The investigation results on the reduction of slag from flash smelting furnace and the use of carbon granulates obtained from fine-grained waste materials of both the coal enrichment and coking processes have been presented in the paper. The investigation results on the reduction of slag from flash furnace and the use of carbon granulates obtained from fine-grained waste materials of both the coal enrichment and coking processes have been presented in the paper

B. Oleksiak

G. Siwiec

L. Socha

T. Matuła

W. Stanek

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585METALURGIJA 53 (2014) 4, 585-587G. SIWIEC, B. OLEKSIAK, T. MATUŁA, L. SOCHA, W. STANEKREDUCTION OF COPPER SLAG WITH THE USE OF CARBON GRANULATESReceived – Prispjelo: 2013-11-05Accepted – Prihvaćeno: 2014-04-30Preliminary Note – Prethodno priopćenjeISSN 0543-5846METABK 53(4) 585-587 (2014)UDC – UDK 669.3:666.88:66.094.1:669.041=111G. Siwiec, B. Oleksiak, T. Matuła - Silesian University of Technology, Faculty of Materials Engineering and Matallurgy, Katowice, PolandL. Socha - Technical university of Ostrava, Faculty of Metallurgy and Materials Engineering, Ostrava, Czech RepublicW. Stanek - Silesian University of Technology, Faculty of Power and Environmental Engineering, Gliwice, PolandThe investigation results on the reduction of slag from fl ash smelting furnace and the use of carbon granulates ob-tained from fi ne-grained waste materials of both the coal enrichment  and coking processes have been presented in the paper. The investigation results on the reduction of slag from fl ash furnace and the use of carbon granulates obtained from fi ne-grained waste materials of both the coal enrichment and coking processes have been presented in the paper.Keywords: copper, slag, reduction, fl ash furnace, carbon granulateINTRODUCTIONThe processes of metal recovery from primary raw materials are inevitably connected with the large scale generation of harmful wastes. This in turn means de-struction of environment. At the same time the character of the processes require large amount of unrenewable natural resources such as metal ores and coal. Their ex-ploration has a negative effect on environment and re-duces the existing natural deposits. Over the last decade coal deposits have been reduced by 50 % which is il-lustrated in Figure 1.Having analyzed how fast the metals ore reserves are depleted, it is almost sure that their production will have to be seriously reduced in the forthcoming 20 years. Figure 2 presents the relevant data. One of the ways to reduce the over-exploration of mineral raw ma-terials under discussion is the recycling of scrap iron and metal bearing wastes. The reduction of energy con-sumption in the course on the two mentioned above processes or the use of alternative fuels might also help solve the problem.The investigation have been carried out for many years, specially with regard to technology of pig-iron and steel production as well as lead recovery form scrap wastes [1 - 9]. Numerous research reports proved that the thermoecological cost of many types of waste mate-rials used in the process can be signiﬁ cantly lowered in comparison with the processes which make use of pri-mary raw materials [10 -14]. The investigation results on the reduction of slag from ﬂ ash furnace and the use of carbon granulates obtained from ﬁ ne-grained waste materials of both the coal enrichment and coking proc-esses have been presented in the paper. The slag gener-ated during the blister copper production is character-ized by a considerable amount of this metal, at times up to 16 % mass. The authors discuss the potentiality of replacing the breeze, which is currently used, by carbon granulates made of cheaper waste materials containing carbon. The introduction of such reducers might signiﬁ -cantly lower the unit cost of copper smelting since the average price of anthracite dusts is ca. 90 euro/Mg and the price of breeze 50 Euro/Mg. The cost of caking op-eration reaches 30 Euro/Mg.0501001502002502001 2002 2003 2004 2005 2010 2011 2012YearsR/P / years0 50 100 150 200 250 300iron orecopper orezinc orelead oretin oregold oresilver oreYearsFigure 1 Coal reservesFigure 2 Suffi  ciency of non-ferrous metal ores586  METALURGIJA 53 (2014) 4, 585-587G. SIWIEC et al.: REDUCTION OF COPPER SLAG WITH THE USE OF CARBON GRANULATESTHE EXPERIMENTAL PARTIn Table 1, a composition of ﬂ ash smelting slag that was used in all the experiments is presented. As carbon reducers, coke and anthracite dusts were applied.Table 1 Chemical composition of the investigated slagFractions of individual components / %massCopper slagCoke dustAnthracite dustCu 11,6Pb 3,25Fe 10,63S 0,03 0,6 1,7CaO 13,28SiO2 31,84MgO 5,08Al2O3 8,95C 88,5 10,3Ash 60,0 25,1All reductive smelting processes were performed in a PT 40 electric furnace. The smelting process involved two basic operations:   Introducing a reducer and limestone into the melt-ing pot preheated to a required temperature.   Pouring liquid copper slag over the components. The operations have been performed in the system similar to technological process realized at KGHM ‘Polska Miedz’. Before smelting, reducers were sub-jected to the agglomeration process in a balling disc us-ing the following parameters: disc rotation = 28 rpm, disc slope angle = 40 degrees.STUDY RESULTS AND DISCUSSIONIn Table 2, post-reduction copper, lead and iron con-tents in the slag are presented. Based on these values, a so-called slag reduction degree was estimated using the following equation: %100)( 000 ⋅⋅⋅−⋅= omkkmmR mCmCmCS  (1)where:m0 and mk – initial and ﬁ nal slag mass, respectivelyC0m and Ckm –  initial and ﬁ nal metal content in the slag, respectivelyIn Figures 3 and 4, graphic interpretations of the re-sults against the reduction curve determined based on the results of smelting processes with coke breeze are presented. For all applied carboniferous materials, the copper reduction degree was above 80 % as early as after one hour. For 5-hour processes, the value of this parameter was higher than 97 %. The lead reduction de-gree depended on the process duration and was as fol-lows: 25 % to 84 % for one hour and 83 % to 92 % for 5 hours. The experimental ﬁ ndings also showed that for the granulated reducer, the reduction degrees of both copper and lead were higher than for the ﬁ ne-grained reducer, which was probably a result of better kinetic conditions of mass transfer in the gaseous phase in the reduction process of the discussed oxides. Table 2  Contents of selected components in the slag after the reduction process*Charge material Time/ hCu content in the slag / %massPb content in the slag / %massCureduc./ %Pb redu / %Slag + bulk coke dust1 0,024 0,018 83,21 56,52Slag + bulk coke dust5 0,003 0,0068 98,00 83,86Slag + coke dust granulate1 0,003 0,0059 97,84 84,84Slag + coke dust granulate5 0,0015 0,0038 99,10 91,87Slag + bulk anthra-cite dust1 0,0123 0,013 90,66 64,80Slag + bulk anthra-cite dust5 0,0021 0,0047 98,51 88,14Slag + anthracite dust granulate1 0,0034 0,0332 97,90 26,96Slag + anthracite dust granulate5 0,002 0,0059 98,90 88,41* - Mean values from two experiments50607080901000 1 2 3 4 5 6Time / hPb reduction degree / %slag+coke dust granulateslag+coke dust granulateslag +bulk anthracite dustslag+anthracite dust granulatestandart curve of Pb reduction7080901000 1 2 3 4 5 6Time / hCu reduction degree / %slag+bulk coke dust slag+coke dust granulateslag+bulk anthracite dust slag+anthracite dust granulatestandard curve of Cu reductionFigure 3 Results of lead reduction from industrial oxide slagsFigure 4  Results of copper reduction from industrial oxide slags587METALURGIJA 53 (2014) 4, 585-587G. SIWIEC et al.: REDUCTION OF COPPER SLAG WITH THE USE OF CARBON GRANULATESSUMMARYThe experiments demonstrated a potential use of granulates made of ﬁ ne-grained carboniferous materials as reducers in the process of copper oxide slag smelting. However, it should be noted that with respect to appli-cation of these granulates, an appropriate agglomera-tion technology and studies on the granulate effects on the environment during their combustion should be de-veloped and conducted, respectively.AcknowledgementsThe study was conducted under the Research Project No. PBS1/A1/21/2012, ﬁ nanced by the National Re-search and Development Center – Poland.REFERENCES[1] M. Czapla, M. Karbowniczek, A. Michaliszyn: Archives of Metallurgy and Materials 53 (2008) 2, 559-565.[2] P. Migas, M. Karbowniczek: Archives of Metallurgy and Materials 55 (2010) 4, 1147-1157. [3] K. Michalek, L. Camek, Z. Piegza, V. Pilka, J. Moravka: Archives of Metallurgy and Materials 55 (2010) 4, 1159-1165.[4] M. Niesler, J. Stecko, L. Blacha, B. Oleksiek: Metalurgija 53 (2014) 1, 37-39.[5] J. Lipart, T. Matuła, M. Niesler, L. Blacha, J. Filipczyk: Metalurgija 52 (2013) 4, 493-496[6] M. Niesler, L. Blacha, J. Łabaj, T. Matuła, Metalurgija 52 (2013) 4, 521-524. [7] J. Łabaj, M. Słowikowski,W. Żymła, J. Lipart: Metalurgija 52 (2013) 1, 68-70. [8] H. Beer, W. Beier: Stahl und Eisen (1991) 11, 25-37.[9] J. Tomeczek, S. Gil: Fuel Processing Technology, 91 (2010), 1564-1568.[10] S. Gil, P. Mocek, W. Bialik: Chemical and Process Engine-ering 32 (2011) 2, 155-169.[11] N. Gugus: Izwiestija Vyssz. Uczeb. Zav., Czernaja Mietal-lurgija (1990) 11, 8-10.[12] S.N. Pietruszow, W.L. Bosyj: Metallurg (1982) 5, 9-10.[13] A. Ziębik, W. Stanek: International Journal of Energy Re-search, 30 (2006) 2, 101-114.[14] J. Lipart, T. Matuła, M. Niesler, L. Blacha, J. Filipczyk: Metalurgija 52 (2013) 4, 493-496.Note: Nowak P. is responsible for English language, Katowice, Poland

Reduction of copper slag with the use of carbon granulates

The investigation results on the reduction of slag from fl ash smelting furnace and the use of carbon granulates obtained
from fi ne-grained waste materials of both the coal enrichment and coking processes have been presented
in the paper. The investigation results on the reduction of slag from fl ash furnace and the use of carbon granulates
obtained from fi ne-grained waste materials of both the coal enrichment and coking processes have been presented
in the paper.Web of Science53458758

Siwiec, Grzegorz

Oleksiak, Beata

Matuła, Tomasz

Socha, Ladislav

Stanek, Wojciech

DSpace at VSB Technical University of Ostrava

Directory of Open Access Journals

585 METALURGIJA 53 (2014) 4, 585-587G. SIWIEC, B. OLEKSIAK, T. MATUŁA, L. SOCHA, W. STANEKREDUCTION OF COPPER SLAG WITH THE USE OF CARBON GRANULATESReceived – Prispjelo: 2013-11-05Accepted – Prihvaćeno: 2014-04-30Preliminary Note – Prethodno priopćenjeISSN 0543-5846METABK 53(4) 585-587 (2014)UDC – UDK 669.3:666.88:66.094.1:669.041=111G. Siwiec, B. Oleksiak, T. Matuła - Silesian University of Technology, Faculty of Materials Engineering and Matallurgy, Katowice, PolandL. Socha - Technical university of Ostrava, Faculty of Metallurgy and Materials Engineering, Ostrava, Czech RepublicW. Stanek - Silesian University of Technology, Faculty of Power and Environmental Engineering, Gliwice, PolandThe investigation results on the reduction of slag from fl  ash smelting furnace and the use of carbon granulates ob-tained from fi  ne-grained waste materials of both the coal enrichment  and coking processes have been presented in the paper. The investigation results on the reduction of slag from fl  ash furnace and the use of carbon granulates obtained from fi  ne-grained waste materials of both the coal enrichment and coking processes have been presented in the paper.Keywords: copper, slag, reduction, fl  ash furnace, carbon granulateINTRODUCTIONThe processes of metal recovery from primary raw materials are inevitably connected with the large scale generation of harmful wastes. This in turn means de-struction of environment. At the same time the character of the processes require large amount of unrenewable natural resources such as metal ores and coal. Their ex-ploration has a negative effect on environment and re-duces the existing natural deposits. Over the last decade coal deposits have been reduced by 50 % which is il-lustrated in Figure 1.Having analyzed how fast the metals ore reserves are depleted, it is almost sure that their production will have to be seriously reduced in the forthcoming 20 years. Figure 2 presents the relevant data. One of the ways to reduce the over-exploration of mineral raw ma-terials under discussion is the recycling of scrap iron and metal bearing wastes. The reduction of energy con-sumption in the course on the two mentioned above processes or the use of alternative fuels might also help solve the problem.The investigation have been carried out for many years, specially with regard to technology of pig-iron and steel production as well as lead recovery form scrap wastes [1 - 9]. Numerous research reports proved that the thermoecological cost of many types of waste mate-rials used in the process can be signiﬁ  cantly lowered in comparison with the processes which make use of pri-mary raw materials [10 -14]. The investigation results on the reduction of slag from ﬂ  ash furnace and the use of carbon granulates obtained from ﬁ  ne-grained waste materials of both the coal enrichment and coking proc-esses have been presented in the paper. The slag gener-ated during the blister copper production is character-ized by a considerable amount of this metal, at times up to 16 % mass. The authors discuss the potentiality of replacing the breeze, which is currently used, by carbon granulates made of cheaper waste materials containing carbon. The introduction of such reducers might signiﬁ  -cantly lower the unit cost of copper smelting since the average price of anthracite dusts is ca. 90 euro/Mg and the price of breeze 50 Euro/Mg. The cost of caking op-eration reaches 30 Euro/Mg.0501001502002502001 2002 2003 2004 2005 2010 2011 2012YearsR/P / years0 50 100 150 200 250 300iron orecopper orezinc orelead oretin oregold oresilver oreYearsFigure 1 Coal reservesFigure 2 Suffi   ciency of non-ferrous metal ores586   METALURGIJA 53 (2014) 4, 585-587G. SIWIEC et al.: REDUCTION OF COPPER SLAG WITH THE USE OF CARBON GRANULATESTHE EXPERIMENTAL PARTIn Table 1, a composition of ﬂ  ash smelting slag that was used in all the experiments is presented. As carbon reducers, coke and anthracite dusts were applied.Table 1 Chemical composition of the investigated slagFractions of individual components / %massCopper slagCoke dustAnthracite dustCu 11,6Pb 3,25Fe 10,63S0 , 0 3 0 , 6 1 , 7CaO 13,28SiO2 31,84MgO 5,08Al2O3 8,95C8 8 , 5 1 0 , 3Ash 60,0 25,1All reductive smelting processes were performed in a PT 40 electric furnace. The smelting process involved two basic operations:    Introducing a reducer and limestone into the melt-ing pot preheated to a required temperature.     Pouring liquid copper slag over the components. The operations have been performed in the system similar to technological process realized at KGHM ‘Polska Miedz’. Before smelting, reducers were sub-jected to the agglomeration process in a balling disc us-ing the following parameters: disc rotation = 28 rpm, disc slope angle = 40 degrees.STUDY RESULTS AND DISCUSSIONIn Table 2, post-reduction copper, lead and iron con-tents in the slag are presented. Based on these values, a so-called slag reduction degree was estimated using the following equation:  % 100 ) (00 0 ⋅⋅⋅− ⋅ =omk kmm R m Cm Cm C S  (1)where:m0 and mk – initial and ﬁ  nal slag mass, respectivelyC0m and Ckm –   initial and ﬁ  nal metal content in the slag, respectivelyIn Figures 3 and 4, graphic interpretations of the re-sults against the reduction curve determined based on the results of smelting processes with coke breeze are presented. For all applied carboniferous materials, the copper reduction degree was above 80 % as early as after one hour. For 5-hour processes, the value of this parameter was higher than 97 %. The lead reduction de-gree depended on the process duration and was as fol-lows: 25 % to 84 % for one hour and 83 % to 92 % for 5 hours. The experimental ﬁ  ndings also showed that for the granulated reducer, the reduction degrees of both copper and lead were higher than for the ﬁ  ne-grained reducer, which was probably a result of better kinetic conditions of mass transfer in the gaseous phase in the reduction process of the discussed oxides. Table 2   Contents of selected components in the slag after the reduction process*Charge material Time/ hCu content in the slag / %massPb content in the slag / %massCureduc./ %Pb redu / %Slag + bulk coke dust10 , 0 2 4 0 , 0 1 8 8 3 , 2 1 5 6 , 5 2Slag + bulk coke dust5 0,003 0,0068 98,00 83,86Slag + coke dust granulate10 , 0 0 30 , 0 0 5 9 9 7 , 8 4 8 4 , 8 4Slag + coke dust granulate5 0,0015 0,0038 99,10 91,87Slag + bulk anthra-cite dust1 0,0123 0,013 90,66 64,80Slag + bulk anthra-cite dust5 0,0021 0,0047 98,51 88,14Slag + anthracite dust granulate1 0,0034 0,0332 97,90 26,96Slag + anthracite dust granulate50 , 0 0 20 , 0 0 5 9 9 8 , 9 0 8 8 , 4 1* - Mean values from two experiments50607080901000123456Time / hPb reduction degree / %slag+coke dust granulateslag+coke dust granulateslag +bulk anthracite dustslag+anthracite dust granulatestandart curve of Pb reduction7080901000123456Time / hCu reduction degree / %slag+bulk coke dust slag+coke dust granulateslag+bulk anthracite dust slag+anthracite dust granulatestandard curve of Cu reductionFigure 3 Results of lead reduction from industrial oxide slagsFigure 4  Results of copper reduction from industrial oxide slags587 METALURGIJA 53 (2014) 4, 585-587G. SIWIEC et al.: REDUCTION OF COPPER SLAG WITH THE USE OF CARBON GRANULATESSUMMARYThe experiments demonstrated a potential use of granulates made of ﬁ  ne-grained carboniferous materials as reducers in the process of copper oxide slag smelting. However, it should be noted that with respect to appli-cation of these granulates, an appropriate agglomera-tion technology and studies on the granulate effects on the environment during their combustion should be de-veloped and conducted, respectively.AcknowledgementsThe study was conducted under the Research Project No. PBS1/A1/21/2012, ﬁ  nanced by the National Re-search and Development Center – Poland.REFERENCES[1]  M. Czapla, M. Karbowniczek, A. Michaliszyn: Archives of Metallurgy and Materials 53 (2008) 2, 559-565.[2]  P. Migas, M. Karbowniczek: Archives of Metallurgy and Materials 55 (2010) 4, 1147-1157. [3]  K. Michalek, L. Camek, Z. Piegza, V. Pilka, J. Moravka: Archives of Metallurgy and Materials 55 (2010) 4, 1159-1165.[4]  M. Niesler, J. Stecko, L. Blacha, B. Oleksiek: Metalurgija 53 (2014) 1, 37-39.[5]  J. Lipart, T. Matuła, M. Niesler, L. Blacha, J. Filipczyk: Metalurgija 52 (2013) 4, 493-496[6]  M. Niesler, L. Blacha, J. Łabaj, T. Matuła, Metalurgija 52 (2013) 4, 521-524. [7]  J. Łabaj, M. Słowikowski,W. Żymła, J. Lipart: Metalurgija 52 (2013) 1, 68-70. [8]  H. Beer, W. Beier: Stahl und Eisen (1991) 11, 25-37.[9]  J. Tomeczek, S. Gil: Fuel Processing Technology, 91 (2010), 1564-1568.[10]  S. Gil, P. Mocek, W. Bialik: Chemical and Process Engine-ering 32 (2011) 2, 155-169.[11]  N. Gugus: Izwiestija Vyssz. Uczeb. Zav., Czernaja Mietal-lurgija (1990) 11, 8-10.[12]  S.N. Pietruszow, W.L. Bosyj: Metallurg (1982) 5, 9-10.[13]  A. Ziębik, W. Stanek: International Journal of Energy Re-search, 30 (2006) 2, 101-114.[14]  J. Lipart, T. Matuła, M. Niesler, L. Blacha, J. Filipczyk: Metalurgija 52 (2013) 4, 493-496.Note: Nowak P. is responsible for English language, Katowice, Poland

Reduction of copper slag with the use of carbon granulates

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