Reaction Sequences in Flash Smelting and Converting Furnaces: An In-depth View

Flash smelting and flash converting are mature technologies in copper and nickel sulfide smelting. The sensitivity of operation concerning the furnace design is evident. It is obvious that when two unit operations are carried out in separate spaces in the same furnace, skills related to maintenance of suspension oxidation of fine minerals, fluxing, fluid as well as heat flows and the overall energy balance are required. Despite these fundamental features, the flow-sheet wide understanding of linking the suspension oxidation of sulfides with the subsequent smelting processes in the furnace as well as the chemistry of its off-gas train is largely absent in the scientific literature. This review gives a detailed outlook on the microscale phenomena in flash smelting and flash converting furnaces accumulated during the last decades. It connects their vital features and chemistries with the reaction tendencies and heat fluxes in the different parts and reaction zones of the furnace as well as in the off-gas train from the smelter to the acid plant. Graphic Abstract

On the Kinetic Behavior of Recycling Precious Metals (Au, Ag, Pt, and Pd) Through Copper Smelting Process

The recycling and recovery of precious metals from secondary materials, such as waste-printed circuit boards, are an important area of circular economy research due to the limited existing resources and increasing amount of e-waste produced by the rapid development of technology. In this study, the kinetic behavior of precious metals Au, Ag, Pt, and Pd between copper matte and iron-silicate slag was investigated at a typical flash smelting temperature of 1300 °C in both air and argon atmospheres. SEM–EDS, EPMA, and LA-ICP-MS-advanced analysis methods were used for sample characterization. The results indicate that precious metals favor the matte phase over slag, and the deportment to matte occurred swiftly within a short time after the system had reached the experimental temperature. With increasing contact times, the precious metals were distributed increasingly into the sulfide matte. The distribution coefficients, based on experimentally measured element concentrations, followed the order of palladium > platinum > gold > silver in both air and argon, and the matte acted as an efficient collector of these precious metals. The obtained results can be applied to industrial copper matte smelting processes, and they also help in upgrading CFD models to simulate the flash smelting process more precisely. Graphical Abstract

Behavior of copper and lead during mineralurgical and hydrometallurgical processing of flash smelting slag

There are only a few smelters processing copper concentrates directly into blister copper. Despite the many advantages of this process, a serious challenge of this technology is the need to process the resulting flash smelting slag. It contains 12–15% copper and 2.5–4% lead. In this form, it cannot be considered as waste material and, therefore, a high-temperature reduction process is carried out. This decopperization process is energy- and time-consuming. The use of mineralurgical and hydrometallurgical processes, selective enrichment of the appropriate slag fractions in copper and lead, followed by its hydrometallurgical processing and recovery of Cu and Pb could be an interesting supplement to the methods used so far. The article presents results of research on the possibility of separation of useful components from copper slag using the original method of sieve analysis, gravitational enrichment and magnetic separation. Preliminary results of tests were made on a laboratory scale. Then, selective leaching of copper and lead from flash smelting slag was carried out, obtaining very promising results.

Effect of Oxygen Content and Temperature On Stabilization of Arsenic in Copper Smelting System

Arsenic-bearing wastes from copper smelting system are usually disposed by trapping them in slag tailing. However, arsenic in slag tailing is not that stable, which can infiltrate into the groundwater, threatening the environment and human health. The solidification/stabilization (S/S) of arsenic is the only way to deal with arsenic contamination. The flash smelting method shows relatively high S/S ability of arsenic, but the process and mechanism remain unclear. In this paper, we aim at revealing the effect of atmosphere on the S/S process of arsenic owing to the different content of oxygen in reaction shaft and sedimentation tank in copper smelting system. Calcium arsenate, SiO2, Fe2O3 and iron powders were sintered at different temperature in air and argon to simulate the S/S reaction. The results show that the sintering product is Fe-Si oxide in air and fayalite in argon, and the fayalite possesses better capacity to solidify arsenic than that of Fe-Si oxide. The toxicity characteristic leaching procedure (TCLP) results reveal that the leached concentration of arsenic from fayalite fabricated at 1200 ℃ is only 2.916 mg L-1, which satisfies the identification standard for hazardous substances in China. Furthermore, the theoretical calculation reveals that AsO4 and SiO4 tetrahedrons can be connected by O atoms when sintered in argon, and the Si-O-As covalent bond can evidently inhibit the release of As atom from fayalite. This work can not only clarify the S/S mechanism of arsenic in flash smelting process, but also provide theoretical guidances to dispose arsenic-bearing waste harmlessly.

Special Issue on “Process Modeling in Pyrometallurgical Engineering”

This Special Issue on “Process Modeling in Pyrometallurgical Engineering” consists of 39 articles, including two review papers, and covers a wide range of topics related to process development and analysis based on modeling in ironmaking, steelmaking, flash smelting, casting, rolling operations, etc [...]