Modelling copper smelting – the flash smelting plant, process and equipment

Taskinen, Pekka; Lindberg, Daniel; Xia, Jiliang

doi:10.1080/25726641.2019.1688904

Cited by 13 publications

(19 citation statements)

References 82 publications

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“…The distribution coefficients of copper, iron, and sulfur between matte and slag were calculated using the following Eq. [3]: where [wt pct Me] and (wt pct Me) refer to the experimentally measured elemental concentrations in matte and slag, respectively. The distribution coefficients of elements investigated are displayed in Figure 6 as a function of matte grade.…”

Section: Distributions Of Copper Iron and Sulfur Between Matte Amentioning

confidence: 99%

“…COPPER flash smelting has been the leading technology for primary copper sulfide smelting [1] because of its low energy consumption and environmental impact, reduced operational costs, and high on-line availability. [2,3] The P SO 2 , generated by the slag and matte formation reactions, in the horizontal settler of the flash smelting furnace (FSF) is equal to the prevailing total pressure. [4,5] Since the late 1970s, the smelting capacity of the FSF has been increased by 100 to 200 pct since technical oxygen (> 95 pct O 2 ) was adopted into copper smelting, [2,6] resulting in increased SO 2 content of the off-gas to > 50 vol pct SO 2 .…”

Section: Introductionmentioning

confidence: 99%

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Equilibrium of Copper Matte and Silica-Saturated Iron Silicate Slags at 1300 °C and $$ P_{{{\text{SO}}_{ 2} }} $$ of 0.5 atm

Chen

Avarmaa

Klemettinen

et al. 2020

Metall Mater Trans B

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Experimental study on the phase equilibria between copper matte with silica-saturated iron silicate slags was conducted at 1300 °C and $$ P_{{{\text{SO}}_{ 2} }} $$ P SO 2 = 0.5 atm. The high-temperature isothermal equilibration in silica crucibles under controlled flowing CO-CO2-SO2-Ar was followed by quenching in an ice–water mixture and direct phase composition analyses by an electron probe X-ray microanalyzer. The equilibrium compositions for matte and slag, as well as the distribution coefficients, were displayed as a function of matte grade. The data set obtained at $$ P_{{{\text{SO}}_{ 2} }} $$ P SO 2 = 0.5 atm and the previous study at $$ P_{{{\text{SO}}_{ 2} }} $$ P SO 2 = 0.1 atm by the authors enabled an investigation on the impacts of $$ P_{{{\text{SO}}_{ 2} }} $$ P SO 2 as well as Al2O3 and CaO additions on phase equilibria in the multiphase copper matte smelting system. Thermodynamic calculations using MTDATA software were performed to compare the experimental results with modeling. The present results enrich the fundamental thermodynamic information for the matte/slag/tridymite/gas equilibria in the primary copper smelting process at high $$ P_{{{\text{SO}}_{ 2} }} $$ P SO 2 .

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Section: Distributions Of Copper Iron and Sulfur Between Matte Amentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Equilibrium of Copper Matte and Silica-Saturated Iron Silicate Slags at 1300 °C and $$ P_{{{\text{SO}}_{ 2} }} $$ of 0.5 atm

Chen

Avarmaa

Klemettinen

et al. 2020

Metall Mater Trans B

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“…Many industrial applications have been improved over the years thanks to the use of computational fluid dynamics (CFD), a technique that helps to significantly improve process design capabilities. Industrial drying processes [1] are among the applications that benefit from CFD, and many kinetic models have been developed [2]. The adaptability of CFD allows different flow processes to be modeled.…”

Section: Introductionmentioning

confidence: 99%

Modeling a Fluidized Bed Dryer through Computational Fluid Dynamics and the Discrete Element Method

et al. 2021

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The internal phenomena of a concentrate dryer were studied to significantly improve the modeling and design of a melting process. The present study coupled computational fluid dynamics and the differentiated elements method to obtain detailed information about complex phenomena in the simulated obtention of copper metal while keeping fluids physically stable. It was possible to understand the behavior from the point of view of the fluid and dynamics with acceptable margins of error. The study is part of the critical process line at Caletones Smelter in Chile, which produces ca. 450 000 tons of fine copper per annum, representing 2 % of total annual global copper demand and making the subject of this study highly relevant.

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“…A significant increase in modeling development has been seen since the introduction of commercially available computational fluid dynamics (CFD) software. The development of the Outotec flash smelting furnace (FSF) and process modeling has been reviewed in a recent review paper [23]. The aim of the modeling studies reported here is to find a feasible computational method by using commercial simulation software packages for gaining a better understanding of the fluid dynamics of the settling matte droplets in the slag layer.…”

Section: Introductionmentioning

confidence: 99%

“…However, as the geometries and phenomena in the models are computationally extremely intensive, the additional features have to be included one by one as a longer-term target. Finally, the models and knowledge developed will be used to help find ways to reduce copper losses and develop processes and their operational efficiency in a similar manner as has been done with the FS reaction shaft models [23]. In this paper, the fluid dynamics modeling results are presented, and the results obtained with the two software packages are compared.…”

Section: Introductionmentioning

confidence: 99%

Computational Approaches for Studying Slag–Matte Interactions in the Flash Smelting Furnace (FSF) Settler

2020

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Computational methods have become reliable tools in many disciplines for research and industrial design. There are, however, an ever-increasing number of details waiting to be included in the models and software, including, e.g., chemical reactions and many physical phenomena, such as particle and droplet behavior and their interactions. The dominant method for copper production, flash smelting, has been extensively investigated, but the settler part of the furnace containing molten high temperature melts termed slag and matte, still lacks a computational modeling tool. In this paper, two commercial modeling software programs have been used for simulating slag-matte interactions in the settler, the target being first to develop a robust computational fluid dynamics (CFD) model and, second, to apply a new approach for molten droplet behavior in a continuum. The latter is based on CFD coupled with the discrete element method (DEM), which was originally developed for modeling solid particle-particle interactions and movement, and is applied here for individual droplets for the first time. The results suggest distinct settling flow phenomena and the significance of droplet coalescence for settling velocity and efficiency. The computing capacity requirement for both approaches is the main limiting factor preventing full-scale geometry modeling with detailed droplet interactions.

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Modelling copper smelting – the flash smelting plant, process and equipment

Cited by 13 publications

References 82 publications

Equilibrium of Copper Matte and Silica-Saturated Iron Silicate Slags at 1300 °C and $$ P_{{{\text{SO}}_{ 2} }} $$ of 0.5 atm

Equilibrium of Copper Matte and Silica-Saturated Iron Silicate Slags at 1300 °C and $$ P_{{{\text{SO}}_{ 2} }} $$ of 0.5 atm

Modeling a Fluidized Bed Dryer through Computational Fluid Dynamics and the Discrete Element Method

Computational Approaches for Studying Slag–Matte Interactions in the Flash Smelting Furnace (FSF) Settler

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