Mathematical modeling of minor-element behavior in flash smelting of copper concentrates and flash converting of copper
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I. I N T R O D U C T I O N
THE behavior of arsenic, antimony, bismuth, and lead is o f great importance during copper smelting operations. These elements can affect adversely the mechanical properties of product copper and also are a major concern as environmental pollutants. Basic studies on the behavior of these elements in the Noranda process t~-2~and Peirce-Smith converting rs 61 have been reported in recent years. Jalkanen et al.17] analyzed the distribution of the minor elements in the settler region of the flash smelting furnace. They also included the effect of suspension of one phase in another, resulting from incomplete settling. Fairly good agreement was obtained between the observed and predicted values, indicating the validity of such thermodynamic analysis. Makinen and Hafs fS1 have reported a pilot plant study on the behavior of some minor elements during flash smelting. A multivariate model was developed by the authors for in-house use to predict the elimination under various conditions, but the details were not reported. Itagaki and Yazawa E61 extended their thermodynamic analysis to the flash reactor by introducing a vaporsaturation factor. However, this approach does not address the varying temperature of the particles, and the effect of various operating parameters cannot be obtained. An offshoot of flash-smelting technology is the flashconverting process, proposed as an alternative to conventional Peirce-Smith converting. 19,~~ Asteljoki and Kyto I~1 recently have presented pilot plant data on the behavior of minor elements during flash converting. P.C. CHAUBAL, formerly Assistant Professor, Department of Metallurgy and Metallurgical Engineering, Umversity of Utah, Salt Lake City, UT, is wlth Inland Steel Company, Research Laboratories, 3001 E. Columbus Drive, E. Chicago, IN 46322. H.Y. SOHN is Professor, Department of Metallurgy and Metallurgical Engineering, University of Utah, Salt Lake City, UT 84112-1183. D.B. GEORGE is Techntcal Superintendent, Kennecott Utah Smelter, P.O. Box 329, Magna, UT 84044 L.K. BAILEY, formerly Metallurgical Engineer, Kennecott, Salt Lake Ctty, UT, is Manager, Waste Management Programs for Kerr-McGee Corporation, Technology Division, P O. Box 25861, Oklahoma City, OK 73125. Manuscript submitted July 31, 1987. METALLURGICAL TRANSACTIONS 13
A fundamental model describing minor-element behavior during oxidation of chalcopyrite concentrate or copper mattes has not been presented yet. In the present work, thermodynamics and mass-transfer process are combined to develop a model based on first principles to study the minor-element behavior in flash-smelting and flash-converting processes. This study deals with the behavior of four of the most undesirable species in copper smelting, i.e., arsenic, antimony, bismuth, and lead. II. M O D E L D E V E L O P M E N T The elimination of minor elements to the gas phase takes place by volatilization as the concentrate particles travel down the reactor shaft. Once the particles reach the molten bath below, the oxides produced go
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