Integrated Experimental and Modelling Research for Non‐Ferrous Smelting and Recycling Systems

The Synergistic Copper Process concept

“…The liquidus temperatures in the FeO x -CaO-SiO 2 systems for the range of temperatures and oxygen pressures encountered in copper smelting and converting are well established (see Figure 8) (Nikolic, Henao, et al 2008;Nikolic, Hayes, et al 2008a, 2008b, 2008c, 2009a, 2009b, 2009cHidayat et al 2012Hidayat et al , 2015. These data and the use of thermodynamic databases and computer tools make it possible to predict the outcomes of these reactions and to optimise the process conditions in each case (Jak et al 2016).…”

“…Using the thermochemical information available and the databases that have been developed describing the chemical properties of the systems (Shishin et al 2016), in conjunction with the FactSage computer platform (FactSage 2002), it is possible to predict trends in process behaviour with reasonable certainty (Jak et al 2016). Input to the FactSage computer program in the form of the operational parameters for the processesthe feed components, their compositions and temperatures, and the total gas pressure of the system.…”

“…The calculations undertaken for copper flash smelting (Jak et al. 2016) have shown that there are significant potential economic benefits to the use of PCP in the matte smelting process. Assuming the PCP to consist of 51.1 wt-% Cu(OH) 2 , 27.9 wt-% CuSO 4 , 12.7 wt-% CaSO 4 , 5.0 wt-% CaCO 3 and 3.3 wt-% H 2 O a smelting operation with 150 t h −1 feed producing 262 kt Cu annually can increase copper output by approximately 3%, that is by 8000 t/y Cu by the addition of PCP with the only adjustment to the process being a change in the Fe/SiO 2 ratio in the slag from 1.1 to 1.2 and reducing the dust recycle from 6 to 5 wt-%; the silica flux requirements and slag fall are simultaneously reduced.…”

“…These data and the use of thermodynamic databases and computer tools make it possible to predict the outcomes of these reactions and to optimise the process conditions in each case (Jak et al. 2016).

Figure 8 Liquidus isotherms in the CaO–‘FeO’–SiO 2 system at oxygen pressure 10 −6 atm (Hidayat et al.

…”

Modelling of liquid phases and metal distributions in copper converters: transferring process fundamentals to plant practice

“…Using the thermodynamic databases and computer capabilities currently available it is possible to simulate the chemical and thermal changes taking place in different reactor configurations operating practices, and demonstrate the differences between different converter practices. Examples of this type of calculation to copper smelting and converting processes are given in (Jak et al 2016;Nikolic et al 2018d).…”