Recycling at Boliden´s Rönnskär Smelter: Metallurgical challenges · 2013. 10. 9. ·...
Transcript of Recycling at Boliden´s Rönnskär Smelter: Metallurgical challenges · 2013. 10. 9. ·...
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Recycling Metals from Industrial Waste [email protected]
Recycling at Boliden´s Rönnskär Smelter:
Metallurgical challenges
Theo Lehner Caisa SamuelssonMgr. Business Development Ass. ProfBoliden Mineral AB Luleå Univ. of Tech.Adj. ProfLuleå Univ. of Tech.
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Recycling Metals from Industrial Waste [email protected]
Rönnskär’s Metallurgy
Cu
Fe
S
Sulfurproducts
slag
Copper99.998%
O2
silica
+
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Recycling Metals from Industrial Waste [email protected]
Converting Refining
SecondaryRawMaterials
CopperConc.
Lead Conc.Dryer
FluidizedBed Roaster
ElectricSmelting Furnace
Flash Furnace
Fuming Plant
Kaldo PlantLead Refinery
Converter Aisle
Anode Casting Plant
PreciousMetalsPlant
Sulphur Products Plant
ElectrolyticRefinery
SulphuricAcidSulphurDioxide
GoldSilverSeleniumPt/Pd-sludge
Dryer
Dryer
CopperCopper SulphateCrude Nickel SulphateLead
Zinc ClinkerIron Sand
Gas FlowCopper FlowLead Flow
Electronic Scrap
1
4
32
7
5 6
8x Recycling
illustrated
9
Rönnskär’s MetallurgyFlowsheet
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Collecting all
1 Receiving, weighing, sampling, assaying
Contract
Radiak check on arrival
Weighing
Sampling
Sample preparation
Assaying
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Separating Arsenic from concentrate and waste by partial roasting
•Autogenous drying of sulfide sluge
2 Roasting
[FeAsS + CuFeS4] +O2
[FeCuSx + Fe3O4 ]
+ As4O6 (g) + SO2(g)
Note: buffered by excess FeSx / Fe3O4
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
2 Roasting
In off-gas system at decreasing temperature:
“MeS (s) + As4O6 (g) + Hg (g) + SO2(g) → As2O3(s) + HgS(s) +MeS”
Complex dust for stabilization and deposit
Dust capture and treatment
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Separating Zinc from Copper
•Collecting precious metals
3 Electric Smelting
ZnS
[Cu2S,FeS,Fe3O4,ZnS,SiO2, Au]
(ZnO-FeO-SiO2) +{ FeS-Cu2S,Au }+ SO2
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: Rönnskär’s Electric Furnace
!
Matte
Slag
Calcine + Cu-Zn-ashes + dust + SiO2
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Separating Copper from Fe-S
•Collecting precious metals
2(FeS)matte + 3(O2)air + (SiO2)flux= (2(FeO)x SiO2)slag + 2(SO2)off gas [1]
(Cu2S) + (O2) air = 2Cu + (SO2)off gas [2]
4 Converting
Substance Combustion Energy[ kJ/ kg]
Fe S2 8
S 10
C 33
Air + O2
N2 + SO2
BUT:
O2/kg ! And
BTU
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Slag - properties
•Impurity capacity
•Eq. slag, matte, metal…
•Composition
•Liquidus temperature
•Formation of high temperature melting phases
•Viscosity
•Etc…….
4 Converting
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Separating Organics from Copper and slag
•Collecting precious metals
5 KALDO
[Cu,Fe,Au,Ni,Zn,Al2O3,SiO2, plastics]
[Cu-Fe-Zn-Au-Ni] + (FeO-SiO2-Zn,Pb) + CO2
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Separating copper from others by electrorefining
6 Refining
Cu 99.998
CuSO4
NiSO4
PM slimes
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Recycling Metals from Industrial Waste [email protected]
4N8…but I do not know if my roots are in the mine or in scrap …
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Recycling Metals from Industrial Waste [email protected]
Metallurgy: collecting – separating
•Separating zinc and lead from slag
•Collecting precious metals
7 Fuming
(ZnO) + C Zn(g) + CO
Zn(g) + CO + O2 ZnO + CO2
(FeO-SiO2, Cu, Au,Ag, Ni,S)
(FeO-SiO2) + {Cu-Fe-S, Ag} + [Cu-Fe-Sb-Ni,Au,Ag]
“fume”
”Iron sand”
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Recycling Metals from Industrial Waste [email protected]
Designed for recycling ?
8 Complex scrap
AddedAg Al Au Be C Cr CRT Cu Fe In LCD Mg Ms Ni P Pb plast Pt Sb Sn SS Zn
Ag
Base Al
Au
Be
C
Cr
CRT
Cu
Fe
In
LCD
Mg
Ms
Ni
P
Pb
plast
Pt
Sb
Sn
SS
Zn
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Recycling Metals from Industrial Waste [email protected]
Conclusion :Metallurgists can!
if you let them do…. And can find them…..