Minimization of Copper Losses in Copper Smelting Slag During Electric Furnace Treatment

Abstract

In the quest to achieve the highest metal recovery during the smelting of copper concentrates, this study has evaluated the minimum level of soluble copper in iron-silicate slags. The experimental work was performed under slag-cleaning conditions for different levels of Fe in the matte and for a range of Fe/SiO 2 ratios in the slag. All experiments were carried out under conditions where three phases were present (copper-matte-slag), which is the condition typically prevailing in many slag-cleaning electric furnaces. The %Fe in the electric furnace matte was varied between 0.5 wt.% and 11 wt.%, and two different Fe/SiO 2 ratios in the slag were used (targeted values were 1.4 and 1.6). All experiments were performed at 1200°C. From thermodynamic considerations, from industrial experience, and from the results obtained in this study, the minimum soluble copper content in the electric furnace slag is expected to be near 0.55 wt.% Cu. This level does not account for a portion of the copper present as mechanically entrained matte/metal droplets. Taking this into account, the current authors believe an overall copper level in discard slag between 0.7 wt.% and 0.8 wt.% can be obtained with optimal operating conditions. For these conditions, the copper losses in the slag are roughly 75% as dissolved copper and 25% as entrained matte and copper. Such conditions include operating the electric furnace at metallic copper saturation, maintaining the %Fe in the electric furnace matte between 6 wt.% and 9 wt.%, not exceeding a slag temperature of 1250°C, and controlling the Fe/SiO 2 ratio in the smelting furnace slag at £1.5. In addition, magnetite reduction needs to be performed efficiently during the slag-cleaning cycle so as to maintain a total magnetite content of £7 wt.% in the discard slag. The authors further consider that under exceptionally well-controlled conditions, a copper content in electric furnace discard slag between 0.55 wt.% and 0.7 wt.% can be obtained, by minimizing entrained matte and copper solubility in the discard slag.

Thermodynamic Properties and Phase Equilibria in the Ternary Cu-Pb-Fe System

“…On the other hand, the studies on removal of lead and iron from Cu-Fe-Pb alloys had been performed [74]. Recently, Coursol et al [75] came to the conclusion that minimum soluble copper content in the electric furnace slag is expected to be about 0.55 wt% Cu ranging up to about 1.3 wt%. However, good understanding of the achievable theoretical limits will allow one to assess the discrepancy between the real situation and ideal conditions of phase equilibrium.…”

Study of the corrosion resistance on nano-ZrO2 doped MgO ceramic composites by copper slag.

“…% Cu) as secondary phases. Iron is the main element in copper slags, > 40% [5,6]. Data of XRF analysis collected in Table 1 indicate that the copper and iron contents (in wt.%) are 1.84 and 42.82, respectively, are in the above-mentioned ranges for copper slags wt.…”

Losses of copper and precious metals with slag in mine smelting of copper-, lead containing raw materials

“…The envisaged measures to reduce the loss of metals with slag using additional equipment (electrically heated sedimentation tanks) or by flotation do not provide the proper effect of increasing the extraction of metals. The loss of non-ferrous metals with slag is a global problem that every enterprise tries to solve with the help of locally available resources and technical means [1][2][3].…”