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WO2024213821A1 - Four de fusion en suspension - Google Patents

Four de fusion en suspension Download PDF

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Publication number
WO2024213821A1
WO2024213821A1 PCT/FI2023/050211 FI2023050211W WO2024213821A1 WO 2024213821 A1 WO2024213821 A1 WO 2024213821A1 FI 2023050211 W FI2023050211 W FI 2023050211W WO 2024213821 A1 WO2024213821 A1 WO 2024213821A1
Authority
WO
WIPO (PCT)
Prior art keywords
settler
matte
smelting furnace
slag
suspension smelting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/FI2023/050211
Other languages
English (en)
Inventor
Peter BJÖRKLUND
Markku Lahtinen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Metso Metals Oy
Original Assignee
Metso Metals Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Metso Metals Oy filed Critical Metso Metals Oy
Priority to AU2023442361A priority Critical patent/AU2023442361A1/en
Priority to CN202380098431.3A priority patent/CN121175440A/zh
Priority to PCT/FI2023/050211 priority patent/WO2024213821A1/fr
Priority to KR1020257037268A priority patent/KR20250174055A/ko
Priority to CN202420780302.4U priority patent/CN222352861U/zh
Publication of WO2024213821A1 publication Critical patent/WO2024213821A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B15/00—Obtaining copper
    • C22B15/0026—Pyrometallurgy
    • C22B15/0028—Smelting or converting
    • C22B15/003—Bath smelting or converting
    • C22B15/0032—Bath smelting or converting in shaft furnaces, e.g. blast furnaces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B11/00—Making pig-iron other than in blast furnaces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/0033—In fluidised bed furnaces or apparatus containing a dispersion of the material
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B15/00—Obtaining copper
    • C22B15/0026—Pyrometallurgy
    • C22B15/0028—Smelting or converting
    • C22B15/003—Bath smelting or converting
    • C22B15/0041—Bath smelting or converting in converters
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B15/00—Obtaining copper
    • C22B15/0026—Pyrometallurgy
    • C22B15/0028—Smelting or converting
    • C22B15/0047—Smelting or converting flash smelting or converting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B15/00—Obtaining copper
    • C22B15/0026—Pyrometallurgy
    • C22B15/0028—Smelting or converting
    • C22B15/005—Smelting or converting in a succession of furnaces
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B15/00—Obtaining copper
    • C22B15/0026—Pyrometallurgy
    • C22B15/0054—Slag, slime, speiss, or dross treating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D3/18—Charging particulate material using a fluid carrier
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B15/00—Obtaining copper
    • C22B15/0026—Pyrometallurgy
    • C22B15/0028—Smelting or converting
    • C22B15/003—Bath smelting or converting
    • C22B15/0041—Bath smelting or converting in converters
    • C22B15/0043—Bath smelting or converting in converters in rotating converters

Definitions

  • the present invention relates to a suspension smelting furnace .
  • the present invention also relates to a method for using said suspension smelting furnace .
  • the process usually involves oxidation of the concentrate in a flash smelting furnace ( FSF) to produce matte .
  • the matte may then then be fed to a flash converting furnace ( FCF) or a Peirce Smith converter, where the matte i s further oxidi sed .
  • FCF flash converting furnace
  • Peirce Smith converter a flash converting furnace
  • s lag is formed both in the FSF and FCF or Peirce Smith converter .
  • the slag typically comprises a significant amount of metals and should thus be recycled back to one or several furnaces for further processing in order to improve the yield of the process .
  • the slag from the FCF or Peirce Smith converter should be recycled to the FSF .
  • the recycling of slag consumes a lot of resources as the slag is typically granulated by water sprays , stored in bins and fed into a dryer before being fed back into the furnaces .
  • the granulation of the slag consumes a lot of water, since water is mainly used to cool down the slag and to break it into smaller particles . This causes steaming losses and particle contamination of the granulation water, which requires further treatment before reuse of the water is possible .
  • energy is required to heat up the slag again to a temperature sufficient to melt the slag.
  • the slag granulation water needs to be cooled by a secondary cooling water circuit, which further consumes energy and water.
  • a suspension smelting furnace comprising: i. a reaction shaft (5) provided with a burner for burning concentrate or matte (4) and feeding concentrate or matte (1) into the reaction shaft (5) to form a jet of an at least partially oxidised suspension (6) in the reaction shaft (5) , ii.
  • a settler (8) in communication with a lower end of the reaction shaft (5) , wherein the settler (8) has an inner space (9) and a first end wall structure (27) at one end of the settler (8) and a second end wall structure (28) at the opposite end of the settler (8) and a landing zone (7) for the jet of oxidised suspension (6) in the inner space (9) of the settler (8) below the lower end of the reaction shaft (5) , and wherein the settler (8) extends in two opposite directions from the landing zone (7) so that the settler (8) comprises a first settler part (18) on a first side of the landing zone (7) and a second settler part (19) on an opposite second side of the landing zone (7) , and wherein the settler (8) is configured to receive the at least partially oxidised suspension (6) from the reaction shaft (5) at the landing zone (7) and to form a layer of matte or metal alloy (10) and a layer of slag (11) on top of the layer of matte or metal alloy (10) in the inner space
  • a method for producing matte or metal alloy in a suspension smelting furnace comprising: i. feeding concentrate or matte (1) by means of a burner for burning concentrate or matte (4) into a reaction shaft (5) of the suspension smelting furnace to form a jet of an at least partially oxidised suspension (6) in the reaction shaft (5) , ii.
  • the settler (8) has an inner space (9) and a first end wall structure (27) at one end of the settler (8) and a second end wall structure (28) at the opposite end of the settler (8) , and wherein the settler (8) extends in two opposite directions from the landing zone (7) so that the settler (8) comprises a first settler part (18) on a first side of the landing zone (7) and a second settler part (19) on an opposite second side of the landing zone (7) , iii.
  • a layer of matte or metal alloy (10) and a layer of slag (11) on top of the layer of matte or metal alloy (10) in the inner space (9) of the settler (8) iv. discharging slag (14) from the layer of slag (11) in the settler (8) through a first taphole (15) arranged in the second settler part (19)
  • the first taphole (15) is arranged in the vertical direction at a level above the second taphole (17)
  • the method further comprises vi .
  • Figure 1 is a schematic illustration of a suspension smelting furnace according to the first embodiment of the invention, wherein the feeding means (30) is arranged in the first distal end of the first settler part (18) and the first taphole (15) and the second taphole (17) are arranged in the second distal end of the second settler part (19) .
  • FIG. 2 is a schematic illustration of a suspension smelting furnace according to the first embodiment of the invention, wherein the feeding means (30) is arranged in the roof of the settler in the first settler part (18) and the first taphole (15) and the second taphole (17) are arranged in the second distal end of the second settler part (19) .
  • FIG 3 is a schematic illustration of a suspension smelting furnace according to the first embodiment of the invention, wherein the feeding means (30) is arranged in the side wall of the settler in the first settler part (18) and the first taphole (15) and the second taphole (17) are arranged in the second distal end of the second settler part (19) .
  • Figure 4 is a schematic illustration of a suspension smelting furnace according to the first embodiment of the invention, wherein the feeding means (30) is arranged in the first distal end of the first settler part (18) and the first taphole (15) is arranged in the second distal end of the second settler part (19) and the second taphole (17) is arranges in the side wall of the second settler part (19) .
  • FIG. 5 is a schematic illustration of a suspension smelting furnace according to the first embodiment of the invention, wherein the feeding means (30) is arranged in the first distal end of the first settler part (18) and the second taphole (17) is arranged in the second distal end of the second settler part (19) and the first taphole (15) is arranges in the side wall of the second settler part (19) .
  • a suspension smelting furnace comprising: i. a reaction shaft (5) provided with a burner for burning concentrate or matte (4) and feeding concentrate or matte (1) into the reaction shaft (5) to form a jet of an at least partially oxidised suspension (6) in the reaction shaft (5) , ii.
  • a settler (8) in communication with a lower end of the reaction shaft (5) , wherein the settler (8) has an inner space (9) and a first end wall structure (27) at one end of the settler (8) and a second end wall structure (28) at the opposite end of the settler (8) and a landing zone (7) for the jet of oxidised suspension (6) in the inner space (9) of the settler (8) below the lower end of the reaction shaft (5) , and wherein the settler (8) extends in two opposite directions from the landing zone (7) so that the settler (8) comprises a first settler part (18) on a first side of the landing zone (7) and a second settler part (19) on an opposite second side of the landing zone (7) , and wherein the settler (8) is configured to receive the at least partially oxidised suspension (6) from the reaction shaft (5) at the landing zone (7) and to form a layer of matte or metal alloy (10) and a layer of slag (11) on top of the layer of matte or metal alloy (10) in the inner space
  • the concentrate or matte (1) Prior to feeding the concentrate or matte (1) to the concentrate or matte burner (4) , it may be dried to a moisture content of 0 to 1 % , preferably in a steam or rotary dryer or a matte grinding mill. This consumes steam or fuel in the form of natural gas or fuel oil.
  • the suspension smelting furnace may be a Flash Smelting Furnace (FSF) or a Flash Converting Furnace (FCF) .
  • FSF Flash Smelting Furnace
  • FCF Flash Converting Furnace
  • the settler (8) may be configured to receive the at least partially oxidised suspension (6) from the reaction shaft (5) at the landing zone (7) and to form a layer of matte (10) and a layer of slag (11) on top of the layer of matte (10) in the inner space (9) of the settler (8) .
  • the settler (8) may be configured to receive the at least partially oxidised suspension (6) from the reaction shaft (5) at the landing zone (7) and to form a layer of metal alloy (10) and a layer of slag (11) on top of the layer of metal alloy (10) in the inner space (9) of the settler (8) .
  • the jet of the at least partially oxidised suspension may be formed in the burner and guided to the settler through the reaction shaft.
  • the jet of the at least partially oxidised suspension (6) is in one embodiment heated to a temperature sufficient to completely melt the concentrate or matte.
  • the jet of the at least partially oxidised suspension (6) is preferably heated to a temperature of 1100 to 1600 °C, or 1250 to 1450 °C, for example 1300 °C. It has been found that heating the jet of the at least partially oxidised suspension (6) to these temperatures ensures that the suspension (6) is completely melted, and that the viscosity of the slag is suitable for separation of the two phases, i.e. slag and matte or metal alloy.
  • Concentrate may refer to ore concentrate that is the product of metal ore mines.
  • concentrate may comprise copper or nickel concentrate comprising copper and iron or nickel and iron in the form of copper or nickel and iron sulphides.
  • the exact composition of the concentrate may vary depending on the geographical origin of the metal ore.
  • the concentrate is fed to the reaction shaft in a solid state as fine granules.
  • the suspension smelting furnace may be an FSF and/or FCF and the metal alloy may comprise copper blister.
  • the metal alloy comprises at least 60 wt.-%, or at least 80 wt . - % or 100 wt.-% copper blister.
  • the copper blister may comprise copper, iron and sulphur.
  • the copper blister comprises 96 to 99.5 wt.-% copper and 0.01 to 0.5 wt.-% iron.
  • the suspension smelting furnace may be an FSF.
  • the FSF may be used in combination with a Peirce Smith converter to produce high grade nickel matte.
  • the high grade nickel matte may comprise nickel, iron and sulphur.
  • the high grade nickel matte comprises 96 to 99.5 wt.-% nickel and 0.01 to 0.5 wt . -% iron .
  • At least partially oxidised may refer to at least 60 wt.-%,70 wt.-%, 80 wt.-%, 90 wt.-% or 100 wt.-% of the iron present in the furnace feed being in an oxidized state.
  • An oxidized state may refer to the iron elements being in the form of oxidic compounds and the wt.-% may refer to the percentage of the iron present in the furnace feed being in an oxidized state. It is particularly advantageous to form a jet wherein at least 70 wt.-% of the iron is in an oxidized state because this reduces the oxidation requirement, which otherwise would be performed further down the process line.
  • the slag may comprise copper and iron oxides as well as fluxing agents if copper concentrate has been used and nickel and iron oxides as well as fluxing agents if nickel concentrate has been used.
  • the fluxing agents may be compounds comprising silica and/or calcium, in one embodiment, silicon dioxide is used as fluxing agents when the suspension smelting furnace is an FSF and lime, calcium carbonate or calcium oxide is used as fluxing agents when the suspension smelting furnace is an FCF.
  • the fluxing agents may be fed to the reaction shaft. The fluxing agents decrease the viscosity of the slag which facilitates the discharge of slag from the suspension smelting furnace and minimises the formation of material to be reverted.
  • the weight ratio of iron to silicon dioxide in the FSF slag is 0.9 to 2.0, or 0.7 to 1.8, for example 1.0 to 1.5.
  • Silicon dioxide, lime, calcium carbonate or calcium oxide is particularly useful as fluxing agents because they are relatively inexpensive while still giving the desired result of lowering the viscosity of the slag.
  • in communication with refers to an open space being available between the discussed components such that the components share the open space, and such that material can be freely exchanged between the components.
  • the settler (8) may further comprise two side walls, a bottom and a roof extending between the first end wall structure (27) and second end wall structure (28) .
  • the end wall structures (27,28) may have the form of a square or rectangle such that the side walls, bottom and roof extend from the peripheries of the first end wall (27) to the peripheries of the second end wall (28) , and thereby form a closed space between the end walls (27,28) , bottom, roof and sidewalls.
  • the reaction shaft (5) may be located in the roof and the layer of slag and matte or metal alloy (10,11) may rest on the bottom when the device is in use.
  • the bottom may slope downwardly for example in an inclined and/or curved manner towards the first and second taphole (15,17) for facilitating the discharge of slag and matte or metal alloy.
  • the feeding means (30) for feeding molten material (31) to the suspension smelting furnace comprises a launder or an opening for introducing the molten material (31) continuously or batchwise.
  • the feeding means (30) for feeding molten ma- terial (31) to the suspension smelting furnace may comprise a pot or a ladle for feeding the molten material (31) batchwise.
  • the molten material (31) may be fed to the suspension smelting furnace through gravity. This has the added utility that no energy is required for conveying the molten material (31) .
  • the temperature of the molten material (31) is preferably between 1000 °C and 1450 °C, or between 1220 °C and 1320 °C, for example 1270 °C. It has been found that these temperatures are high enough to maintain e.g. slag as the molten material in a liquid form but low enough not to damage the equipment used.
  • the suspension smelting furnace according to the first aspect may comprise an uptake shaft (13) for leading process gases (12) from the suspension smelting furnace via the uptake shaft (13) , wherein the uptake shaft (13) has a lower end in communication with the settler (8) in the second settler part (19) .
  • the process gases (12) may comprise sulfur dioxide, carbon dioxide, water, metal containing vapors, nitrogen and some reaction shaft product in the form of unsettled suspension particles.
  • the unsettled suspension particles which are dust, comprise copper or nickel compounds depending on if copper or nickel concentrate has been used in one embodiment.
  • the process gases (12) may be led to a heat exchanger for cooling the process gases followed by gas and solid separation.
  • the heat exchanger is typically but not necessarily a steam boiler, which cools the gases by evaporating water into steam. Dust may be separated from the gas in the gas and solid separation.
  • the gas and solid separator may be an electrostatic precipitator, which collects and separates the dust from the gases. In one embodiment, the dust is recycled back to the burner (4) of the reaction shaft (5) of the suspension smelting furnace. The heat from the cooling may be recovered and used as electricity.
  • the dust may be recycled from the uptake shaft (13) of the suspension smelting furnace (an FSF or FCF) via the heat exchanger and solid separation to the burner (4) of the same suspension smelting furnace.
  • the dust may be recycled from the uptake shaft (13) of one suspension smelting furnace, e.q. an FCF, via the heat exchanger and solid separation to the burner (4) of another suspension smelting furnace, e.g. an FSF. Recycling the dust improves the yield of the copper or nickel in the end product as some copper or nickel is still present in the dust.
  • the copper yield may be improved if copper concentrate is used, and the nickel yield may be improved if nickel concentrate is used.
  • the burner (4) according to the first aspect further be suitable for feeding a fluxing agent (1) , a reaction gas containing oxygen (1) , solidified slag (1) , dust and/or material to be reverted (1) .
  • the dust may be recycled and treated as described above.
  • the fluxing agents may be as described above.
  • reaction gas containing oxygen facilitates the oxidation of the concentrate/matte in the reaction shaft (5) .
  • sol idi fied s lag refers to s lag produced in a suspension smelting furnace , which has been discharged via the first taphole and solidified .
  • the slag may be discharged from an FCF and recycled to an FSF if copper concentrate has been used, for example .
  • the slag may be recycled from a Peirce Smith converter to an FSF if nickel concentrate has been used .
  • the slag may also be discharged from the same suspension smelting furnace to which it is recycled regardless of if copper or nickel concentrate has been used .
  • the slag may be solidified and granulated using water and/or air and/or nitrogen prior to being fed to the suspens ion smelting furnace .
  • Material to be reverted may refer to any reaction shaft product that has accumulated from the off-gas lines , the launders or ladles and the furnaces .
  • the material to be reverted may be fed to the suspens ion smelting furnace by mixing it with the main feed or through a separate feeder .
  • Solidified slag and material to be reverted usually comprise a significant amount of metals and by recycling these to the suspension smelting furnace (the same suspension smelting furnace from which they originate or to another suspension smelting furnace ) the remaining metals may be recovered .
  • no fluxing agents are fed to the burner ( 4 ) when the suspens ion smelting furnace i s an FCF and copper concentrate is used .
  • the copper present in the matte may be oxidised to convert a part of the copper into copper oxide .
  • the presence of copper oxide in the slag assists in liquefying the slag .
  • the desired ratio may be achieved by inj ecting the reaction gas containing oxygen through the burner to achieve a partial pressure (pO2) of from 1 to 100 Pa, or from 2 to 70 Pa, or from 10 to 30 Pa.
  • the concentration of oxidised copper in the slag is from 30 to 90 wt.-%, or from 35 to 70 wt.-%, or from 40 to 60 wt.-%, of the total weight of the slag. Accordingly, it may be possible to convert copper containing material to blister copper without use of conventional fluxing agents.
  • the desired temperature of the burner may be dependent on the desired concentration of oxidised copper in the converter slag. The temperature is typically at least 1200°C to ensure that the slag is in a molten phase and to attain acceptable yield of copper. When lower concentration of copper oxide is present in the slag a higher temperature may be required. The temperature is for example from 1220 to 1450°C, from 1250 to 1400, or from 1300 to 1380°C.
  • the oxidised copper concentration in the slag of the FCF may be 5 to 30 wt.-%.
  • the matte according to the first aspect may comprise copper matte and the metal alloy may comprise blister copper or the matte may comprise nickel matte.
  • the matte according to the first aspect may comprise copper matte or nickel matte, depending on if copper or nickel concentrate has been used.
  • the matte comprises at least 60 wt.-%, or at least 80 wt . - % , or 100 wt.-%, copper matte or nickel matte.
  • Matte may refer to the product of an FSF to which concentrate and oxygen has been fed.
  • the matte may comprise iron and copper sulphides and the copper content of the matte may be 40 to 75 wt.-%, if copper concentrate has been used.
  • the matte may comprise iron and nickel sulphides and the nickel content of the matte may be 13 to 72 wt.-%, if nickel concentrate has been used.
  • the matte is fed to the reaction shaft (5) of an FCF in a solid state as fine granules if copper concentrate has been used. As such, it may be required to cool down and granulate the matte originating from the FSF prior to feeding the matte to the FCF.
  • the matte is usually cooled and granulated by water and/or air and/or nitrogen and crushed into fine granules using a grinding mill. The grinding mill may use natural gas or steam as fuel.
  • the matte is fed to a Peirce Smith converter in a liquid state if nickel concentrate has been used.
  • the molten material (31) according to the first aspect may comprise slag, preferably wherein the slag comprises iron and copper oxides and fluxing agents or wherein the slag comprises iron and nickel oxides and fluxing agents .
  • the molten material (31) may comprise at least 60 wt . - % , or at least 80 wt.-% or 100 wt.-% slag.
  • the slag comprises iron and copper oxides and fluxing agents, if copper concentrate has been used.
  • the slag may comprise 0.4 to 40 wt.-% copper and 5 to 55 wt.-% iron.
  • the slag comprises iron and nickel oxides and fluxing agents, if nickel concentrate has been used.
  • the slag may comprise 0.3 to 30 wt.-% nickel and 25 to 60 wt.-% iron.
  • the slag may be recycled from the suspension smelting furnace slag discharge to the feeding means of the same suspension smelting furnace or to another suspension smelting furnace.
  • an FSF may be used to produce copper matte and the copper matte may be fed to an FCF, then the slag from the FCF may be recycled to the FSF in a molten form, if copper concentrate has been used.
  • an FSF may be used to produce nickel matte and the nickel matte may be fed to a Peirce Smith converter, then the slag from the Peirce Smith converter may be recycled to the FSF in a molten form, if nickel concentrate has been used.
  • the inventors have surprisingly found that by recycling molten material and particularly slag from one suspension smelting furnace to another suspension smelting furnace or from a Peirce Smith converter to a suspension smelting furnace in a molten form through the feeding means (30) described herein a number of advantages are achieved. Firstly, energy is saved as the material does not need to be cooled down, granulated and reheated between the furnaces. Also, water and/or air and/or nitrogen used in the granulation is saved. Further, by enabling material to be fed in a liquid form between the furnaces, material, e.g. slag, can be withdrawn and fed continuously between the furnaces.
  • the feeding means (30) according to the first aspect may be located closer to the first end wall structure (27) in the first settler part (18) than to the middle of the settler ( 8 ) .
  • the inner space (9) of the settler (8) may be in communication with the lower end of the reaction shaft (5) at a point of the settler (8) that is closer to the middle of the settler (8) than one of the ends of the settler (8) .
  • the settler (8) according to the first aspect may have an elongated configuration.
  • the settler has the shape of a cuboid, wherein the cuboid rests on its base in a horizontal position.
  • the settler may be 12 to 30 m long, 4 to 12 m wide and 1 to 3 m high.
  • the configuration of the settler (8) has a number of advantages.
  • the first part of the settler (18) has a low dust content, since the gas and dust are sucked together with the offgases through the gas phase of the second settler part (19) towards the uptake shaft (13) .
  • This lower dust content creates a relatively dust free atmosphere for the feeding means (30) .
  • This relatively dust free atmosphere is beneficial for minimising dust emissions from the furnace through the feeding means (30) .
  • the first part of the settler (18) has a lower pressure than the second settler part (19) , since gas and dust are sucked together with the off-gases through the gas phase of the second settler part (19) towards the uptake shaft (13) . This lower pressure is beneficial for minimizing SO2 emissions from the furnace through the feeding means (30) .
  • the suspension smelting furnace may comprise a partition baffle for preventing oxidised dust created in the suspension smelting furnace from entering at least a sec tion of the first settler part (18) .
  • the partition baffle may extend from the roof of the first settler part (18) downwards into the first settler part (18) .
  • the partition baffle may further minimise the dust content and lower the pressure in the first settler part (18) .
  • the end of the settler wall that is closer to the reaction shaft wears a lot, because of the closeness of the reaction shaft, which is the hottest part of the settler.
  • the end wall of the settler is located at a distance from this hottest part of the settler and thus wear will not be an issue.
  • the suspension smelting furnace comprises reducing agent feeding means for feeding reducing agent (s) into at least one of the layers of matte or metal alloy and the layer of slag (10,11) in the first settler part (18) .
  • the first settler part (18) may also comprise a burner for creating a reducing atmosphere in at least a section of the first settler part (18) .
  • the burner may be used for creating a reducing atmosphere in at least a section of the first settler part (18) , for example by consuming oxygen present in the first settler part (18) in the burning process. This further reduces the oxygen content in the first settler part (18) .
  • the first settler part (18) may have a first proximal end at the landing zone (7) and a first distal end at the opposite end of the first settler part (18) which first distal end also is the first end wall structure (27) of the settler (8) , and wherein the feeding means (30) is arranged at the first distal end of the first settler part (18) .
  • the feeding means (30) may be arranged in a side wall of the settler in the first settler part (18) . This is illustrated in Figure 3.
  • the feeding means (30) may be arranged in the roof of the settler in the first settler part (18) . This is illustrated in Figure 2.
  • the feeding means (30) may be at a distance of 0.2 to 2 m, or 0.4 to 1.8 m, or 0.6 to 1.6 m from the first end wall structure (27) .
  • the feeding means (30) may comprise a launder for guiding the molten material extending from the end wall structure (27) or side wall or roof of the settler (8) into the inner space of the settler (9) .
  • the lauder can guide the molten material such that the molten material is not in direct contact with the end wall structure (27) or side wall or roof of the settler (8) . In this way, the inner structure of the settler does not wear due to a constant contact with freshly introduced hot molten material.
  • the location of the feeding means (30) gives the advantage of maximising the distance between the inlet of the feeding means (30) and the reaction shaft (5) , which gives the maximum possible contact time between the molten material and the product of the furnace. This is beneficial as the amount of material exchange between the molten material, especially slag, and the reaction shaft product in maximised.
  • the second settler part (19) may have a second proximal end at the landing zone (7) and a second distal end at the opposite end of the second settler part (19) which second distal end also is the second end wall structure (28) of the settler (8) , and wherein the first taphole (15) and the second taphole (17) are arranged at the second distal end of the second settler part (19) .
  • the first tap hole (15) may be arranged in the side wall of the settler (8) in the second settler part (19) and preferably at a distance of less than 2 m from the end wall (28) .
  • the second tap hole (17) may be arranged in the side wall of the settler (8) in the second settler part (19) and preferably at a distance of less than 2 m from the end wall (28) .
  • Both the first and second tap hole (15,17) may be located in the sidewall or one of the first or second taphole (15,17) may be located in the sidewall and one of the first or second taphole (15, 17) may be located in the end wall (28) .
  • the location of the first and second tap holes (15, 17) gives the advantage of forcing the melt from the feeding means (30) to move through the reaction shaft output material before entering the tap hole.
  • the suspension smelting furnace according to the first aspect may comprise sucking means for leading process gases (12) from the suspension smelting furnace.
  • the sucking means is a blower further down the process gas line.
  • a method for producing matte or metal alloy in a suspension smelting furnace comprising: i. feeding concentrate or matte (1) by means of a burner for burning concentrate or matte (4) into a reaction shaft (5) of the suspension smelting furnace to form a jet of an at least partially oxidised suspension (6) in the reaction shaft (5) , ii.
  • the settler (8) has an inner space (9) and a first end wall structure (27) at one end of the settler (8) and a second end wall structure (28) at the opposite end of the settler (8) , and wherein the settler (8) extends in two opposite directions from the landing zone (7) so that the settler (8) comprises a first settler part (18) on a first side of the landing zone (7) and a second settler part (19) on an opposite second side of the landing zone (7) , iii.
  • a layer of matte or metal alloy (10) and a layer of slag (11) on top of the layer of matte or metal alloy (10) in the inner space (9) of the settler (8) iv. discharging slag (14) from the layer of slag (11) in the settler (8) through a first taphole (15) arranged in the second settler part (19)
  • the first taphole (15) is arranged in the vertical direction at a level above the second taphole (17)
  • the method further comprises vi .
  • suspension smelting furnace is an FSF
  • concentrate (1) may be fed to the burner (4) and if the suspension smelting furnace is an FCF, matte (1) may be fed to the burner (4) .
  • the method may comprise forming a layer of matte (10) under the layer of slag (11) and if the suspension smelting furnace is an FCF the method may comprise forming a layer of metal alloy (10) under the layer of slag (11) .
  • the suspension smelting furnace is an FSF copper or nickel concentrate may be fed to the burner .
  • the method according to the second aspect may further comprise leading process gases (12) from the suspension smelting furnace via an uptake shaft (13) having a lower end in communication with the settler (8) in the second settler part (19) .
  • the method according to the second aspect may further comprise feeding a fluxing agent (1) , a reaction gas containing oxygen (1) , solidified slag (1) , dust (1) and/or material to be reverted (1) by means of the concentrate burner or a matte burner (4) .
  • the matte may comprise copper matte and the metal alloy may comprise blister copper or the matte may comprise nickel matte .
  • the matte according to the second aspect may comprise copper or nickel matte , depending on if copper or nickel concentrate has been used .
  • the metal alloy according to the second aspect may comprise blister copper .
  • the molten material ( 31 ) according to the second aspect may comprise slag, wherein the slag may comprise iron and copper oxides and fluxing agents , or wherein the slag may comprise iron and nickel oxides and fluxing agents .
  • the feeding means ( 30 ) may be located closer to the first end wall structure ( 27 ) in the first settler part ( 18 ) than to the middle of the settler ( 8 ) .
  • the molten material ( 31 ) according to the second aspect may be recycled from a second suspension smelting furnace or a Peirce Smith converter to the feeding means ( 30 ) .
  • the molten material may be recycled from an FCF to an FSF if copper concentrate has been used or from a Peirce Smith converter to an FSF if nickel concentrate has been used .
  • matte is fed from the FSF to the FCF from which slag is recycled back to the FSF, if copper concentrate has been used .
  • matte is fed from the FSF to the Peirce Smith converter from which slag i s recycled back to the FSF, if nickel concentrate has been used .
  • the inner space ( 9 ) of the settler ( 8 ) may be in communication with the lower end of the reaction shaft (5) at a point of the settler (8) that is closer to the middle of the settler (8) than one of the ends of the settler (8) .
  • the settler (8) according to the second aspect may have an elongated configuration.
  • the first settler part (18) may have a first proximal end at the landing zone (7) and a first distal end at the opposite end of the first settler part (18) , which first distal end also is the first end wall structure (27) of the settler (8) , and wherein the feeding means (30) may be arranged at the first distal end of the first settler part (18) .
  • the second settler part according to the second aspect may have a second proximal end at the landing zone (7) and a second distal end at the opposite end of the second settler part (18) which second distal end also is the second end wall structure (28) of the settler (8) , and the first tap hole (15) and the second taphole (17) may be arranged at the second distal end of the second settler part (19) .
  • the process gases (12) from the suspension smelting furnace according to the second aspect may be led via the uptake shaft (13) by sucking.
  • the following example illustrates two processes where copper blister was produced in a process comprising an FSF and an FCF according to the invention.
  • copper concentrate was fed to the FSF where copper matte and slag was produced.
  • the copper matte was fed to the FCF where copper blister and slag was produced.
  • process 1 no slag was recycled to the FSF from the FCF in a molten form.
  • some slag was recycled from the FCF to the FSF in a solid form.
  • slag was recycled from the FCF to the FSF 5 in a molten and some slag was recycled in a solid form.
  • process 2 resulted in several OPEX savings as well as in a reduced water consumption compared to process 1 . This has a great positive effect on the environment as well as the economy .

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

La présente invention concerne un four de fusion en suspension, comprenant une cuve de réaction (5), un décanteur (8), un premier trou de coulée (15), un second trou de coulée (17) et des moyens d'alimentation (30) pour introduire un matériau fondu (31) dans le four de fusion en suspension.
PCT/FI2023/050211 2023-04-14 2023-04-14 Four de fusion en suspension Pending WO2024213821A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
AU2023442361A AU2023442361A1 (en) 2023-04-14 2023-04-14 Suspension smelting furnace
CN202380098431.3A CN121175440A (zh) 2023-04-14 2023-04-14 悬浮熔炼炉
PCT/FI2023/050211 WO2024213821A1 (fr) 2023-04-14 2023-04-14 Four de fusion en suspension
KR1020257037268A KR20250174055A (ko) 2023-04-14 2023-04-14 현탁액 제련로
CN202420780302.4U CN222352861U (zh) 2023-04-14 2024-04-15 悬浮熔炼炉

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/FI2023/050211 WO2024213821A1 (fr) 2023-04-14 2023-04-14 Four de fusion en suspension

Publications (1)

Publication Number Publication Date
WO2024213821A1 true WO2024213821A1 (fr) 2024-10-17

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KR (1) KR20250174055A (fr)
CN (2) CN121175440A (fr)
AU (1) AU2023442361A1 (fr)
WO (1) WO2024213821A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1979000058A1 (fr) * 1977-07-22 1979-02-08 Boliden Ab Procede de production de fer brut a partir d'un materiau contenant du sulfure de fer
WO2015158963A1 (fr) * 2014-04-17 2015-10-22 Outotec (Finland) Oy Procédé de production de cuivre de cathode

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1979000058A1 (fr) * 1977-07-22 1979-02-08 Boliden Ab Procede de production de fer brut a partir d'un materiau contenant du sulfure de fer
WO2015158963A1 (fr) * 2014-04-17 2015-10-22 Outotec (Finland) Oy Procédé de production de cuivre de cathode

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
J. LIU, A.E.M. WARNER, T.A. UTIGARD, C.M. DIAZ, M. FEZZANI: "Miniplant oxygen flash smelting of bulk copper-nickel sulfide concentrate: the effect of coke addition on process metallurgy", YAZAWA INTERNATIONAL SYMPOSIUM . METALLURGICAL AND MATERIALS PROCESSING: PRINCIPLES AND TECHNOLOGIES, vol. 2, 2 March 2003 (2003-03-02) - 6 March 2003 (2003-03-06), pages 131 - 141, XP009560100, ISBN: 0-87339-547-6 *

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CN121175440A (zh) 2025-12-19
CN222352861U (zh) 2025-01-14
KR20250174055A (ko) 2025-12-11

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