesuvius, aims to reduce operator risks and improve efficiency. The text details the use of high-temperature 3D scanning technology to create a clay model replica of a copper skull, which is then used to program a robot for precise lancing and build-up removal. The successful trial of the Vesuvius Anteris 360 scanner, capable of scanning temperatures up to 1300°C, is highlighted. Future work involves lab-scale tests with a frozen copper skull and the eventual goal of implementing the robot on a live blister taphole. The chapter concludes with the potential of this robotic solution to revolutionize smelting operations by reducing manual handling and improving taphole longevity.

AI Generated

This summary of the content was generated with the help of AI.

Copper, the Energy Transition and Sustainability-Processing Opportunities

P. J. Mackey, A. Vahed, A. E. M. Warner

This chapter delves into the crucial role of copper in the global energy transition and sustainability efforts. It begins by examining the historical significance of copper and its current applications in electrical equipment, construction, and renewable energy technologies. The text then explores the global supply and demand dynamics, highlighting the projected increase in copper demand driven by traditional economic growth and the energy transition. Challenges in sustainable copper production, such as declining ore grades and the need for low-CO2 copper, are thoroughly discussed. The chapter also reviews innovative technologies and solutions aimed at meeting future copper demand, including the use of hydrogen in copper smelting and the potential of carbon capture and storage technologies. Additionally, it addresses the environmental and economic implications of copper production, providing a comprehensive overview of the current state and future prospects of the copper industry. The chapter concludes with a forward-looking perspective on how the copper industry can adapt to meet the demands of a sustainable future.

AI Generated

This summary of the content was generated with the help of AI.

Alternative MA Spinel-Based Lining Concept for Tuyere Zone in Pierce-Smith-Converter

A. Stachel, J. Kreyca, D. Gregurek, J. Schmidl

This chapter delves into the evaluation of magnesia-alumina (MA) spinel bricks as a potential alternative to traditional magnesia-chromite (MgCr) bricks in Peirce-Smith-Converters (PSC). The study focuses on the performance of these bricks in the tuyere zone, where significant wear occurs. Through extensive field trials and post-mortem analyses, the chapter provides a detailed comparison of the residual brick thickness, infiltration resistance, and chemical composition of MA spinel and MgCr bricks. The results indicate that MA spinel bricks offer better infiltration resistance and, in some cases, decreased wear rates compared to MgCr bricks. The chapter also discusses the importance of selecting appropriate brick thicknesses for areas with significant wear. The findings suggest that MA spinel bricks could be a viable alternative to traditional MgCr bricks, offering improved performance and potentially reducing the environmental impact of the converting process.

AI Generated

This summary of the content was generated with the help of AI.

Projects in Asia and Americas: Flash and TSL Furnace Pneumatic Handling Supplied Since ‘Copper 2022’

Mark Coleman, Angie Quinn

Qlar, a rebranded Schenck Process, specializes in sustainable and circular solutions for heavy industries, particularly non-ferrous metals. The company offers advanced pneumatic conveying and injection technologies to optimize production processes and reduce emissions. Qlar's solutions are designed to handle highly abrasive, potentially explosive, and toxic materials reliably, safely, and economically. The text discusses various case studies, including projects in Asia and the Americas, where Qlar has successfully implemented its technologies. These case studies highlight the company's ability to deliver transformational solutions that reduce running costs, improve availability, and lower maintenance intervention. Qlar's ProPhase technology and ProDV valve are particularly noteworthy, as they offer exceptional performance and reliability. The text also emphasizes Qlar's commitment to sustainability and circular solutions, which are increasingly important in today's industrial landscape. By reading the full text, professionals will gain a deeper understanding of Qlar's innovative technologies and their applications in the non-ferrous metals industry. They will also learn about the company's extensive experience and its ability to deliver high-quality solutions that meet the unique challenges of the industry.

AI Generated

This summary of the content was generated with the help of AI.

Abstract

Qlar the new name of the Schenck Process Group is an established customer-driven solutions provider, utilising its knowledge, expertise, and technologies to transform production processes. Qlar has developed many quality solutions and are well-respected for applying Pneumatic Conveying and Injection to solve problems in non-ferrous smelters. Handling concentrates, mattes, fuels, additives, and metallurgical dusts. Our solutions have always been long lasting, low maintenance, high performance, easily refurbished as new, helping to deliver low pneumatic handling costs throughout our 50-year history. Now we also provide condition monitoring to maintain performance and lower carbon footprint throughout the life of the equipment. We can benchmark our own and competitor systems or deliver condition monitoring on a continuous basis. Working with flash copper smelters around the world we have references at New Boliden, Codelco, Aurubis, PASAR, Manyar and others working with Metso Outotec Direct with end Users. Working with TSL furnaces we have delivered several fuel handling systems and some dust handling with both Glencore and Metso Outotec Ausmelt and direct with Users. Delivering with high accuracy and low maintenance, carbon, green-carbon, or e-scrap to the lance to control the melt temperature and viscosity. Qlar can handle materials up to 600 ºC and can convey over a 1 km in a single drop. Conveying to remote location for disposal, injecting directly into a furnace through lances, return to furnace burner feed, deliver, and dose. Qlar are a great partner. Enabling cirQlar solutions: to get your vision enabled. This paper looks to introduce our solutions with examples recently installed in Asia and the Americas since the last Copper Conference. The paper seeks to show how working in partnership with Qlar delivers not only the best equipment but can maintain performance and deliver maximum value both commercially and environmentally.

Benchmarking and Refining of Pneumatic Handling Systems in Smelters

Mark Coleman, Angie Quinn

This chapter delves into the applications of big data and artificial intelligence in enhancing the efficiency of pneumatic handling systems in smelters. It highlights Qlar's expertise in developing cloud-based control and monitoring systems, which enable real-time performance measurement and remote troubleshooting. The text presents several case studies showcasing significant improvements in energy consumption and system performance through the use of Qlar's CONiQ Cloud e-Dense Meter and other innovative solutions. By leveraging data analytics and AI, Qlar aims to provide industry-leading control systems that optimize operational costs and reduce maintenance interventions. The chapter concludes with a vision for the future, emphasizing the potential for continuous improvement and the development of better tools year over year. Readers will gain insights into how advanced technologies can be applied to achieve sustainable economic benefits and maintain high system availability in heavy industries.

AI Generated

This summary of the content was generated with the help of AI.

Abstract

Qlar (formerly the Schenck Process Group) is an established customer-driven solutions provider, utilising its knowledge, expertise, and technologies to transform production processes. Qlar has developed many quality solutions and is well-respected for applying pneumatic conveying and injection to solve problems in non-ferrous smelters, for over 50 years, handling concentrates, mattes, fuels, additives, and metallurgical dusts. During 2024 Schenck Process rebranded Qlar, to show our commitment, to sustainable and cirQlar solutions. Our solutions have always been long lasting, low maintenance, high performance, easily refurbished, helping to deliver low pneumatic handling costs throughout our 50-year history. But now we are adding condition monitoring to maintain performance and lower carbon footprint throughout the life of the equipment. We now have added benchmarking and maintenance aids to our portfolio ensuring our systems continue to offer the same low environmental footprint they were designed and commissioned to deliver. Unfortunately, pneumatic handling systems are often maintained poorly or by teams who do not understand the changes they make to solve a one-off problem then cost the company much more in power going forward. We now have a flow and pressure monitor which allows us to harvest data and investigate the system performance. This works not only for our systems, but any pneumatic handling system. If you have dense phase conveying systems, there is more than likely some improvements we can make to save energy and therefore give a quick return on investment. Our simple CONiQ Cloud e-Dense meter is mounted in the clean side air supply and harvests data either to the on-board storage, or direct to the cloud, then full remote interrogation and support is available from Qlar. Basic parameters are displayed on the units HMI. Already installed in your challenging environment the systems are suitable for smelter use. Data is always interesting but once uploaded to the cloud and analysed with AI ‘Intelligent Review’ can indicate improvements to performance for the maintenance team to carry out. Our UK test centre can characterise materials, design flow angles, minimum valve sizes, hopper design, pick up velocities, delivery methodologies using our vast array of pneumatic conveying equipment to demonstrate possible improvements or complete solutions where you have a desire to introduce or a need to eliminate inconsistent performance in your smelter handling. Our team of experienced service engineers can attend site and work with your team to improve systems or with the aid of the CONiQ Cloud e-Dense meter we can use that analysis and support on a daily ongoing basis, remotely. This paper discusses the Qlar approach to reliable pneumatic handling for a more sustainable solution with examples from recent installations. Minimising energy and carbon usage is vital, this equipment can reduce your waste in dense phase conveying. Enabling cirQlar solutions! Working in partnership with Qlar delivers not only the equipment that makes processes work but provides data, maintains performance, and delivers value both commercially and environmentally.

Selecting the Best ISASMELT™ Flowsheet for Your Copper Project

S. Nicol, B. Hogg, O. Mendoza, S. Nikolic

This chapter delves into the ISASMELT™ technology, a leading method for smelting both primary and secondary copper. It explores various flowsheet options to optimize operational costs, environmental impact, and overall plant performance. The text compares different configurations, emphasizing the importance of selecting the right flowsheet for specific project goals. It also discusses the technology's advantages, such as low emissions, high metal recovery, and flexibility. The chapter concludes that the ISASMELT™ flowsheets offer the most competitive smelting economics, with each site optimized based on local requirements and project objectives. Professionals will gain insights into the benefits of the Jameson Concentrator™ for copper recovery from smelter slags and the importance of assessing similar technologies separately. The text provides a comprehensive overview of the ISASMELT™ technology, making it a valuable resource for those involved in copper smelting projects.

AI Generated

This summary of the content was generated with the help of AI.

Improvements in the Performance of Copper ISASMELT™ Furnaces with Operational Rigour

S. Nicol, M. Prince, J. Edwards, B. Hogg

The chapter delves into the advancements in ISASMELT™ furnace technology, with a particular focus on the performance and operational rigour of the ISASMELT™ lance. It explores the design and functionality of the lance, emphasizing its role in agitating the molten bath and driving chemical reactions. The text also discusses the importance of accurate monitoring and maintenance practices to ensure the longevity and efficiency of the furnace components. Key topics include the operational duties of the ISASMELT™ lance, such as providing optimum splash, symmetrically agitating the bath, and efficiently transferring oxygen into the slag. The chapter also highlights the developments in lance design and maintenance, including the use of cast swirlers and advanced monitoring sensors. The conclusion underscores the significant improvements in lance life and operational efficiency achieved through these advancements, demonstrating the ongoing evolution of ISASMELT™ technology.

AI Generated

This summary of the content was generated with the help of AI.

Direct-to-Blister to Flash Converting and Transition of Slag Systems: Proposed Future for Olympic Dam Smelter

David Bott, Yan-Hui Yang, Paul Fitzgerald

The chapter delves into the current operations of the Olympic Dam smelter, which utilizes a direct-to-blister flash smelting furnace (DBF) to produce blister copper and high-grade slag. As the smelter considers expanding to process increased volumes of concentrate, the article explores the viability of transitioning to a conventional matte smelting and converting furnace flowsheet. This transition is necessitated by the expected changes in feed composition, which will challenge the economic viability of the current flowsheet. The proposed future flowsheet involves adding new facilities for concentrate handling and a primary smelting furnace to produce copper matte, which will then be processed by the existing DBF operating as a converting furnace. The article discusses the challenges of converting the existing DBF to a double flash process, including modifications required for the furnace and the addition of new anode furnaces. It also explores the potential for continued operation of the electric slag furnace (ESF) and the economic implications of this decision. The chapter provides a detailed analysis of the slag systems, including the phase diagram for the FeO x –CaO–SiO 2 –Cu 2 O system and the effects of SiO 2 content on calcium ferrite liquidus temperature. It presents three potential routes for transitioning from silicate slag to calcium ferrite slag, each with its own advantages and challenges. The article concludes with recommendations for future study work and the potential benefits of delaying the transition until a subsequent major outage to minimize risks and operational inefficiencies.

AI Generated

This summary of the content was generated with the help of AI.

Renovation and Expansion of the Bor Smelter of Serbia Zijin Copper

Shi Cong Lan, Xian Jian Guo, Xi Ming Jian

The chapter delves into the extensive renovation and expansion project of the Bor Smelter in Serbia, undertaken by Zijin Copper. The project aimed to address the smelter's outdated equipment, high energy consumption, and environmental pollution issues. Key focus areas included the smelting system, electrolysis refinery, sulfuric acid plant, and rare and precious metal plant. The renovation involved modernizing the flash furnace, converting system, anode furnaces, and casting system, as well as implementing advanced environmental protection measures such as a desulfurization system and wastewater treatment facilities. The project resulted in a significant increase in production capacity, with the smelter now producing over 180,000 tons of copper cathode annually. Energy consumption was reduced by switching from heavy oil to natural gas, and the operation rate of the flash furnace reached over 98.35%. Environmental improvements included a reduction in sulfur dioxide emissions and the implementation of zero water discharge policies. The chapter also highlights the smelter's transformation into a model of green manufacturing, with all valuable metals in intermediate materials being recycled and hazardous waste converted into harmless solid waste.

AI Generated

This summary of the content was generated with the help of AI.

Abstract

The Bor smelter of Serbia Zijin Copper Company is the former RTB Bor smelter of Serbia, which was started up on June 7, 1961. The original process is “Reverberatory furnace smelting + P.S. converter + anode furnace + electrolytic refining”. The smelter was renovated in 2013 to change the reverberatory furnace to flash furnace for smelting and build new sulfuric acid plant, but original four P.S. converters, three anode furnaces and the two sets of electrolytic refining were still retained. The original converter had the capacity of 160 ton of matte per cycle operation, and the inserted wood was used for reduction in the original anode furnaces and the furnace handled 220 ton of copper each cycle operation. The small anode plate was adopted in electrolytic refining. The production capacity of the smelter was 80,000 tons of copper cathode per year after the renovation, the problems of old and backward equipment, high energy consumption and serious environmental pollution of the smelter have not been solved. After Serbia Zijin Copper Company took over the Bor smelter in December 2018, the plan of expansion and renovation was made for increasing production, reducing energy consumption and improving environmental protection. The expansion and renovation project consists of 63 sub-projects in various systems such as smelting, electrolysis, offgas, and fugitive gas handling, sulfuric acid plant and precious metal plant, etc., the smelter was shut down in April 2022 for the renovation and started up in April 2023. Through expansion and renovation, the production of the smelter is increased to 180 kt/a copper cathode, 900 kt/a sulfuric acid, and 2.5 t/a gold, and the energy consumption per ton copper is decreased from 8 kg of heavy oil to 1.1 Nm³ of natural gas for flash furnace, and from 52 kg of heavy oil to 23 Nm³ of natural gas for anode furnace. The operation rate of the flash furnace reached more than 98.35% and the copper content of the flash slag is reduced from 1.8 to 1.05%. The conversion rate of the sulfuric acid system increases from 98.5 to ≥99.92%. The de-sulfur efficiency of the desulfurization system is more than 99%. The comprehensive power consumption per ton cathode in electrolytic refining is reduced from 450 to 400 kWh and the current efficiency is increased from 93 to ≥97%. The copper recovery of smelter increases from 97 to 98.5%. The quality product rate reached 100%. The effluent, residue, and fugitive gas of the smelter are well treated and recycled, and the environmental protection emission indicators are better than the Serbia national and EU standard, which completely changed the ecological environment of Bor city in Serbia. The smelter became a model of green factory.

Injection of Dry Copper Concentrates in the Ausmelt Top-Submerged Lance (TSL) Furnace

Stefanie Creedy, Ross Andrews, David Bott, Paul Fitzgerald

This chapter delves into the innovative approach of injecting dry copper concentrates into the Ausmelt Top-Submerged Lance (TSL) furnace, a method aimed at enhancing energy efficiency and reducing CO2 emissions in copper smelting. The study, conducted as part of BHP’s Olympic Dam operations expansion, explores the potential benefits of dry feed injection, particularly for concentrates with higher Cu to S ratios. The chapter details the pilot plant testwork, which successfully demonstrated stable operation and lower feed carryover rates compared to conventional roof feeding. It also discusses the commercial scale outcomes, highlighting the potential for a 50% reduction in offgas volume and a 90% reduction in fuel consumption and associated CO2 emissions. The chapter concludes that dry feed injection is a viable process option that can be combined with traditional roof feeding, tailored to specific copper concentrate compositions, and offers potential for debottlenecking and expansion pathways for new builds.

AI Generated

This summary of the content was generated with the help of AI.

Southern Peru Ilo Copper Smelter—Operational Improvements After Its Modernization

Enrique Herrera, Manuel Munguía

The chapter delves into the operational improvements and environmental advancements at the Southern Peru Ilo Copper Smelter following its modernization in 2007. Key topics include the implementation of the Isasmelt furnace technology, the reduction of sulfur emissions, and the significant decrease in fuel oil consumption. The text also discusses the challenges faced and solutions implemented to improve slag chemistry and control accretions formation in the waste heat boiler. Additionally, the upgrade of the sulfuric acid plant and the smelter's productivity performance are highlighted. The chapter concludes with the smelter's plans for future sustainability and expansion, emphasizing its commitment to high productivity, competitive operating costs, and stringent safety standards.

AI Generated

This summary of the content was generated with the help of AI.

Properties and Copper Reduction Kinetics of Three Types of Converting Slags

Chunlin Chen, Tao Kan, Yan-Hui Yang, David Bott, Paul Fitzgerald, Robert West

This chapter delves into the properties and copper reduction kinetics of three types of converting slags: calcium ferrite, iron silicate, and ferrous calcium silicate (FCS). The study reviews commercial continuous copper converting processes, highlighting the operating conditions and slag systems used. It compares the thermodynamic and physical properties of the slags, including viscosity, electrical conductivity, thermal conductivity, and surface tension, and their impact on the converting process. The chapter also presents experimental data on the reduction kinetics of copper from these slags, revealing that calcium ferrite and iron silicate slags have similar reduction rates, while FCS slag exhibits a slower reduction rate. The findings suggest that the reduction kinetics are likely controlled by mass transfer in the liquid slag phase, influenced by slag viscosity. The study concludes that understanding these properties and kinetics is crucial for optimizing the continuous converting process in copper production.

AI Generated

This summary of the content was generated with the help of AI.

The Future of Refractory Material Selection—A Data-Driven Approach

Werner Liemberger, Jürgen Schmidl, Hanna Olefirenko, Wagner Moulin-Silva

This chapter delves into the future of refractory material selection, focusing on the integration of AI and machine learning to create a data-driven approach. It begins by outlining the critical role of refractory materials in industries such as metallurgy, glass, and cement, emphasizing their ability to withstand extreme conditions. The text then explores the various wear mechanisms that affect refractory materials, including chemical, mechanical, and thermal factors, and how these mechanisms influence material selection. The chapter also discusses the traditional expert-driven selection process and its limitations, highlighting the need for a more efficient and accurate method. The core of the article presents an AI-powered refractory recommendation system, detailing its architecture and components, such as the interactive request completion component, process information database, and material selection model. It explains how this system can process unstructured data, generate material relevance scores, and provide recommendations based on specific use-case requirements. The chapter concludes by addressing the challenges and potential solutions in implementing such a system, suggesting that AI-driven innovations could transform the refractory industry, similar to their impact on other sectors like microchip design.

AI Generated

This summary of the content was generated with the help of AI.

Tellurium Recovery from Blister Copper and Copper Matte: A Review

Lea Tiedemann, Eric Klaffenbach

This review delves into the critical aspects of tellurium recovery from blister copper and copper matte, focusing on soda refining, hydrometallurgical processes, and the challenges of tellurium recovery from copper matte. The study explores the thermodynamics of tellurium removal via soda refining, highlighting the impact of oxygen partial pressure on the distribution of tellurium compounds in the slag. Various hydrometallurgical methods for tellurium recovery from soda slag are examined, including water leaching, sodium sulfide leaching, and aqua regia leaching, each with different precipitation and electrowinning techniques. The review also addresses the less-studied area of tellurium recovery from copper matte, proposing partial converting and oxidative leaching as potential methods. The conclusion emphasizes the need for further research to optimize these processes and improve tellurium recovery efficiency. Professionals will gain insights into the latest advancements and challenges in tellurium recovery, making this review an essential resource for those involved in metallurgical and chemical engineering processes.

AI Generated

This summary of the content was generated with the help of AI.

Solubility Behavior of ZrO2 in Primary Copper Slags

Damaris Legenstein, Eric Klaffenbach

This chapter delves into the solubility behavior of zirconium dioxide (ZrO2) in primary copper slags, a critical aspect for professionals dealing with complex secondary raw materials. The study focuses on key parameters such as slag chemistry, temperature, and oxygen partial pressure, which control ZrO2 solubility. Through meticulous experiments, the research team investigated the dissolution kinetics of various ZrO2 materials in both flash smelting furnace (FSF) and converter slags. The findings reveal that the maximum ZrO2 solubility ranges from 0.8 to 2 weight percent, with the dissolution process being faster in FSF slags compared to converter slags. Notably, fine ZrO2 materials exhibit higher solubility. The study also highlights that the dissolution process is largely complete within the first 30 minutes, with SEM analysis showing that not all ZrO2 particles are fully dissolved, indicating that excess ZrO2 was added. The liquid slag contains an average of 0.8 weight percent ZrO2. This comprehensive analysis provides valuable insights into the behavior of ZrO2 in industrial copper smelting processes, offering a deeper understanding of the factors influencing solubility and dissolution kinetics.

AI Generated

This summary of the content was generated with the help of AI.

An Update to the Fluxing Practice of the Rio Tinto Kennecott Copper Flash Converter

Maxwell Drexler

This chapter delves into the thermodynamic fundamentals of accretion formation in copper flash converting furnaces, focusing on the impact of silica and arsenic on slag liquidity. Through high-temperature experiments and thermodynamic calculations, researchers developed operating diagrams that summarize the effects of furnace operating conditions on the slag system. The text discusses the operational changes implemented to reduce silica and arsenic levels, leading to improved control of accretion and enhanced furnace efficiency. It also introduces a predictive tool developed by the University of Queensland research team, which aids in optimizing furnace conditions and maintaining desired slag chemistry. The chapter concludes with a discussion on the updated fluxing strategy, which aims to balance the need for protective sidewall accretion with the avoidance of excessive buildup and the formation of undesirable high-calcium phases.

AI Generated

This summary of the content was generated with the help of AI.

Degradation Mechanism of Magnesia-Chrome Refractory in Copper Making

Soumendu Das, Sirshendu Das, Kartick Chandra Khan, Biswajit Ghosh, Sunanda Sengupta, Prasant Kumar Naik

This chapter delves into the degradation mechanisms of magnesia-chrome refractories used in copper production furnaces, focusing on their structural changes and performance under extreme conditions. It examines the impact of slag infiltration on the microstructure of refractories, highlighting how this process leads to the formation of cracks and weakens the material's integrity. The text also explores the role of advanced refractories in enhancing furnace efficiency and longevity, comparing different types of refractories and their performance in various furnace environments. Additionally, it discusses the development of new-generation refractories designed to withstand aggressive slag attacks, offering superior performance compared to traditional materials. The chapter concludes with insights into the future of refractory technology in copper production, emphasizing the need for continuous innovation to meet the demands of modern industrial processes.

AI Generated

This summary of the content was generated with the help of AI.

Analyzing Gold and Silver Recovery from Copper Smelting to Anode Slime Treatment

Elmira Moosavi-Khoonsari, Nagendra Tripathi

This chapter delves into the critical aspects of gold and silver recovery from copper smelting to anode slime treatment, emphasizing the economic and technical importance of these processes. It explores the first-pass recovery rates (FPRs) of gold and silver, which are crucial for maximizing profitability, especially during high gold prices. The text discusses the primary loss mechanisms, with gold physical loss due to matte and copper entrainment in slag being the dominant pathway, while gold chemical loss is negligible. Silver, however, exhibits more complex behavior with both physical and chemical losses. The chapter compares different copper smelting technologies, such as flash smelting and bath smelting, and their impact on PM distribution and FPRs. It also examines the influence of copper converting technologies on gold and silver recovery, noting that Peirce-Smith Converting technology outperforms others in gold recovery. The analysis extends to copper refining and anode slime treatment, highlighting the efficiency of hydrometallurgical routes over traditional hybrid routes. The chapter concludes by stressing the need for further research to gather detailed slag composition data for more accurate silver recovery rate estimations.

AI Generated

This summary of the content was generated with the help of AI.

Direct Observation of the Combustion Behavior of Copper Concentrate Using a Micro-Drop Tube Furnace

Yuko Goto, Shota Miyake, Shungo Natsui, Hiroshi Nogami

This chapter delves into the combustion behavior of copper concentrate particles using a specialized micro-drop tube furnace. The study focuses on the direct observation of single particle combustion, capturing detailed images with high-speed cameras and microscope lenses. Key findings include the expansion and rupture of particles, the formation of a reticular pattern on the particle surface, and the vigorous dispersion of droplets. The combustion behavior of copper concentrate is compared with that of pure CuFeS2 and FeS2 reagents, revealing similarities and unique characteristics. The high-resolution imaging provides unprecedented insights into the combustion process, highlighting the formation of an envelope flame and the release of sulfur dioxide. The conclusions suggest that the vigorous dispersion of droplets during combustion could significantly impact particle collisions and coalescence in industrial flash furnaces. This research offers valuable data for optimizing metallurgical processes and improving the efficiency of copper concentrate combustion.

AI Generated

This summary of the content was generated with the help of AI.

Improving Feed Distribution in Flash Smelting: A CFD-DEM Approach

Bhavin Desai, Parag Malode, Akash Verma, Vilas Tathavadkar, Yogesh Patel, Kiran Soni, Manohar Gupta

This chapter delves into the challenges of uneven feed distribution in flash smelting furnaces and how it affects smelting efficiency and heat loss. Through the use of Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD) models, the study evaluates the impact of non-uniform feed distribution in the reaction shaft. The conventional feeder design is analyzed, revealing issues such as feeder jamming, low smelting efficiency, and high build-up. The study then explores design modifications to the feeder, aiming for a more uniform distribution of feed material. The optimized feeder design, featuring a greater number of splitters at various angles and heights, is tested both in scaled-down physical models and in actual field trials. The results show a significant reduction in feeder jamming frequency, a substantial decrease in heat loss, and an improvement in matte grade. The chapter concludes with a detailed comparison of the conventional and modified feeder designs, highlighting the benefits of the optimized design in terms of operational stability and efficiency.

AI Generated

This summary of the content was generated with the help of AI.

A Relevance of Selenide Capacity to Copper Smelting Slag

Bhavin Desai, Vilas Tathavadkar, Somnath Basu

This chapter delves into the persistent issue of selenium loss during copper smelting, focusing on the role of selenide capacity in slag. Through meticulous experiments with synthetic slag and matte, the study reveals that selenium primarily dissolves in the matte by replacing sulfur, with negligible dissolution in the slag. The investigation proposes that selenium loss to the slag is mainly due to the entrapment of matte particles during slag-matte separation. The study also highlights the influence of impurity species on selenium distribution and challenges previous conclusions based on in-process samples. The results indicate that the fayalitic slag used in copper smelting has a capacity to hold sulfur but not selenium, suggesting that the concept of selenide capacity may not be a viable measure for selenium content in slag. This research offers valuable insights for improving selenium recovery in copper smelting operations, emphasizing the need for further investigation into the behavior of selenium in the presence of impurities.

AI Generated

This summary of the content was generated with the help of AI.

Slag Cleaning Electric Furnace Bath Temperature Profile Test Work Results

Y.-H. Yang, M. O. Sullivan, S. Chen, R. West

This chapter delves into the temperature profiles of an electric furnace used in copper smelting, focusing on the slag and blister bath during different operational stages and under varying power factors. The investigation reveals distinct temperature characteristics at the interface between slag and blister, with notable temperature drops and variations in profiles. The study explores how different power factors influence heat generation and distribution within the furnace, affecting the temperature difference between slag and blister. Additionally, the chapter discusses the impact of bath agitation and the importance of consistent temperature measurement procedures. The findings highlight the significance of power factor in optimizing the smelting process and improving overall furnace efficiency. The chapter concludes with practical recommendations for enhancing temperature measurement and process control, based on the detailed analysis of temperature profiles and their implications for the copper smelting operation.

AI Generated

This summary of the content was generated with the help of AI.

Plant Trial Evaluation of Concentric Versus Single-Pipe Sonic Tuyeres in Continuous Copper Converting

Joël P. T. Kapusta

This chapter delves into the evaluation of concentric and single-pipe sonic tuyeres in continuous copper converting, focusing on their ability to enhance safety, reduce operational costs, and extend the campaign life of converting vessels. The text begins with an introduction to the socio-economic challenges faced by copper and nickel smelters, emphasizing the need for continuous innovation and improvement. It then describes the characteristics of concentric and single-pipe sonic tuyeres, highlighting their benefits such as eliminating the need for punching, reducing refractory wear, and allowing higher oxygen enrichment levels. The core of the chapter presents the results of a plant trial where both types of sonic tuyeres were tested simultaneously in a continuous copper converter. The trial demonstrated the punchless operation of the tuyeres, their ability to form protective accretions, and their significantly reduced refractory wear rates compared to conventional tuyeres. The chapter concludes with key lessons learned from the trial, including the importance of proper compressor selection, control loop tuning, and stakeholder communication. The text also shares the successful commercial implementation of sonic injection in the continuous converter, marking a milestone in the industry. This chapter offers valuable insights into the practical applications and benefits of sonic injection technologies, making it a compelling read for professionals seeking to optimize their converting processes.

AI Generated

This summary of the content was generated with the help of AI.

Abstract

After close to 30 years developing and promoting sonic injection for the nonferrous metals industry, I am finally witnessing a growing momentum of interest for the technology when an ever increasing number of engineers and managers from copper and nickel smelters reach out to me with renewed enquiries. Moreover, technology suppliers and engineering firms are also voicing their interest in collaborative development and implementation of sonic tuyeres for their clients. Although I am delighted that my long-held belief in the benefits of the technology and my persistent efforts to promote it seem to be bearing fruit, I remain well aware that the road to global acceptance of sonic injection is still an arduous one. Nevertheless, this growing momentum of interest is making me more motivated than ever! And in this spirit, I believe that the 12^th International Copper conference could not be a more suitable time and place to demonstrate that sonic injection offers a much wider portfolio of technologies than just the high oxygen shrouded tuyere. In fact, depending on the process where the sonic tuyeres will be implemented—whether in copper smelting, copper or nickel converting, or copper refining—a large range of options are available by selecting the type of sonic tuyere or lance, e.g., concentric or single-pipe, and by varying the type of reactive and shrouding gases. In this paper, I am first briefly describing the characteristics of the concentric and single-pipe sonic tuyeres. Next, to offer a practical illustration of two such sonic tuyere alternatives, I present key results of a plant trial in continuous copper converting where a concentric sonic tuyere and a single-pipe sonic tuyere were tested and evaluated simultaneously. I describe their characteristics and briefly discuss their respective performance. Then, to conclude, I share some important lessons learned during the plant trial that should be valuable for engineers and managers of copper and nickel smelters wishing to test or implement sonic injection. Such lessons are critical and particularly valuable when considering that retrofitting sonic tuyeres is a lower capital expenditure solution in smelter modernization, whether the goals are to improve operators’ safety and work hygiene with punchless blowing, to intensify processes to increase production or lower off-gas volumes, or to increase vessel campaign life.

Distribution of Pb, Zn, Fe, As, Sn, Sb, Bi and Ni Between Oxide Liquid and Metal in the “CuO0.5”–CaO–SiO2 System in Equilibrium with Cu Metal at 1450 °C

Georgii Khartcyzov, Denis Shishin, Maksym Shevchenko, Evgueni Jak

This chapter delves into the distribution of elements such as Pb, Zn, Fe, As, Sn, Sb, Bi, and Ni between oxide liquid and metal in the 'CuO0.5'–CaO–SiO2 system at 1450°C. The study highlights the importance of understanding these distributions for optimizing the recycling of WEEE (Waste from Electrical and Electronic Equipment) via Cu smelting. The research employs experimental methods to investigate the phase equilibria and compares the results with thermodynamic models, finding a good agreement. The study also explores the correlation between the solubility of copper oxide in the oxide liquid and the oxygen partial pressure over the system. The findings provide a complete description of the distribution of the selected elements and contribute to the optimization of thermodynamic models for complex multicomponent systems. This work is crucial for metallurgical engineers and researchers working on improving the efficiency and environmental sustainability of recycling processes.

AI Generated

This summary of the content was generated with the help of AI.

Throat Accretion Management at the Olympic Dam Flash Furnace

Mark O’Sullivan, Robert West

This chapter delves into the complexities of managing throat accretions in the flash furnace at the Olympic Dam smelter. It begins by outlining the smelter's process flow and the challenges posed by accretions, which are formed by the buildup of dust particles in the furnace throat. The text explores the formation mechanism of these accretions, highlighting the role of dust composition and operational conditions. A significant focus is placed on the impact of reducing conditions and the thermodynamics of phase equilibria, which influence the liquidus temperature and phase composition of the dust. The chapter also presents innovative strategies for accretion management, including settler oxygen injection and forecasting inspection frequencies based on feed composition. These strategies have proven effective in increasing the intervals between throat cleans, thereby improving operational efficiency. The chapter concludes with a summary of the findings and the potential for further improvements in accretion management.

AI Generated

This summary of the content was generated with the help of AI.

Design and Operational Improvements at the Olympic Dam Flash Furnace

Mark O’Sullivan, Robert West

The chapter delves into the design and operational improvements at the Olympic Dam Flash Furnace, focusing on extending campaign life from 3 to 6 years. Key topics include the evolution of cooling element designs, refractory management techniques, and strategies for minimizing hearth growth. The text highlights the successful implementation of cast-around monel cooling elements and the staged rollout of cooling elements in high-wear regions. It also discusses the use of thermocouples for monitoring refractory conditions and the impact of sidewall burners on hearth management. The conclusion emphasizes the significant extension of furnace campaign life achieved through targeted design improvements and enhanced operational strategies.

AI Generated

This summary of the content was generated with the help of AI.

Mechanical Conveying and Crushing of Waste Heat Boiler Dust

Eero Lehtilä, Harri Talvensaari

This chapter delves into the critical aspects of designing and optimizing waste heat boiler (WHB) drag chain conveyors. It begins by examining the impact of baffle designs on temperature profiles within the conveyor, highlighting how different configurations can lead to elevated temperatures and thermal stress. The text then explores the role of grates in managing dust accumulation and protecting the conveyor from large particles, discussing the trade-offs between grate size and maintenance requirements. A significant portion of the chapter is dedicated to material selection, comparing the performance of boron steel and cementation steel chains under various conditions. The study concludes with key recommendations for improving conveyor design, emphasizing the importance of thermal compensation and suitable material choices. Readers will gain a comprehensive understanding of the factors influencing conveyor performance and learn practical strategies for enhancing efficiency and durability in industrial settings.

AI Generated

This summary of the content was generated with the help of AI.

Design Optimization of Blister and Casting Launders: A Flow Analysis Approach

Rafael Berti, Helio Villanueva, Dave Jakelski, Reza Farshidi, Sina Mostaghel

This chapter explores the design optimization of blister and casting launders for efficient molten copper transportation in a copper smelting operation. The study focuses on flow trajectory analysis, heat transfer analysis, and boundary condition validation using advanced numerical simulation techniques. Key findings include the optimization of launder geometry to minimize flow instabilities, reduce heat loss, and prevent metal solidification. The chapter also discusses the validation of numerical models and the impact of different tapping flow rates on flow trajectory. Additionally, it presents design modifications for the movable and rotating launders to enhance operational flexibility and minimize splashing. The results demonstrate significant improvements in flow behavior and heat transfer efficiency, providing valuable insights for professionals in the metallurgical industry.

AI Generated

This summary of the content was generated with the help of AI.

Improvements to the Aurubis Bulgaria Copper Plant 2014–2024

D. Kirilov, T. Kurth, V. Hadzhiyski

The chapter delves into the significant technological advancements and environmental improvements at the Aurubis Bulgaria Copper Plant from 2014 to 2024. It highlights major projects like Aurubis Bulgaria 2014 and Fit For Future 2015, which involved substantial investments to increase productivity and meet environmental standards. The text details innovations in the flash smelting furnace, waste heat boiler, and converters, including the introduction of a removable Peirce-Smith converter to reduce downtime. Additionally, it covers enhancements in the sulfuric acid plant and the installation of solar parks to reduce carbon emissions. The chapter concludes with the positive impact of these improvements on the plant's throughput, equipment lifetime, and environmental performance, showcasing a decade of continuous innovation and sustainability efforts.

AI Generated

This summary of the content was generated with the help of AI.

Multicomponent Phase Equilibria Study for Secondary Copper Recycling Applications

Dieter Verwaest, Maksym Shevchenko, Georgii Khartcyzov, Bart Blanpain, Evgueni Jak

This chapter delves into the critical role of phase equilibria in the multicomponent system relevant to copper recycling, focusing on the 'CuO 0.5'–PbO–ZnO–'FeO 1.5'–SiO 2 –'SnO 2'–NiO–(CaO–AlO 1.5 –MgO–SbO 1.5) system. The study employs advanced experimental techniques to validate thermodynamic models, aiming to optimize the recovery of multiple metals from scrap. Key findings include the identification of coexisting phases such as tridymite, cassiterite, spinel, and olivine, and their interactions under varying temperatures and oxygen partial pressures. The results provide valuable insights into the optimization of slag compositions and fluxing strategies, enhancing the efficiency of copper recycling processes. The chapter concludes with a discussion on the implications for managing increasing impurity levels in copper scrap, offering practical solutions for sustainable metal recovery.

AI Generated

This summary of the content was generated with the help of AI.

A Combined Molecular Dynamics—Experimental Investigation of Oxidic Slag Properties

Inge Bellemans, Pieter-Jan Boeykens, Héléna Verbeeck, Kim Verbeken

This chapter delves into the properties of oxidic slags, focusing on their electrical conductivity, which is vital for the operation of electric furnaces in recycling and decarbonization processes. The study employs molecular dynamics (MD) simulations and experimental investigations to understand the structure-property relationships of slags, particularly in the CaO–Al2O3–SiO2 system. Two empirical force fields are compared for their accuracy in simulating transport properties, and the importance of long equilibration times and large system sizes is emphasized. The research also addresses the challenges in measuring and simulating slag conductivities, highlighting the need for careful experimental procedures and realistic simulation conditions. The findings contribute to the development of digital twinning for pyrometallurgical processes, supporting the transition to more sustainable and efficient metallurgical practices. The chapter concludes with insights into the potential of ab-initio MD and machine learning techniques for future research on slag properties.

AI Generated

This summary of the content was generated with the help of AI.

Refractory Wear and WEEE Scrap Recycling

S. Lackner, J. Kreyca, D. Gregurek, J. Schmidl

The exponential growth in electrical and electronic equipment usage has led to a surge in WEEE (Waste of Electrical and Electronic Equipment) scrap, presenting both challenges and opportunities for recycling. This chapter delves into the unique refractory wear issues encountered in WEEE scrap recycling processes, highlighting the impact of varying slag compositions, high organic content, and the presence of gaseous halogens. It explores the distinct properties of WEEE-based slags compared to traditional fayalitic slags, offering insights into the chemical analysis of different slag types. The text concludes by emphasizing the importance of durable refractory lining concepts and the need for specialized recycling processes to handle the complexities of WEEE scrap effectively.

AI Generated

This summary of the content was generated with the help of AI.

Sustainable Smelter Modernization: Engineering a Brownfield Solution for a Matte Settling Electric Furnace (MSEF) Replacement

Warren van der Struys, Robert Brandt, Ernest Rex

The chapter delves into the complexities of modernizing the Freeport Miami Smelter, particularly the replacement of the Matte Settling Electric Furnace (MSEF). Key topics include the integration of advanced technologies like laser scanning and Building Information Modeling (BIM) to address brownfield constraints, the design and operational principles of the new MSEF, and the innovative solutions implemented to overcome engineering challenges. The project aimed to improve operational efficiency, reduce downtime, and align with sustainability objectives. The successful execution of the MSEF replacement project not only enhances the operational efficiency of the Freeport Miami Smelter but also provides valuable insights for similar brownfield modernization efforts globally. The chapter concludes with the pending installation of the new MSEF, highlighting the potential for sustainable smelter modernization through innovative engineering solutions.

AI Generated

This summary of the content was generated with the help of AI.

Evaluation of Oxyfuel Combustion Systems for Enhanced Efficiency and Emission Reduction in Launder Heating Applications

B. Ferreira, A. Deneys, W. Mahoney, R. Farshidi, S. Mostaghel, D. Jakelski, R. Berti, H. Villanueva

This study delves into the evaluation of oxyfuel combustion systems for enhanced efficiency and emission reduction in launder heating applications, particularly in the context of copper smelting. The research compares the performance of oxyfuel burners against conventional air-fuel burners, focusing on heating rates, temperature distribution, and NOx emissions. The experimental setup involved four launder troughs instrumented with thermocouples to measure temperature profiles. Various burner configurations, including single and multiple J-burner setups with staging, were tested. The results demonstrated that oxyfuel burners provided faster heating rates, more uniform temperature distribution, and significantly lower NOx emissions. Numerical simulations were employed to estimate heat transfer phenomena and burner effectiveness, further validating the experimental findings. The study concludes that oxyfuel burners, especially with staged combustion, offer superior performance and environmental benefits, making them a viable alternative to traditional air-fuel systems in launder heating applications.

AI Generated

This summary of the content was generated with the help of AI.

Integrated Solutions for Processing Complex Concentrates: Codelco’s Approach to Manage Arsenic-Containing Materials with Roasting, Smelting, and Dust Processing

Gerardo R. F. Alvear Flores, Felipe Lagno Sánchez

This chapter delves into Codelco's comprehensive strategy for handling arsenic-containing copper concentrates, focusing on roasting, smelting, and dust processing. It begins by outlining the global demand for copper and the associated challenges, such as resource complexity and regulatory pressures. The text then introduces Codelco's five focus areas for sustainable copper production, with a particular emphasis on managing arsenic. The chapter provides an in-depth look at the processing of complex arsenic-containing concentrates, highlighting various technologies and their development stages. It also describes Codelco's integrated processing cluster in the northern area of Chile, including the Ministro Hales Division Roasting Plant, the Chuquicamata Smelter, and the Ecometales Plant. The chapter concludes by discussing the advantages of Codelco's approach, such as the disposal of arsenic as a stable compound, the production of sustainable copper, and the ability to process external high-arsenic-containing concentrates. Additionally, it explores future opportunities and strategies for optimizing the operation of these assets.

AI Generated

This summary of the content was generated with the help of AI.

Brazilian Ferronickel Smelter Improves Slag Granulation Operation Using Copper Water-Cooled Launders

Marco Santos, Antonio Patricio, Leandro Patricio, Deyvid Silva, José Rodrigues, Manuel Rodriguez, Rafael Carias

This chapter explores the transformation of the slag granulation process at the Anglo American Barro Alto ferronickel plant in Brazil. It delves into the challenges faced with traditional steel launders and the innovative solution of implementing copper water-cooled launders. The text discusses the design considerations, thermal simulations, and operational results that justified the switch. It highlights the significant improvements in productivity, safety, and maintenance efficiency achieved through this modification. The study also covers the optimization of slag flow and granulation control, as well as the reduction of splashes and spills. The conclusion underscores the advantages of copper launders, including reduced launder temperature, improved slag flow, extended lifespan, easier maintenance, and enhanced safety. This chapter provides a comprehensive overview of the benefits and practical implications of adopting copper water-cooled launders in ferronickel smelting processes.

AI Generated

This summary of the content was generated with the help of AI.

Post-mortem Investigation of Magnesia-Chromium Brick Corrosion by Speiss in a Copper Smelting Furnace: Key Findings

X. Wen, M. Shevchenko, D. Gregurek, J. Schmidl, L. Konrad, R. Walton, E. Jak

This chapter delves into the post-mortem investigation of magnesia-chromium brick corrosion caused by speiss in copper smelting furnaces. The study focuses on the mechanisms of speiss infiltration and deposition, the effects on refractory lining integrity, and the chemical phase-equilibria involved. Key findings include the identification of significant degradation associated with the formation of complex magnesium-calcium-lead arsenates. The analysis of refractory-free and speiss-infiltrated samples reveals the gradation of speiss buildup and the impact of oxidizing conditions on refractory degradation. The study concludes that liquid speiss, due to its high density and reduced solidus temperature, effectively penetrates the refractory lining, leading to intergranular corrosion and reduced spalling resistance. This detailed examination provides valuable insights into the technical and environmental challenges faced in copper production, particularly with the increasing arsenic levels in feedstocks.

AI Generated

This summary of the content was generated with the help of AI.

Integrated Experimental High Temperature Viscosity Measurement and Modeling Research in Multicomponent Slag System

D. Fadhlurrahman, R. Starykh, M. Shevchenko, E. Nekhoroshev, E. Jak

This chapter delves into the critical role of viscosity in slag systems, particularly in metallurgical processes. It highlights the challenges and advancements in measuring high-temperature viscosity using the rotating bob method, emphasizing the importance of minimizing contamination through innovative crucible designs. The study also explores the development and optimization of viscosity models, such as the Modified Polynomial Model and the Quasichemical Viscosity Model, which are essential for predicting slag behavior under various conditions. The integration of experimental data with these models allows for a more accurate understanding of slag viscosity, which is crucial for optimizing industrial processes. The chapter concludes with insights into the practical applications of this research, demonstrating how it can be applied to improve slag management in industrial settings, particularly in secondary copper smelting. The detailed analysis and innovative approaches presented in this chapter make it a valuable resource for professionals seeking to enhance their understanding of slag viscosity and its implications for metallurgical processes.

AI Generated

This summary of the content was generated with the help of AI.

Blister Copper Taphole Monitoring Development

F. Marx, D. Bezuidenhout, L. Nel, N. Daly, A. Gibson

This chapter delves into the critical aspects of blister copper taphole monitoring and maintenance in smelting operations. It explores the integration of various factors influencing taphole performance, including design, installation, and tapping practices. The text highlights the challenges in accurately assessing taphole condition and the limitations of traditional maintenance strategies. Innovative methods, such as finite element analysis (FEA) models and optimized thermocouple placement, are discussed to improve the accuracy of taphole wear measurements. The study also investigates the impact of cooling water temperature on taphole wear and proposes data-driven strategies for more efficient maintenance. The findings suggest that better-located thermowells and improved control of installation methodologies can enhance the reliability and availability of tapholes, ultimately leading to safer and more cost-effective smelting operations.

AI Generated

This summary of the content was generated with the help of AI.

Novel Copper Slag Cleaning Furnace Design, Supply and Construction

F. Marx, H. Joubert, J. Jonker, T. Peng, B. Matsetela

The chapter delves into the design and construction of a novel slag cleaning furnace for the Kamoa Copper smelter complex, located in the Democratic Republic of the Congo. It explores the direct-to-blister flash (DBF) smelting process, which produces high-purity copper metal, and the crucial role of the slag cleaning furnace (SCF) in optimizing recoveries and production. The text highlights the collaborative efforts between Tenova Pyromet and China Nerin Engineering Co., Ltd., which resulted in a flexible and class-leading slag cleaning operation. It also discusses the innovative electrode configuration, which allows for varying power input at different locations and times during the slag cleaning process. The chapter concludes with the successful cold commissioning of the slag cleaning furnace and the planned hot commissioning within 2025, positioning the Kamoa Copper Mining Complex as one of the world's largest copper producers.

AI Generated

This summary of the content was generated with the help of AI.

Optimizing Feed System Performance in Rio Tinto Kennecott Flash Smelting: Challenges and Solutions

Aibyek Khamkhash, Suresh Krishnamurthy, Leandro Meneses, Ram Muthuraman, David Manczak

The chapter delves into the challenges faced by the Rio Tinto Kennecott Smelter in maintaining uniform heat loads and consistent material distribution in its flash smelting furnace. It highlights the issues of uneven refractory wear and accretion patterns, which were linked to the original feed system design. The text details the significant upgrades implemented during the July 2024 shutdown, including the installation of a new feed bin chute, Metso-style air slide, feed inlet chute, and Metso Octaburner disperser. These upgrades aimed to improve feed distribution and air delivery, leading to more uniform temperature profiles and reduced refractory wear. The chapter also discusses the post-startup challenges encountered, such as frequent acid plant trips and the resulting increase in plenum backpressure. Solutions to these issues, including plenum modifications and blower upgrades, are explored in detail. The performance evaluation section presents data on reaction shaft skin temperatures, feed inlet thermocouples, and copper content in slag, demonstrating the improvements achieved through the upgrades. Regular internal inspections confirmed the positive impact of the new components on furnace performance. The chapter concludes with a summary of the operational improvements and recommendations for further refinements to ensure long-term stability and efficiency in the flash smelting process.

AI Generated

This summary of the content was generated with the help of AI.

Evaluation of Implementation Trefimet High-Tech Thermal Lances on Tapping Process at BHP Olympic Dam Operation

Sebastián Núñez, Antonio Umaña, Abigaile Gibson, Danny Jenkins

This chapter delves into the evaluation of high-tech thermal lances, specifically the Trefimet TR-38 model, for the tapping process in the Electric Slag Cleaning Furnace at BHP Olympic Dam. The study compares the performance, speed, and wear on taphole components of the TR-38 with traditional burning bars. Laboratory tests and field trials at Olympic Dam revealed significant improvements in performance, with the TR-38 achieving a 128% higher speed and reducing the meters of product used per opening by 61%. Additionally, the TR-38 showed a 30% increase in the minimum remaining refractory thickness, indicating potential longevity benefits for taphole components. The chapter also discusses the method used for requirement analysis and the correlation between laboratory and field test results. The findings suggest that implementing the TR-38 thermal lance could enhance operational efficiency, safety, and cost savings in the tapping process. Future work includes long-term tests to further validate these results and assess the impact on safety and incident reduction.

AI Generated

This summary of the content was generated with the help of AI.

Impact of Sphalerite on the Olympic Dam Surface Processing Flowsheet

Samuel Carey, Vanessa Liebezeit

This chapter delves into the impact of sphalerite on the surface processing flowsheet of Olympic Dam, one of the world's largest copper and gold resources. The focus is on the Sapphires mine area, which has unique zinc concentrations in sphalerite, posing metallurgical processing risks. The chapter explores the mineralogy and metallurgical behavior of sulphides, highlighting the copper-sulphur ratio as a key indicator. It discusses the processing flowsheet, including concentrating, smelting, and refining circuits, as well as leaching processes for copper and uranium recovery. The chapter also touches on the historical and recent investigations of the Sapphires area, providing insights into its potential for future expansion projects. Readers will gain a comprehensive understanding of the challenges and opportunities presented by the presence of sphalerite in the Sapphires mine area, and its implications for the overall processing flowsheet at Olympic Dam.

AI Generated

This summary of the content was generated with the help of AI.

Arsenic in Copper Refining and Its Influence on Refractory Lining

Klaudia Wisniewska-Tobiasz

This chapter delves into the challenges posed by arsenic in copper refining, focusing on its impact on refractory linings. It explores the increasing presence of arsenic in copper ores and its detrimental effects on the refining process and refractory materials. The chapter examines various methods for arsenic removal, including roasting, concentrate mixing, and ore leaching, highlighting their effectiveness and applications. It also investigates the corrosion of refractory materials by arsenic oxides and slags containing arsenic, providing detailed post-mortem analyses and model thermodynamic calculations. The findings reveal the mechanisms of corrosion and the formation of new phases that contribute to the wear of refractory linings. The chapter concludes by emphasizing the importance of understanding and mitigating the corrosive effects of arsenic to enhance the durability of refractory materials in copper refining processes.

AI Generated

This summary of the content was generated with the help of AI.

Olympic Dam Electric Slag Cleaning Furnace Blister Taphole Optimisation for Increased Copper Production

Abigaile Gibson, Kathy Ehrig, Vanessa Liebezeit, Danny Rhys Jenkins

This chapter delves into the optimization of blister taphole design in the Electric Slag Cleaning Furnace (EF) at Olympic Dam to boost copper production and safety. Key topics include the critical role of refractory materials, the impact of maintenance strategies on furnace performance, and the results of trials comparing different refractory types. The chapter highlights the importance of selecting the right refractory materials to withstand mechanical, thermal, and chemical stresses, and discusses the design and maintenance of tapholes to enhance production throughput. The findings from trials comparing RK10SR and RK30SR refractory materials are presented, showing their performance under similar operating conditions. The conclusion emphasizes the need for continuous optimization of refractory materials and maintenance procedures to achieve increased copper production and safety.

AI Generated

This summary of the content was generated with the help of AI.

Abstract

As we move towards green energy from renewable sources, copper is an essential resource to support decarbonisation of the modern world. The demand for copper is increasing whilst the available copper resources are degrading in quality. One challenge for the future is how we can optimise existing processes to support an increase in copper production. Copper is produced at the BHP Copper SA Smelter based at Olympic Dam. The Electric Slag Cleaning Furnace (EF) blister taphole refractory materials and throughput variables are analysed to enable a safe increase in taphole refractory life. An increase in refractory life results in the potential for more copper throughput of the taphole between planned maintenance periods. Alumina (Al₂O₃) refractory with 30% chromium oxide (Cr₂O₃) (RK30SR) has been trialled in direct comparison to the existing Al₂O₃ refractory with 10% Cr₂O₃ (RK10SR) to determine whether there are advantages for either composition. Mineralogical analysis on very small sample dimensions (i.e. size) has shown a potential advantage due to the higher amount of Cr₂O₃. Further investigation is advised to provide a sufficient sample size required to validate the results. The Al₂O₃ refractory with 30% Cr₂O₃ is 1.4× more expensive than the Al₂O₃ refractory with 10% Cr₂O₃ and therefore should only be implemented once additional throughput will be achieved. The previous 2020 target to increase the throughput of the EF blister tapholes by 40% using a new taphole design (Essack et al. in Blister tapping: increasing production with CFD. Santiago, pp. 655–665) installed in 2021 has been achieved with the existing lower Cr₂O₃ refractory. The maximum allowable copper tonnes tapped through the taphole is the current driver of downtime for refractory replacement. The existing refractory is sufficient to achieve another 20% improvement from the 2020 tonnes limit. At this point, the number of lances used to open the taphole becomes the limitation for copper production. Therefore, the impact of lance usage needs to be addressed as a priority with continuation of the refractory trial once higher lance throughput is achieved, and any benefits expected from the Al₂O₃ refractory with 30% Cr₂O₃ can be realised whilst in use.

Thermodynamic Behavior of Tin in Primary/Secondary Smelting Systems Using Lime-Ferrite Slag

Naoyuki Hashimoto, Shigeru Ishikawa, Fumito Tanaka

This chapter delves into the thermodynamic behavior of tin in primary and secondary copper smelting systems using lime-ferrite slag. The study focuses on the solubility and distribution of tin under different conditions, including temperature, oxygen potential, and the Fe/CaO ratio. Key findings reveal that the solubility of tin in lime-ferrite slag increases with higher temperatures and lower oxygen potentials. The phase equilibria between the slag and molten copper are meticulously examined, highlighting the formation of different tin oxides and their impact on the slag's composition. The study also discusses the practical implications for copper smelting and converting operations, particularly when dealing with feeds rich in tin. By controlling the Fe/CaO ratio, operators can avoid the precipitation of magnetite and stannic oxide, ensuring continuous and efficient copper production. This research is part of a broader project aimed at enhancing the sustainability of copper pyrometallurgy through intensive recycling.

AI Generated

This summary of the content was generated with the help of AI.

Application of XGC Cyclone Smelting and Electrical Furnace Slag Cleaning for India KCL Smelter

Tang Bin, Jianjun Liu, Weian Fu, Weizhong Guo, Gengtao Chen, Zhengzhu Jian, Jinhui Liu, Jian Zhang, Yutong Cai

This chapter delves into the application of XGC cyclone smelting and electric furnace slag cleaning technologies at the KCL Smelter, a state-of-the-art copper plant with a capacity of 500 KTPA. The text highlights the use of two slag-cleaning electric furnaces to reduce copper content in slag effectively. It provides an in-depth look at the operation principles of the cyclone concentrate burner, which solves common issues like concentrate feeding segregation and overheating, thereby improving the flash furnace's operating rate and oxygen utilization. The chapter also explores the structure and function of the flash smelting furnace, including its reaction tower, settler, and uptake shaft. Furthermore, it discusses the electric furnace slag cleaning process, detailing the treatment of both flash furnace slag and Peirce Smith Converter slag. The text concludes with the expected completion of the project in July 2025, positioning the KCL Smelter as a model for copper smelting plants worldwide. With its detailed technical indicators and 3D model diagrams, this chapter offers a comprehensive overview of these advanced technologies, making it an essential read for professionals in the field.

AI Generated

This summary of the content was generated with the help of AI.

CAPEX Structure of Greenfield Copper Smelter Investment

Lauri Pesonen, Hannu Johto, Ville Sihvola

This chapter delves into the CAPEX structure of greenfield copper smelter investments, highlighting the growing demand for copper driven by global megatrends. It explores the challenges of meeting this demand through brownfield investments and the necessity of expanding primary production. The text provides a detailed breakdown of the cost components of a typical smelter complex, including feed material storage, smelting furnaces, converting furnaces, and various other essential areas. It also discusses the influence of different parameters on the economics of the investment, such as the impact of location on man-hour costs and the significance of mechanical equipment supply. The chapter concludes with a summary of the cost structure and the effects of different project stages on overall costs, offering valuable insights for professionals in the mining and metallurgy industries.

AI Generated

This summary of the content was generated with the help of AI.

Metallurgical Education—A Sound Investment for the Future

Peter C. Hayes

The chapter delves into the pressing issue of the global shortage of metallurgical engineers, highlighting the declining number of graduates and the closure of metallurgical engineering programs in Western universities. It discusses the implications of this shortage on the sustainability of the discipline and the ability to meet future production targets. The text emphasizes the need for increased investment in metallurgical processing and education to address global challenges in energy generation, transportation, and advanced materials manufacturing. It also explores the role of industry in developing a metallurgy workforce for the future, suggesting practical ways to attract and inspire young people to take up careers in metallurgy. The chapter concludes with a call to action for industry and government to prioritize investments in metallurgical education and workforce development to ensure the long-term sustainability of the sector.

AI Generated

This summary of the content was generated with the help of AI.

Research and Implementation Program on Phase Equilibria and Thermodynamics of Molten Slags, Matte, Speiss, and Metal Systems for Primary and Secondary Pyrometallurgy

E. Jak, M. Shevchenko, D. Shishin, J. Chen

This chapter delves into the research and implementation program focused on phase equilibria and thermodynamics of molten slags, matte, speiss, and metal systems, crucial for primary and secondary pyrometallurgy. It explores the significance of thermodynamics and phase equilibria in optimizing pyrometallurgical processes, emphasizing the control of key output parameters such as chemical composition, heat balance, and phase equilibria. The text discusses the development of advanced thermodynamic predictive tools, which are essential for process optimization and can be integrated into 'Pyro-GPS' systems for complex plant flowsheet optimization. Additionally, it highlights the integration of experimental and thermodynamic modeling, which has enabled the rapid development of complex thermodynamic databases. The chapter also outlines the current status of the thermodynamic database development, including recent revisions and improvements, and discusses the importance of collaboration between academia, industry, and government in driving innovation in the field. Furthermore, it addresses the need for skilled staff and the role of university academics in bridging the gap between research and industrial practice. The text concludes with a call for collaborative efforts to advance the digitalization of pyrometallurgical processes, highlighting the significant opportunities and risks involved.

AI Generated

This summary of the content was generated with the help of AI.

Abstract

Modern society challenges include increasing overall metal demand and associated shortage of good quality concentrates, increasing variety of metals needed for high-technological devices, changes associated with energy transition, rapid growth of recycling, present sustainability, circular economy, and environmental constraints. These factors increase the complexity of the pyrometallurgical process chemistry that in turn require robust predictive capabilities. Significant recent progress in analytical and experimental techniques, thermodynamic theory, and computational capabilities in high-temperature research are critical to tackle this task. An integrated experimental and thermodynamic modelling research program on complex multicomponent multi-phase gas–slag–matte–speiss–metal–solids systems with the Cu₂O–PbO–ZnO–FeO–Fe₂O₃–CaO–Al₂O₃–MgO–SiO₂–S major and As–Sn–Sb–Bi–Ag–Au–Ni–Co–Cr–Na minor elements is under way in response. The program has been supported for nearly two decades by several consortia currently consisting of 15 major international companies with over 30 operations in 15 countries around the world that brings together many different groups of professionals. The experiments involve high-temperature equilibration in controlled gas atmospheres, rapid quenching, and direct measurement of equilibrium phase compositions using a combination of the microanalysis techniques including electron probe X-ray microanalysis and laser ablation ICP-MS. The thermodynamic modelling is undertaken using the FactSage™ software package with advanced thermodynamic solution models. Implementation of the research outcomes involves ongoing collaboration of researchers and industry technologists and systematic advanced professional training. An overview of recent progress in research, implementation, and applications in industrial practice will be presented in the paper. The aim of the paper is to share the authors’ experiences in developing and running this research program to facilitate possible future further developments and collaborations in the field of complex pyrometallurgy thermochemistry research.

Thermochemistry Study for BHP Olympic Dam Copper Electric Slag Cleaning Furnace Optimization

Fauzi Rizky Ananda, Hamed Abdeyazdan, Maksym Shevchenko, Jeff Chen, Denis Shishin, Robert West, Mark O’Sullivan, Emily Fletcher, Evgueni Jak

This chapter delves into the thermochemistry of copper electric slag cleaning furnaces, with a particular focus on the 'CuO 0.5'–'FeO'–MgO–SiO 2 system. The study investigates the phase equilibria and the impact of oxygen partial pressure on copper solubility in slag and iron partitioning in the metal phase. Through experimental techniques and industrial sample analysis, the research provides insights into the chemical interaction and thermochemistry of the copper pyrometallurgical process. The findings highlight the significance of oxygen partial pressure in controlling copper and iron concentrations, which is crucial for optimizing furnace operations and minimizing iron deposits in downstream processes. The study also offers a comparison between experimental results and thermodynamic models, emphasizing the need for accurate predictions to enhance process outcomes.

AI Generated

This summary of the content was generated with the help of AI.

Failure Analysis and Corrective Actions for Propane Gas Feed Pipes in Copper Anode Furnaces

Jaakko Korpela, Esa Peuraniemi, Juha Järvi, Petri Latostenmaa

This chapter delves into the failure analysis and corrective actions for propane gas feed pipes in copper anode furnaces at Boliden Harjavalta. The analysis identifies the root causes of pipe failures, including high-temperature sulfidation, chloride-induced corrosion, and structural weaknesses. Corrective actions involved revising operating instructions, testing different pipe materials, and ultimately redesigning the pipe for greater durability. The results show a significant reduction in pipe failures, enhancing both production stability and safety. The chapter also highlights the importance of proper installation and the impact of furnace lining wear on pipe longevity. By addressing these issues, Boliden Harjavalta has improved the reliability and safety of its copper production process.

AI Generated

This summary of the content was generated with the help of AI.

Advanced Design of Injector System for Bath Smelting Technology

Michael Kalisch, Andreas Kemminger, Hans-Jürgen Odenthal, Damara Adiasa, Markus Andreas Reuter

This chapter delves into the advanced design of injector systems for bath smelting technology, focusing on the BlueSmelter process. The injector system, a combination of oxygen/air injector and gas burner, introduces a supersonic gas jet into a liquid melt, enhancing mixing, reaction, and mass transfer. The design and operation of the injector system are crucial for efficient pyrometallurgical processes, and the text provides a detailed explanation of the injector's components, modes of operation, and the results of lab-scale trials and CFD simulations. The injector system's unique design, including the use of a Laval nozzle and coaxial flow operation, is highlighted for its ability to maximize the length of the supersonic oxygen jet. The text also discusses the injector's role in various pyrometallurgical applications, including the BlueSmelter process, and the results of experimental tests and simulations that demonstrate the injector's effectiveness. The chapter concludes with an outlook on future developments and the potential applications of the injector system in other pyrometallurgical processes.

AI Generated

This summary of the content was generated with the help of AI.

Real-Time Estimation of Slag Chemical Composition in Direct-To-Blister Flash Furnace Using a High-Temperature Optical Probe

F. Perez, Jonathan Torres-Sanhueza, F. Lamas, E. Flores, B. Rossel, S. Torres, R. Parra, J. Barbante, Mark O’Sullivan

This chapter explores the implementation and validation of an optical probe system supported by deep learning models to monitor slag copper content in real-time within a direct-to-blister flash-smelting process. The study highlights the challenges faced in copper smelting, including high temperatures, corrosive gases, and dust, which complicate the use of traditional measurement techniques. The optical probe system employs Planck’s radiometry to calculate slag surface irradiance, temperature, and spectral emissivity, which are then used as inputs for deep learning models. The system was validated in a real-case scenario at Olympic Dam’s direct-to-blister flash furnace, demonstrating its effectiveness in providing real-time estimates of slag copper content. The integration of process data, such as copper concentrate feed rate, further enhances the model's accuracy, reducing prediction errors. The chapter also discusses the design and installation of the optical probe, ensuring it can withstand the harsh operating conditions. The results show that the pure radiometric model has a mean absolute error of 1.07% with a standard deviation of 1.37%, while the feed rate-assisted model improves accuracy with a mean absolute error of 0.90% and a standard deviation of 1.18%. This study underscores the potential of combining optical sensing and deep learning to improve process control and efficiency in copper smelting.

AI Generated

This summary of the content was generated with the help of AI.

New Copper Smelter: How to Select the Right Technology and Configuration?

Curtis Strong, Samira Sokhanvaran, Ian Candy

The chapter delves into the pivotal role of copper in the energy transition, driven by its excellent electrical conductivity, essential for renewable energy technologies and data centers. It highlights the projected surge in copper demand due to the global shift towards cleaner energy and increased computing demands. The text explores the current global copper supply and demand dynamics, with a particular focus on the dominance of Chinese smelting capacity. It provides an in-depth analysis of various copper smelting technologies, including bottom-blown furnaces, direct-to-blister processes, flash smelting, and Mitsubishi continuous processes, among others. The chapter also discusses the factors influencing the selection of smelting technologies, such as capital and operating costs, plant throughput, and environmental impacts. It concludes by emphasizing the importance of considering project-specific constraints and objectives when selecting a smelting technology and defining the smelter flowsheet to maximize the probability of project success.

AI Generated

This summary of the content was generated with the help of AI.

Innovative Slag Detection for Improved Copper Recovery, Efficiency, and Safety in Smelting Operations

Derek Stuart

This chapter explores the application of the LAND Slag Detection System (SDS) in copper smelting operations, focusing on its ability to improve metal recovery, efficiency, and safety. The system utilizes mid-wavelength infrared (MWIR) imaging at 3.9 µm to distinguish between copper matte and slag based on their differing emissivities. This automated approach replaces traditional manual methods, offering faster, more reliable, and repeatable results. The SDS has been proven to reduce slag carryover by up to 25%, as demonstrated in a proof-of-concept trial at a European facility. The system's operator interface provides real-time visualization and quantification of the pour, enhancing decision-making and minimizing copper loss. Beyond improved recovery, the SDS significantly enhances operator safety by eliminating the need for direct visual observation of molten material. The implementation of the SDS in copper smelting operations demonstrates a significant step toward more sustainable practices, reducing the need for additional raw materials and minimizing waste. The system's reliance on mid-wavelength infrared technology plays a crucial role in its effectiveness, enabling precise differentiation even under challenging conditions. The combined benefits of enhanced recovery, improved safety, and increased efficiency position the SDS as a vital tool for modern copper smelting operations.

AI Generated

This summary of the content was generated with the help of AI.

Proposal for Strengthening of Smelting-Refinery Capacity in Chile—Chuquicamata Workers’ Union Codelco Chile

Hernán Guerrero Maluenda

This chapter delves into the critical need to strengthen the smelting-refinery (FuRe) capacity in Chile, with a particular focus on the Chuquicamata Division of Codelco. The text highlights the strategic importance of the FuRe business in the copper production value chain, emphasizing the transformation of complex concentrates into high-purity copper cathodes. It explores the unique challenges posed by high arsenic content in Chuquicamata's concentrates and the competitive pressures from Chinese smelters. The proposal outlines several development alternatives, including the adoption of advanced technologies like flash smelting and continuous conversion processes, to enhance productivity and reduce operational costs. Additionally, it discusses the importance of proactive maintenance and the implementation of new management models to ensure sustainability and operational excellence. The chapter concludes with a recommendation to conduct prefeasibility and feasibility studies to evaluate the best business case for Codelco, ensuring the FuRe complex remains competitive and environmentally sustainable.

AI Generated

This summary of the content was generated with the help of AI.

Influence of Minor Elements on Liquidus Temperature in the Cu–As–Sb–S System and Its Implications on the Degradation of a Sole in a Copper Flash Smelting Furnace

Roberto Parra, Camila Mora, Pablo Urzúa, Juan Pablo Harcha, José Palacios

This chapter delves into the intricate world of speiss formation in copper flash smelting furnaces, focusing on the pivotal role of minor elements like sulfur, antimony, and lead. Through advanced thermodynamic modeling using FactSage, the study reveals how these elements significantly alter the liquidus and solidus temperatures, thereby influencing the stability and infiltration potential of speiss. The research highlights the critical impact of arsenic content on furnace operations, demonstrating how its presence can lower temperatures to as low as 300°C, facilitating infiltration into refractory materials. The study also explores the formation of various intermetallic compounds and their phase transitions, providing a detailed map of phase stability under different conditions. Ultimately, the findings underscore the importance of precise control over arsenic and copper grades to mitigate speiss formation and extend furnace longevity.

AI Generated

This summary of the content was generated with the help of AI.

Characterization of Accelerated Sole Degradation by Speiss Infiltration in a Flash Smelting Furnace

Roberto Parra, Camila Mora, Pablo Urzúa, Juan Pablo Harcha, José Palacios

This chapter delves into the critical issue of flash smelting furnace (FSF) sole degradation caused by speiss infiltration, a Cu-As-rich metallic phase with a low melting point and high density. The study employs various analytical techniques, including optical microscopy, X-ray diffraction (XRD), X-ray fluorescence (XRF), and scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS), to characterize the infiltration process and chemical interactions within refractory bricks. The research also compares the infiltration behavior of different refractory bricks using the sessile drop technique. Key findings reveal that speiss infiltration leads to mechanical weakening and chemical reactions with periclase (MgO) and chromite (Cr₂O₃), accelerating the degradation of the refractory material. The study identifies the formation of magnesium metaarsenate (Mg₃(AsO₄)₂) as a significant factor in the chemical degradation process. Additionally, thermodynamic modeling confirms that minor elements like As, S, Sb, and Pb significantly influence speiss infiltration by lowering its solidus and liquidus temperatures. The chapter concludes with recommendations to mitigate speiss formation and infiltration, such as controlling dust recirculation, regulating the Cu grade in the matte, and optimizing the sole design to enhance resistance to speiss wetting.

AI Generated

This summary of the content was generated with the help of AI.

Purge Gas Preheating for Enhanced Steam Dryer Operation in Concentrate Drying

Carl-Gustav Berg, Johannes Lehtonen, Jussi Vaarno, Juho Kyllönen

This chapter delves into the integration of a purge gas preheating system into Kumera steam dryers used in copper smelting operations. It examines the benefits in terms of energy savings, increased equipment availability, reduced maintenance needs, and lower emissions. The study evaluates the environmental, operational, and economic advantages of purge gas preheating, providing a comprehensive assessment of its potential to enhance sustainable and cost-effective smelting operations. The text also explores the system's design, integration, and maintenance, offering practical insights for industry professionals. The conclusion highlights the significant advantages of the purge gas preheating system across operational, environmental, and economic dimensions, making it a valuable technology for modern copper smelting operations.

AI Generated

This summary of the content was generated with the help of AI.

Oxidation–Reduction Process for Copper Concentrates: An Alternative to Smelting–Converting

Igor Wilkomirksy, Marcela Angulo, Roberto Parra, Fernando Parada, Hugo Rojas, Gonzalo Reyes, Maximiliano Roa, Camila Mora

This chapter explores a groundbreaking oxidation-reduction process for copper concentrates, presenting a sustainable alternative to traditional smelting-converting methods. The process involves two main stages: an oxidation step to remove sulfur and transform sulfides into oxides, followed by a reduction step using green hydrogen to produce metallic copper and magnetite. The chapter delves into the pilot-scale development of this technology, highlighting its environmental benefits, such as reduced carbon emissions and the valorization of byproducts like magnetite and silica. Preliminary economic evaluations are presented, comparing the new process with conventional methods and demonstrating its cost-effectiveness. The text also discusses optimization alternatives and the potential impact on the steel and cement industries. The conclusion emphasizes the process's sensitivity to hydrogen prices and its potential to revolutionize copper extraction, making it a compelling read for professionals seeking innovative solutions in mineral processing and environmental sustainability.

AI Generated

This summary of the content was generated with the help of AI.

Improvements of a Copper Dry Feed Loss-In-Weight Feed System: RotoFeed® Installation on a Flash Smelting Furnace

Ryan D. Wilde, Dave Jakelski, Michael Loveless, Shawn Brown, Kyle Galloway, Ramajan Grose, Bradley Malik, Chuck Mitchell, Chris Fountain, Mark Coleman, Gary Bolton, David Craig

The chapter delves into the challenges faced by the copper dry feed loss-in-weight system at Rio Tinto Kennecott's Garfield smelter, particularly the issue of feed flushing. It highlights the innovative solution of installing the RotoFeed® system to address these problems. The text details the modifications made to the system, including the addition of AirSweep® nozzles, the replacement of screw feeders with rotary-valve RotoFeed® units, and upgrades to the drag conveyor. It also discusses the criteria for equipment selection and the additional feed preparation requirements. The results of the implementation are thoroughly analyzed, showing significant improvements in feed rate accuracy and operational efficiency. The chapter concludes with a summary of the ongoing improvements and the potential for future enhancements to extend the functional life cycle of the RotoFeed® system.

AI Generated

This summary of the content was generated with the help of AI.

A Mechanism of As2O3/Sb2O3 Accretion Formation in a Cu/Fe/S/O Solid Matrix in an Electrostatic Precipitator

Rodrigo Diaz, Fernando Gutierrez, Igor Wilkomirsky

This chapter examines the formation of accretions composed primarily of arsenic and antimony trioxides, along with copper and iron sulfates, within the electrostatic precipitator (ESP) of a copper concentrate roasting plant. The study identifies the key factors influencing accretion formation, including gas flow velocity, particle size and composition, re-entrainment, and electrical field strength. It also explores the mineralogical and chemical composition of these accretions, revealing significant variations across different sections of the ESP. The analysis suggests that antimony trioxide (Sb2O3) acts as a nucleation point, facilitating the formation of a crystalline oxide network with arsenic trioxide (As2O3). Additionally, copper and iron sulfates, formed via sulfation reactions, contribute to the accretion process. The study concludes that increasing the operative temperature of the ESP and reducing air infiltrations could minimize accretion formation. It also recommends further experimental work to investigate gas-solid equilibrium in the As2O3/Sb2O3 system. This research provides valuable insights into the mechanisms of accretion formation and offers practical strategies for improving the performance of electrostatic precipitators in industrial settings.

AI Generated

This summary of the content was generated with the help of AI.

CFD Analysis of a Flash Converting Furnace

Matthew White, Thomas Gonzales, Wesley Taylor, Edward Anketell, Anastasiya Mitsui

This chapter provides a detailed analysis of the flash converting furnace (FCF) process, focusing on the typical FCF smelting process, industrial benchmarking, and advanced CFD modelling techniques. The analysis begins with an overview of the typical FCF smelting process, including the granulation, drying, and grinding of matte, and the critical role of the matte burner in achieving optimal combustion efficiency. The chapter then delves into industrial benchmarking, comparing the specific smelting intensity (SSI) and specific reaction energy (SRE) of the typical FCF with other flash furnaces. The CFD analysis section outlines the development and features of a custom-built CFD model, including the use of the Reynolds Averaged Navier Stokes (RANS) equations and the Shear Stress Transport (SST) turbulence model. The results of the CFD analysis are presented, highlighting the velocity streamlines, particle trajectories, temperature distribution, and SO2 liberation rate within the FCF. The chapter concludes with a summary of the findings and the potential applications of CFD analysis in improving FCF operations. Additionally, the chapter discusses Hatch's innovative technologies, such as Waffle cooling elements and concentrate burner technology, which are crucial for improving furnace stability and operational efficiency. This chapter offers a comprehensive overview of the FCF process, providing valuable insights into the optimization and improvement of FCF operations.

AI Generated

This summary of the content was generated with the help of AI.

Increased Treatment of Secondary Raw Materials in the PS Converter Operation at Toyo Smelter and Refinery

H. Wada, S. Sasai, T. Kudo

This chapter delves into the significant advancements made at the Toyo Smelter and Refinery in processing secondary raw materials, focusing on technological improvements and operational strategies. Key topics include the increased treatment of recycled materials, the stabilization of converter slag composition, and the processing of electronic scrap and gold ore. The chapter highlights the successful implementation of measures to enhance the processing of granular materials, leading to a significant increase in production volumes. By understanding and addressing the challenges associated with varying impurity grades and moisture content, the smelter has achieved a more efficient and sustainable copper production process. The conclusion underscores the importance of continuous innovation and adaptation in the face of evolving industry demands and environmental considerations.

AI Generated

This summary of the content was generated with the help of AI.

Thermal Properties of Magnesia-Chromite Refractories in a Precious Metals Top-Blown Rotary Converter

Lotta Kleemola, Lassi Klemettinen, Jukka Kuva, Daniel Lindberg

This chapter delves into the thermal properties and degradation of magnesia-chromite refractories used in a top-blown rotary converter, with a focus on slag-refractory interactions. The study examines the extent of slag infiltration and its impact on the refractory's microstructure and thermal diffusivity. Key findings include the formation of a forsterite phase due to the reaction between magnesia and silica from the slag, and the densification of the refractory structure near the hot face. The research also explores the effects of different slag components, such as PbO and Ag, on the refractory's performance. Additionally, the chapter discusses the implications of these findings for the longevity and cost-effectiveness of furnace linings, as well as the broader context of circular economy in the metallurgical industry.

AI Generated

This summary of the content was generated with the help of AI.

Evaluation of the Suitability of Various Biocarbon Types to Copper Slag Reduction/Cleaning

J. Malinen, J. Pihlasalo, D. Sukhomlinov, M. Lindgren, L. Klemettinen

This chapter delves into the evaluation of various biocarbon types as potential reductants for copper slag cleaning, a process crucial for reducing environmental impact and recovering valuable metals. The study compares the reactivity of ten different biocarbons with traditional fossil carbon reductants, such as metallurgical cokes and anthracite. Key focus areas include the characterization of biocarbon properties, the measurement of reactivity, and the influence of specific characteristics on reactivity. The experiments involved detailed measurements of fixed carbon, volatiles, density, moisture, ash content, and the concentrations of sulfur and chlorine. Reactivity tests were conducted using a high-temperature furnace and ilmenite slag as a model. The results highlight the potential of biocarbon as a more effective and reactive reductant compared to coke, with significant implications for sustainable metallurgical practices. The study concludes that understanding the specific characteristics governing biocarbon reactivity is essential for optimizing its use in copper slag reduction.

AI Generated

This summary of the content was generated with the help of AI.

Slag Chemistry and Partitioning of Trace Elements in Direct-to-Blister Copper Smelting Conditions

Dmitry Sukhomlinov, Marius Kansanaho, Lassi Klemettinen, Hugh O’Brien, Mia Tiljander, Mari Lindgren, Daniel Lindberg

This chapter delves into the slag chemistry and trace element partitioning in direct-to-blister (DtoB) copper smelting, a highly efficient and sustainable process. The study compares recent experimental data with thermodynamic calculations using FactSage v.8.1, focusing on the system Cu–Fe–O–S–CaO–SiO2 with various gangue components. Key findings include the behavior of trace elements such as Ni, Co, Ag, and Ge, and the impact of slag modifiers like alumina and magnesia. The chapter also discusses the industrial relevance of DtoB smelting, highlighting its advantages in energy use, cost efficiency, and environmental impact. The comparison of experimental and industrial data provides insights into the true chemical solubility of copper in slag and the presence of mechanically entrained metal. Additionally, the study emphasizes the need for separate treatment of smelter flue dust to recover germanium efficiently. Overall, the chapter offers a detailed analysis of the DtoB process, making it a valuable resource for professionals seeking to optimize copper smelting operations.

AI Generated

This summary of the content was generated with the help of AI.

Online Cleaning Device for the Furnace Uptake Transition at PASAR Smelter

John Joven Chiong, Anastasiya Mitsui, Matthew White, Brian Wiggins

This chapter delves into the persistent issue of buildup in the furnace gas system, particularly at the transition between the furnace uptake and boiler inlet, known as the throat. The text discusses the challenges posed by molten and sticky particulate matter, which can lead to equipment damage and significant downtime for manual cleaning. The implementation of an online cleaning device, or throat scraper, at the PASAR Smelter is presented as a solution to these problems. The design and installation of the scraper are detailed, highlighting the custom approach required to integrate the device with the existing furnace operation and plant layout. The performance of the scraper is evaluated, with a focus on its ability to reduce the size of falling accretions and minimize the need for manual cleaning. The text also discusses the operational improvements and safety benefits achieved through the use of the scraper, as well as the maintenance requirements and potential areas for further improvement. The conclusion emphasizes the reliability and practicality of the throat scraper as a solution to transition buildup, downtime, and operator safety concerns.

AI Generated

This summary of the content was generated with the help of AI.

The Installation of Two Hydrogen-Ready Anode Furnaces at Aurubis’ Hamburg “Down-Town” Smelter

Thies Fingerhut, Rakan Rahbani, Torben Edens

The chapter delves into the installation of two hydrogen-ready anode furnaces at Aurubis' Hamburg smelter, highlighting the project's goals, design criteria, and successful hydrogen trials. Key topics include the determination of furnace capacity and features, the importance of safety and operational flexibility, and the reduction of oxygen uptake during casting. The chapter also covers the results of hydrogen trials, design specifications for the new furnaces, and the project's ambitious timeline and execution strategies. The project aimed to reduce carbon emissions by up to 5000 tons of CO2 annually, demonstrating Aurubis' commitment to decarbonizing its assets. The successful implementation of hydrogen-ready technology marks a significant step towards achieving the company's environmental targets.

AI Generated

This summary of the content was generated with the help of AI.

Alternative Cooling Medium System for Safe Furnace Operation

Hugo Joubert, Kgomotso Maluleke, Piet Jonker

This chapter delves into the critical evaluation of alternative cooling mediums for furnace operations, focusing on the use of MEG (mono-ethylene glycol) and water mixtures. The text explores the cooling efficiency of these mixtures compared to traditional water cooling systems, highlighting the potential to enhance safety and operational performance. The chapter presents detailed test setups and procedures, including finite element analysis (FEA) modeling and experimental test work, to assess the cooling efficiency and explosion risk of MEG and water mixtures. The results indicate that a 70% MEG to 30% water mixture can achieve similar heat removal rates as water but at higher bulk velocities. The text also discusses the safety advantages of using MEG and water mixtures, as they significantly reduce the risk of explosions when in contact with molten matte. The conclusions emphasize the potential of MEG and water mixtures as a safer and more efficient cooling option for furnace operations, providing valuable insights for professionals in the field.

AI Generated

This summary of the content was generated with the help of AI.

A Study on the Reaction Rate of Iron Sulfide Production from Iron Oxide Sulfidation

Matthew Michalek, Antoine Allanore

This chapter delves into the sulfidation process of iron oxides, a crucial step in metal extraction, particularly for iron. The study focuses on the reaction rates and parameters that influence the efficient conversion of iron oxides into iron sulfides using a rotary kiln. Key topics include the effects of temperature, partial pressures of the sulfidizing agent, and the composition of the iron oxide precursor on the sulfidation process. The research also addresses the challenge of interpreting results due to the existence of several liquid phases during the reaction, which complicates the application of existing models. The study found that the reaction rate for hematite sulfidation increased from 0.0074 cm s−1 to 0.018 cm s−1 and for magnetite sulfidation from 0.038 cm s−1 to 0.148 cm s−1 at temperatures between 650 °C–750 °C. The activation energy of the intrinsic chemical reaction and product layer diffusion for iron oxide sulfidation were calculated, and the residence times were simulated for a pilot-scale demonstration in a rotary kiln. The average calculated reaction order for the experiments was 1.05. This detailed investigation provides valuable insights into optimizing the sulfidation process for enhanced metal recovery from low-grade ores or recycled streams.

AI Generated

This summary of the content was generated with the help of AI.

Enhancing Asset Performance Management with Hatch's Expertise and Digital Solutions

Kelly Levesque, Barb Matthews, Bien Ferrer, Afshin Sadri

This chapter explores the critical role of asset performance management (APM) in maintaining operational efficiency and sustainability in industrial settings. It delves into Hatch's comprehensive APM services, which leverage advanced technologies and expert knowledge to address complex challenges faced by clients. The text discusses the importance of synchronizing production and maintenance data, sharing asset information across systems, and integrating condition monitoring and inspection data for effective asset management. It also highlights the use of predictive analytics and real-time data-driven decision support to optimize asset performance. The chapter includes case studies that demonstrate the practical application of APM services, such as monitoring and maintaining the integrity of flash furnace reaction shafts and furnace binding systems. These case studies illustrate how advanced monitoring techniques and digital tools can enhance maintenance planning and execution, ensuring the longevity and safety of industrial operations. The conclusion emphasizes Hatch's vision to become a comprehensive performance provider, offering individualized performance guarantees and supporting clients in achieving their business objectives.

AI Generated

This summary of the content was generated with the help of AI.

Impact of Oxidizing and Reducing Conditions on the Performance of Alumina-Chrome Refractories in Copper Refining Furnaces

Bradley Fox, Stephen Wisneski, Jonathon McBride

This study delves into the performance of alumina-chrome refractories in copper refining furnaces, focusing on the impact of oxidizing and reducing conditions. Through a field trial and subsequent laboratory tests, the research examines the corrosion resistance of these refractories when exposed to copper oxide under different atmospheric conditions. The field trial revealed unexpected results, with alumina-chrome bricks showing increased corrosion above the tuyeres compared to magnesia-chrome bricks. Laboratory tests confirmed these findings, demonstrating that reducing atmospheres help build a protective corrosion layer, while oxidizing conditions lead to widespread corrosion. The study concludes that alumina-chrome refractories perform best under reducing conditions, highlighting the importance of atmospheric control in copper refining processes. Additionally, the research provides detailed insights into the corrosion mechanisms through SEM/EDS analysis, offering valuable data for professionals seeking to optimize refractory performance in high-wear areas of copper refining furnaces.

AI Generated

This summary of the content was generated with the help of AI.

Innovation in the Control and Blending of Mineral Concentrates

R. S. Alarcon

This chapter delves into the innovative measures implemented by Codelco Chile to improve the quality and control of their copper concentrates. The text focuses on automated systems for managing, loading, and sampling surplus copper concentrates for export, particularly in the Chuquicamata division. It details the blending process, which involves characterizing concentrates by their copper, gold, and arsenic content and using high-intensity mixing devices to achieve commercial copper grades. The chapter also discusses the cleaning process, which includes high-intensity disintegration, wetting, and screening to remove oversized particles. The dispatch process is outlined, highlighting the use of mobile stackers and sampling systems to ensure accurate loading and sampling of concentrates. Pilot-level results indicate a significant reduction in the variability of arsenic, gold, and copper, demonstrating the effectiveness of the blending process. The chapter concludes with the potential impact of these innovations on the commercial transactions of Codelco Chile, emphasizing the company's commitment to continuous improvement and innovation in its processes.

AI Generated

This summary of the content was generated with the help of AI.

Air Granulation of Mattes and Slags—A New Tool in Pyrometallurgy

Santiago Faucher, Aurelio Stammitti, Kelly Lau, Adam Tyedmers, Seong-Il Shim

This chapter explores the advantages of air granulation in pyrometallurgical processes, focusing on safety, efficiency, and metal recovery. It compares traditional methods like pit casting with the innovative air granulation technique, highlighting the reduction in safety risks and improved metal recovery. The text delves into the challenges of traditional methods, such as the mixing of materials and increased metal losses. It also discusses the development and implementation of air granulation technology by UNECO, including its successful application in various industries. The chapter concludes with a comparative analysis of two smelters, demonstrating the significant reduction in metal losses achieved through air granulation. Additionally, the text touches on the environmental benefits and cost savings associated with this technology.

AI Generated

This summary of the content was generated with the help of AI.

The Potential of Multidimensional Modeling Techniques for Advanced Process Control in Metallurgical Recycling Processes

Fabian Diaz, Taopheeck Yusuf, Ali Akouch, Sabrine Khadhraoui, Nikolaus Borowski, Markus Reuter

This chapter delves into the challenges and solutions for optimizing copper recycling in pyrometallurgical processes. It explores the variability in scrap composition and the high energy demands that complicate these processes, leading to inefficiencies and environmental concerns. The text discusses the limitations of traditional process control methods and highlights the potential of advanced modeling techniques, including AI-driven surrogate modeling, thermochemical simulations, and data reconciliation. A key focus is the integration of these techniques into a multidimensional decision-making framework, as demonstrated by the BlueControlApp. This system enhances predictive control, refines slag-metal interactions, and balances multiple objectives such as impurity removal, metal recovery, and energy efficiency. The chapter also presents a case study on copper recycling in a Tilting Refining Furnace (TRF), illustrating the practical application of these advanced techniques. The conclusion emphasizes the future prospects of AI-driven process control in modernizing metallurgical operations, improving efficiency, and sustainability.

AI Generated

This summary of the content was generated with the help of AI.

Freeze Lining at Umicore Hoboken—Progress and Challenges

Robin Vanparys, Lawrence Billington

This chapter delves into the innovative use of freeze linings at Umicore's Hoboken facility to extend the life of copper smelters and reduce operational costs. It highlights the challenges posed by vapor explosions and the potential of alternative coolants like ionic liquids and mono ethylene glycol (MEG) to mitigate these risks. The text also explores slag engineering techniques to enhance the stability and thickness of freeze linings, crucial for maintaining furnace integrity. Through detailed experiments and visual observations, the chapter demonstrates the effectiveness of MEG in reducing explosion severity and the importance of understanding slag composition dynamics. The conclusion emphasizes the need for further research and standardization to ensure the safe and efficient application of freeze linings in industrial settings.

AI Generated

This summary of the content was generated with the help of AI.

Reducing Fugitive Emissions in Smelting Operations: A CFD-Based Study

Farzam Allafchi, Bardia Abbasi, Maria de Campos

This chapter delves into the critical role of ventilation systems in copper smelters, focusing on reducing fugitive emissions and ensuring worker safety. The study employs Computational Fluid Dynamics (CFD) to simulate airflow, temperature distribution, and contaminant dispersion within a conceptual copper smelter building. Key topics include the impact of primary, secondary, and tertiary capture systems on emissions control, the influence of airflow patterns on temperature gradients, and the dispersion of sulfur dioxide (SO2) as the primary contaminant. The research also explores the effectiveness of air curtains and supply fans in preventing emissions egress, as well as the impact of ambient temperature on emissions dispersion. The findings highlight the importance of optimized ventilation design in maintaining air quality and thermal comfort, providing valuable insights for improving environmental and occupational health outcomes in smelting facilities.

AI Generated

This summary of the content was generated with the help of AI.

Improving the Productivity of the Peirce-Smith Converter Aisle at Ilo’s Copper Smelter Plant

Bryan Ceron, Alvaro Jara, Jose Marquez, Telesforo Marquez

This chapter delves into the enhancements made to the Peirce-Smith converter aisle at Ilo's copper smelter plant, focusing on increasing productivity and extending the operational lifespan of the converters. Key topics include the optimization of matte treatment capacity, the impact of operational modifications on refractory wear, and the use of computational fluid dynamics modeling to understand and mitigate wear mechanisms. The study reveals that increasing air flow rates and adjusting slag composition can significantly enhance matte treatment capacity while reducing blowing times per batch. Additionally, the chapter discusses the importance of maintaining optimal bath levels and performing regular maintenance to prolong the lifespan of the converters. The successful implementation of these modifications resulted in a 30% increase in conversion capacity, allowing for greater concentrate processing in the smelting furnace.

AI Generated

This summary of the content was generated with the help of AI.

Springer Professional

About this book

Table of Contents

Pyrometallurgy

Frontmatter