2015-Sustainable Industrial Processing Summit
SIPS 2015 Volume 5: Vanyukov Intl. Symp. / Non-ferrous & KIVCET
| Editors: | Kongoli F, Kozlov P, Tsymbulov L, Fedorov A, Shumskiy V |
| Publisher: | Flogen Star OUTREACH |
| Publication Year: | 2015 |
| Pages: | 310 pages |
| ISBN: | 978-1-987820-28-7 |
| ISSN: | 2291-1227 (Metals and Materials Processing in a Clean Environment Series) |
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Development of Vanyukov Process (Bath Smelting) at Balkhash Smelter
Gulam Kamirdinov1; Erzhan Ospanov2;1KAZAKHMYS SMELTING, Balkhash, Kazakhstan; 2KAZAKHMYS CORPORATION, Almaty, Kazakhstan;
Type of Paper: Regular
Id Paper: 356
Topic: 6
Abstract:
At present time, at Balkhash smelter (BS), two sets of Vanyukov furnace (VF) are successfully operated for the copper-bearing burden processing. Implemented within 25 years, technical solutions and modernization projects have enabled to increase productivity of VF units, integral use of raw materials and reduce risks of environmental pollution. Process and unit of VF represent furnace technology and structure for the high efficiency smelting, passing autogenous, through the appropriate use of burden constituents heating value. Semi-industrial tests of VF were, for the first time, carried out at Balkhash mining and smelting plant (BMSP) in 1974. The industrial development of smelting process of copper concentrates in liquid bath of melt - Vanyukov process (VP) started at BS in 1985-1987 years.
Since 1997, modernization of complex VF-1 was conducted at BMSP. In 1999, for the dust entrainment reduction, VF-1 was reconstructed, for which purpose the uptake area was increased and waste-heat boiler was substituted with the new construction "Uralenergotsvetmet". In 2000, for the burden production increasing of VF - 1 to 120t/hour, the gas-running system was reconstructed and in 2001, reconstruction of electric mixer: for the increasing of slag duration of stay, the electric mixer area was increased, the number of electrodes became six. All these activities enabled to process copper-zinc raw materials and get slags with project targets. In 2003, yet another reconstruction of VF-1 complex was carried out, waste-heat boiler was substituted with new condenser of type ОГ-16/39 of the construction JSC "Sredaztsvetmetenergo". In 2004, the complex VF-2 was constructed with the condenser КУ-16/40. With the commissioning of the complex, VF-2 Balkhash smelter has fully changed over treatment process of copper burden for the process of VF, refusing of smelting process in reverberatory furnace. Constant modernization of VF complexes enabled of reaching the following indicators: Between overhauls campaign - 1,5 year. Maximum smelting rate - 120 t/hour at each of the aggregates. Burden smelting rate - 1 million 3 hundred thousand tons per year. Slag copper grade - to 0,97 %. Matte copper grade - 45-55 %. Copper grade in processed burden - min 12,0 %. At present time, concentrates which are processed at Balkhash smelter are characterized with the chemical composition not providing sulfur content in burden of 30,0 %, what decreases autogenous extent of smelting process for the lack of heat. Also, the VF lack of heat strongly influences concentrate processing of waste slag with the mixture of ore concentrate, drawing off by Balkhash concentrator. This concentrate has a high concentration of magnetite to 7,0 % and its processing demands higher temperatures conduct processes and increasing addition of fluxing materials. At all smelters of Russia where VF are operated, the problem of heat lack is solved by the way of natural gas supply through lances. Under conditions of Balkhash smelter for the maintenance of smelting heat balance, the furnace is supplied with the small amount of solid fuel (mineral coal) to 1,5 tons per hour. Increasing of coal consumption gives a negative impact on gas purifying equipment, because of temperature increase of flue gas and formation of caked mass of dust in the waste-heat boiler, leading to deterioration of traction mode. Partially, the problem of supplementary heat feed was succeed to be solved by the implementation in 2011 on the VF of oil heating devices (OHD), upon the project "Stalproect". Heat supply with the help of oil heating device (OHD) allowed raising the temperature of smelting process and slightly increasing the addition of flux. Quality change of incoming raw materials demanded from technologists of Balkhash smelter research and acceptance of technical decisions, which would have provided productivity increase, receipt of qualitative slags and reduction of copper losses with it. Here are some of them: 1. Lance diameter enlargement, enabling to increase throughput capacity of oxygen into the furnace and boost production of the burden furnace. 2. Implementation of system for the reducing agent supply - and sulphidizer in the furnace end for the reduction of skull formation in the furnace end. 3. Implementation of granulated slag supply of blast-furnace smelting as a calcium flux 4. Change dovetail shape line at the surface of water-cooled copper caisson enabled to protect elements from aggressive action of melt through more stable kish. 5. Implementation of circulating water cleaning for the furnace cooling upon the project of Nalco Company. At the moment, smelting vessels of Balkhash smelter provide complete performance of operational program of Corporation, but in reality of today's competition, there is a necessity of further process perfection, modernization of instrument complex fulfilment. For further development, survey works are conducted with such world institutes and engineering companies as MISIS, Stalproect, Outotek, Doberzhek and many local institutes. Among the plans of Balkhash smelter, we can name implementation of technology of VF cold starting, enabling to exclude emissions release in the time of breaks of sulfuring manufacture, control automation process system improvement, modernization of weighing equipment and furnace load system and many others.