The Integration of Plant Sample Analysis, Laboratory Studies, and Thermodynamic Modeling to Predict Slag-Matte Equilibri
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NICKEL sulfide concentrates are processed at the Kalgoorlie Nickel Smelter (KNS) in an Outotec-type flash furnace to produce nickel matte containing approximately 47 wt pct Ni. The nickel matte and slag are further separated by settling in an electric arc-heated zone attached to the flash furnace. The matte is further processed in a Peirce–Smith converter to produce Ni-rich matte containing approximately 66 wt pct Ni.[1] Iron-silicate slag is used in the converting process at KNS. The majority of the arsenic is observed to partition into the final matte rather than into the slag; i.e., the matte contains approximately 0.5 wt pct arsenic, while the slag contains less than 0.01 wt pct arsenic. Previous research by Font et al.[2] shows that the
TAUFIQ HIDAYAT, DENIS SHISHIN, PETER C. HAYES, and EVGUENI JAK are with the Pyrometallurgy Innovation Centre (PYROSEARCH), School of Chemical Engineering, The University of Queensland, Brisbane, QLD 4072, Australia. Contact email: [email protected] DAVID GRIMSEY is with the Nickel West Kalgoorlie Smelter, BHP Billiton, Kalgoorlie, WA 6430, Australia. Manuscript submitted May 26, 2017.
METALLURGICAL AND MATERIALS TRANSACTIONS B
distribution ratio of arsenic between calcium-ferrite slag and nickel-matte (LAs slag=matte ) is significantly higher than that between iron-silicate slag and nickel-matte, where LAs slag=matte ¼ ðwt pct As in slagÞ=ðwt pct As in matteÞ ½1 For optimization of the operation of the smelter, further information is required on the slag liquidus temperature and LAs slag=matte in the range of conditions of interest to KNS. The aim of the study is to determine the effect of changing slag composition from the iron-silicate slag toward the ‘‘ferrous-calcium-silicate’’ slag on the arsenic recovery into the slag at conditions relevant to the final converter blow. Analysis of the industrial slag samples quenched from the converter furnace, laboratory experimental investigation of the effect of CaO on the slag liquidus and LAs slag=matte , and thermodynamic assessment of Ni, Cu, and As in nickel sulfide smelting and converting using FactSage were carried out. The integration of the plant sample characterization and the high-temperature laboratory experimental and thermodynamic modeling programs ensure the high quality and applicability of the research outcomes.
II.
ANALYTICAL TOOLS
A. Electron Probe X-ray Microanalyzer The compositions of the phases in the industrial and equilibrated samples were measured using electron probe X-ray microanalysis (EPMA) (JEOL JXA 8200L*). An *JEOL is a trademark of Japan Electron Optics Ltd., Tokyo.
acceleration voltage of 15 keV and a probe current of 15 nA were used. The Duncumb–Philibert ZAF correction procedure supplied with the JEOL JXA 8200L probe was applied. Appropriate reference materials from Charles M. Taylor (Stanford, CA) were used as standards for the measurement of 10 elements in the sulfide and oxide phases, i.e., Ni, As, Cu, Fe, S, Ca, Si, Co Al, and Mg. The accuracy of the EPMA measurement was within 1 wt pct. Only
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