Optimization of converting process for matte of oxidized nickel ores and sulfide copper ores joint smelting based on thermodynamic simulation

Abstract

The paper presents the results obtained in the thermodynamic modeling of converting copper-nickel matte (11.3 wt.% Ni + Cu + + Co, 61.5 wt.% Fe, 25.9 wt.% S) produced by joint smelting of oxidized nickel ore and sulfide copper ore. Calculations were made in the approximation of ideal molecular solutions using the HSC Chemistry software package (Outotec Research Oy, Finland). The possibility of low-iron matte, converter slag and gas phase separation was shown. Estimated conditional equilibrium constants of exchange reactions between low-iron matte and slag (KNi/Fe = 0.004÷0.005, KCo/Fe = 0.056÷0.099) are close to ideal values. Statistical data processing was carried out using the mathematical experiment planning method. The converting temperature (t = 1100÷1300 °C) and iron and sulfur oxidation completeness level (q = 0.9÷1.0) determining the air and flux (SiO2) consumption were chosen as the factors to study. Obtained mathematical models of the process were used for its optimization. It was shown that the best converting performance can be achieved at t = 1150 °С and q = 0.950 when the low-iron matte contains 70.7 wt.% Ni + Cu + Co. At a yield of 8.74 % of the charge mass, the nickel, copper and cobalt recovery rates are 67.9, 97.9 and 9.1 %, respectively. The supposed air consumption (145.1 m3 (under normal conditions) per 100 kg of matte) and SiO2 (34.4 kg per 100 kg of matte) as well as slag yield (89.1 % of the charge mass) are close to working regime parameters. The results of the study confirm the possibility of cost-effective processing of poor copper-nickel matte and after experimental verification they can be used to develop automation flowcharts for converter departments at existing and designed production facilities.