Optimizing of Work Arc Furnace to Decopperisation of Flash Slag

Bydałek, A. W.; Biernat, S.; Wołczyński, W.

doi:10.1515/afe-2015-0052

Cited by 5 publications

(6 citation statements)

References 6 publications

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“…Moreover, morphology of the large copper droplet, Fig. 5, could be compared with the morphology of the droplet after common coagulation made under industry conditions in the KGHM -Polska Miedź (Polish Copper) S.A., [3], [4], [5].…”

Section: Coagulation and Solidification Of The Copper Dropletsmentioning

confidence: 99%

Sedimentation of Copper Droplets after their Coagulation and Growth. Laboratory Scale

Wołczyński¹,

Bydałek²

2016

Archives of Foundry Engineering

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The suspension of copper droplets in the slag is considered. The copper/slug suspension is delivered as the product from the direct-toblister process which is applied in the KGHM -Polska Miedź (Polish Copper) S.A. factory. The droplets / slag suspension was treated by a special set of reagents (patented by the authors) to improve the coagulation process. On the other hand, the observations are made to estimate if the melting / reduction process in the furnace is sufficiently effective to avoid a remaining of carbon in the copper droplets. The coagulation process was carried out in the crucible (laboratory scale). However, conditions imposed to the coagulation / solidification process in the laboratory scale were to some extent similar to those applied usually in the industry when the suspension is subjected to the analogous treatment in the electric arc-furnace. Some suggestions are formulated how to improve the industrial direct-to-blister process.

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Section: Coagulation and Solidification Of The Copper Dropletsmentioning

confidence: 99%

Sedimentation of Copper Droplets after their Coagulation and Growth. Laboratory Scale

Wołczyński¹,

Bydałek²

2016

Archives of Foundry Engineering

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“…The eutectic solidification process is a decisive one. The separation of the components [5][6][7] determines the material properties of alloys formed in slag, such as Cu-Pb-Fe. The existence of concentration gradient causes the diffusion in the solid state during the crystallization, what fosters the elimination of segregation.…”

Section: The Isolation and Formation Of The Solid Phasementioning

confidence: 99%

The Concept of Slag Decopperisation in the Flash Furnace Process by Use of Complex Reagents

Bydałek¹,

Wołczyński²,

Biernat³

2015

Archives of Metallurgy and Materials

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The article presents an outline of the new technology of pyrometallurgical processing of slag in the direct-to-blister process. The analysis is based on the example of the production process of KGHM Polish Copper SA. A new way of implementing the technology of recovery of copper from the flash furnace slag by means of different feedstocks has been proposed. The method of controlling the processes is another innovation discussed in the paper. The presented concept intensify the reduction reactions, using the Carbo-N-Ox method, of copper compounds to forms of metallic phases in the slag. The processes of coagulation are accelerated and the processes crystallization of metallic phases are under control.Keywords: slag, decopperisation, reagents, recycling W artykule przedstawiono zarys nowej technologii pyrometalurgicznego przetwarzania żużli w procesie jednostadialnego otrzymywania miedzi. Zaproponowano nowy sposób realizacji technologii odzyskiwania miedzi z żużli z pieca zawiesinowego z zastosowaniem odmiennych materiałów wsadowych. Zaproponowano sposób sterowania procesami. Proponowana koncepcja prowadzi do intensyfikowania reakcje redukcji związków miedzi, metodą Carbo-N-Ox, do postaci faz metalicznych w żużlu. Przyspieszone też zostaną procesy koagulacji faz metalicznych. Zaproponowany został sposób analizy formowania się faz metalicznych w żużlu.

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“…Large ions with low charges (Ca 2+ , Na 1+ ) weakly attract oxygen. Tiemkina [9,14] however, pointed that, the creation of a multi-component systems of ionic complexes-rather than the individual components of the ion-is still a major obstacle in the analysis of local ordered conditions. Other studies [11][12][13] show occurrence of additional melted (melting) and breaking of silicate tetrahedral bridges.…”

Section: The Structure Of Slag In the Liquid Statementioning

confidence: 99%

“…An important factor contributing to the formation of metallic phases of solid slag may be also a segregation of the ingredients during solidification process (including during eutectic solidification [14][15][16][17]). The existence of concentration gradient causes the diffusion in the solid state during the crystallization.…”

Section: The Structure Of Slag In the Liquid Statementioning

confidence: 99%

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Analysis Of Separation Mechanism Of The Metallic Phase Of Slag In The Direct-To-Blister Process

Wołczyński¹,

Bydałek²,

Schlafka³

et al. 2015

Archives of Metallurgy and Materials

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The article discusses the structure of the slag in the liquid state, the properties and interactions within the slag. The analysis of structures occurring in slag suspension were presented with regard to differences in chemical composition in micro-areas. Two different mechanisms for formation of precipitates in Cu-Fe-Pb alloys during extraction were showed.Keywords: decopperised, crystallisation, slag, structure.W artykule omówiono strukturę żużli w stanie ciekłym, oraz właściwości i oddziaływania wewnątrz żużli. Przedstawiono wyniki analiz występujących struktur w żużlu zawiesinowym, w odniesieniu do różnic w składzie chemicznym w mikroobszarach. Wskazano na dwa różne mechanizmy tworzenia wydzieleń stopu Cu-Fe-Pb podczas ekstrakcji. Analysis of the problems IntroductionIncreasing metallurgical yields and improving quality of the metals/alloys requires introducing numerous processes and techniques during designing of solidification, melting and casting. These are, reported in literature, reducing metals oxides present within slags [1][2][3], melt protecting with fluxes [4], melt modification before casting into foundry molds [5,6], riser protecting with insulating sleeves against surplus heat loses [7] as well as considering back-diffusion phenomena in solidifying metals and alloys [8]. The present paper deals with suspension slags of Cu production, their structure, composition, and mechanisms of extraction processes which proceed inside the slags.Suspension slag is formed during the extraction process of copper production in the melting flash. Then-formed suspension slag is directed to the electric furnace-arc where it is decopperisied. Decopperisation causes the reduction of oxides forms of primarily copper, lead and iron and then segregation of a Cu-Fe-Pb alloy. The moment of slag contacting the layer of coke reduction (phase 1), the majority of Cu 2 O is removed and the total copper content of the slag decreases to approx. 2,0%.Over the next 4-5 hours (phase 2) of the process, the content decreases to approx. 0.8%. Following the tapping process (phase 3), the content keeps decreasing and reaches a minimum of approx. 0.5%. The changes of concentration in the slag (particularly in phase 2 and 3) affect the structure and properties what have the decisive impact on the slag suspension decopperisation. The structure of slag in the liquid stateThe properties of the slag are determined by its structure. Slag structure can be described either by the molecular theory [1] or can be analyzed as electrolytes [2]. A. Bydałek and M. Brzózka [3] assumed that the slags in the liquid state were the boundary type of strong electrolyte solutions. In that case slag has ordered construction of the ion and tend to surround cations with oxygen ions. Small ions with high charge (Si 4+ , B 3+ ) strongly attract oxygen and produce a significant density of their immediate environment. Large ions with low charges (Ca 2+ , Na 1+ ) weakly attract oxygen. Tiemkina [9,14] however, pointed that, the creation of a multi-component systems ...

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Optimizing of Work Arc Furnace to Decopperisation of Flash Slag

Cited by 5 publications

References 6 publications

Sedimentation of Copper Droplets after their Coagulation and Growth. Laboratory Scale

Sedimentation of Copper Droplets after their Coagulation and Growth. Laboratory Scale

The Concept of Slag Decopperisation in the Flash Furnace Process by Use of Complex Reagents

Analysis Of Separation Mechanism Of The Metallic Phase Of Slag In The Direct-To-Blister Process

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