World aluminium oxide (alumina) production exceeds 150 million tons per year with > 95 % of it being used for manufacturing of primary aluminium and accounts for about 40 % of production cost of the latter. Making alumina cheaper and in a sustainable way is an urgent need of mankind. During over 150 years of industrial alumina production, the industry became mature and there seems to be little room for major improvement. Nevertheless, several companies in the world are developing innovative processes that could make a breakthrough in the years to come. The presentation describes state of the art and potential for improvement of established alumina technologies in fields of energy efficiency, residue generation, capital and operation cost, as well as status of new developments in the process of alumina production from different raw materials by different methods, including gaps that need to be covered and potential benefits of new processes.

The paper mainly introduces the engineering and operation of the two Kivcet Pb smelters in China. Kivcet process is a flash smelting process developed by VNIItsvetmet, characterized by high raw material flexibility, low energy consumption, high comprehensive recovery of resources as well as an environmental friendly solution. The China Jiangxi Copper Corp. and Zhuzhou Smelter Group (hereinafter referred to as JCC and ZSG respectively) both applied this process to build Pb smelters which were put into operation in March 2012 and January 2013 respectively. Presently, the two Kivcet furnaces are operating well. Hukou Pb & Zn Complex, invested by JCC, has a capacity of 100ktpa Pb and 100ktpa Zn. Its Pb smelting operation uses Kivcet furnace to treat the Pb concentrate blended with 100ktpa leaching residues from the Zn operation, accounting for 40% of the charge. Pb grade in charge is 29%.The other Kivcet Pb Smelting Plant, invested by Zhuzhou Smelter Group, has a designed capacity of 120ktpa lead bullion, which treats 120ktpa of leaching residues and sulfide filter cakes produced from the Zn atmosphere pressure leaching operation, accounting for 40% of the charge. The Pb grade in charge is 34%. The two Kivcet furnaces were successfully put into operation in one trial run in March 2012 and January 2013 respectively. The technical performance indexes and production capacity of both Kivcet furnaces reached or exceeded the design criteria within one year, and some indexes are extremely outstanding, e.g. unit oxygen consumption per ton of charge is 170m3 which is 30 to 50 m3 less than designed value (design criteria 200 m3/t); unit power consumption per ton of charge in EF is 110kVa, which 63% of designed value (design criteria 175kVa/t); and availability of both Kivcet furnaces are above 95%. Kivcet process is an environmental friendly and energy-saving process for Pb metallurgy which is particularly suitable for treating Zn leaching residues. Compared to the conventional roasting method for leaching residue treatment, the Kivcet furnace saves 50% energy, avoids the emission of low SO2 off gas into air, and increases the comprehensive resources recovery of Cu, Ag, Au and S. The Cu recovery is up to 80%, while Ag recovery can be increased to 96% which is 20% higher than conventional Pb smelter, and S recovery can reach up to 97% or higher. The Kivcet Pb Smelting Process has great advantages especially in Pb and Zn complex operations.

Top submerged lance furnaces are new for Russian metallurgy. The first metallurgical plant to use such furnace was "Karabashmed" at Karabash. It uses a single TSL-type furnace as their main smelting unit since 2007. Two more plants - Mednogorskiy Mednoserniy Combinat (at Mednogorsk) and Svyatogor (at Krasnouralsk) are planning to switch from reverberatory furnace (Svyatogor) and shaft furnace (Mernogorsk) to TSL furnaces too in the near future.
Due to this trend, understanding the TSL furnace operation is becoming vital for scientific groups working with the mentioned plants and, therefore, we started our investigation on these process properties to find possible fields for improvement and optimization.
Cold model of TSL furnace was built using plexiglass and plastic tubes in a scale of 1:12 to real furnace. It features several lance options, including single, two-tube, three-tube and different swirl solutions. Blowing was performed using 300 l/min compressor, video was captured using two 100 fps cams. The liquids used were water and different oils.
Series of experiments were conducted using this model to obtain data for future CFD modeling of the process. The parameters that varied during experiments included lance height, lance size, swirl form and amount of air blown.
We measured pressure at the lance tip, torch size, calculated Reynolds criteria and torch penetration depth.
Among valuable statistical data to use in future detailed modeling, the following facts were noted:
1. At high blowing intensity (130-160 l/m, pressure 10-15 kg/cm2) there is a plateau at torch size graph, which means that from 130 to 160 liter per minute there is some kind of equilibrium point, after which pressure becomes high enough for further development of blowing torch;
2. Swirls form (angle, length) have little effect on torch geometry or mixing efficiency. However, positioning swirls too high inside the lance (higher than at 1/3 of total lance height) results in great reduction of their effectiveness. Therefore, swirls should be positioned closer to the lance tip;
3. Air velocity (m/s) varied from 32 to 211 during air blown amount changes from 62 to 272 liter per minute respectively. This range gives us an opportunity to run experiments in conditions either close to real plant furnace conditions or extremely low or high modes.
The next stage of our work is computer modelling based on cold modelling results and then prediction model based on real plant data combined with modelling to find optimal conditions for smelting furnace operation to minimize copper loses with slag.

China, in the framework of the national lead industry developing and modernization plan, has implemented both the most advanced lead smelting processes used worldwide, and domestic technologies developed in recent years. Two major Chinese Corporations, Jiangxi Copper Corporation (JCC), and Zhuzhou Smelter Group Co., decided respectively in 2008 and 2009 to build two new lead smelter of 100-120 kt per year based on Kivcet technology through the purchase of a license granted by VNIItsvetmet Institute of Kazakhstan, while the project execution was committed to the Changsha Design and Research Institute of Nonferrous Metallurgy, Hunan, China by means of an Engineering, Procurement and Construction Contract.<br />Two Italian Companies assured the know how transfer of the industrial Kivcet technology as developed and practiced through their thirty years experience in design and operation of Kivcet Plant: specifically, Forni Engineering S.r.l., Milan, Italy through the supply of a full package of detailed engineering of the Kivcet Unit (also including the Continuous Decopperizing Furnace), and Texeco Consulting, through the supply of technical assistance services in the training and commissioning phase of the Kivcet Unit.<br />Both Kivcet furnaces were successfully started up, between 2012 and 2013, and have been successfully running from that time onward, thus demonstrating, among the others, the ability of Kivcet process and plant to process low-grade lead and polymetallic raw materials of complex composition, with high yield production rate of lead bullion and copper matte. This paper is particularly dealing with the description of procedures for start-up preparation and commissioning of KIVCET units, and the description of theoretical and practical training of the Clients personnel and staff as to process, and maintenance operation as well.

KIVCET furnace incorporates in itself three distinct areas: Flash Reaction Zone, Coke/under-coke lawyer zone and Electric Furnace zone. The products flows from each zone to the other in a continuous mode. Each of these zones have their own operating parameters and as such, in its entirely, the control of KIVCET furnace involves managing of these numerous parameters from various zones. This is not an easy task when performed only with engineer/operator experience and separately for each zone. In this paper a new control technique will be described as applied in Portovesme Company. This technique overcomes many problems since it manages the parameters from different zones simultaneously in order to assure good quality of the products, high productivity and efficiency and protection of refractories.

The creation of fundamentally new pyrometallurgical process (Vanyukov process) became the result of longstanding activity of Professor Andrey V. Vanyukov. The process is very prospective in heavy non-ferrous, noble and platinum metals' metallurgy, power-generating coal burning and recycling of factory and domestic wastes. The information about the stages of creation and development of Vanyukov process, its technological peculiarities and Vanyukov furnace design for processing of various raw material types have been shown. The basic advantages over another modern smelting processes have also been shown. For decades, industrial Vanyukov furnaces have been successfully used by the following largest copper-production enterprises: Norilsk Nikel MMC, Sredneuralsky Copper Smelter and Kazakhmys Corporation (Kazakhstan). Vanyukov furnace was industrially developed at Southern Urals Nickel Plant for the purpose of laterite ore matte smelting. Nowadays, designing of industrial Vanyukov furnace is carried out for Almalyk Mining-Metallurgical Complex (Uzbekistan), together with development of new ways of Vanyukov process application for processing of lead raw materials, laterite ores and copper-nickel concentrates.

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.

The Vanyukov process (VP) and Vanyukov furnace (VF) have a number of technological and design features. These features allow treating different types of waste and raw materials in VF in a wide range of redox and temperature conditions. Design features of Vanyukov furnaces allow creating units that are best suited for our purposes. One of the distinguishing features of VF is the ability to create multizone units, allowing one furnace to carry out multistage processes with different redox conditions.
The basic decisions on the organization of the technological process and design Vanyukov furnaces are considered. The main data on industrial Vanyukov furnaces for processing of copper sulfide concentrates are provided. The experience of processing test of various types of metallurgical raw materials and waste in pilot and industrial furnaces is presented. The perspective directions of Vanyukov process application for complex processing of metallurgical raw materials, slags of non-ferrous metals production, processing of municipal solid and industrial wastes and other are considered.
Keywords: Vanyukov process, Vanyukov furnace, non-ferrous metals, oxidation, matte, slag

Effective extraction of copper from sulphide ores requires careful operation of a copper smelter, which in turn depends very much on chemistry of the feed and resulted slag and matte. For example, chemical composition of copper smelting slags has to be in a certain range to ensure that their properties are within specific limits. Disobeying these rules may lead to complications in smelting operation, poor quality of the copper products, and premature shutdown of the copper smelter.
In the present paper, the microstructure and phase composition of slags from the Almalyk copper flash smelter were investigated experimentally and then modelled to evaluate potential ways of improvement and optimisation of the copper smelting process and its products. The slag samples were taken at different stages of the copper smelting process. Experimental investigation included the XRD, XRF and SEM techniques, which were also confirmed by the traditional wet chemistry analysis. Modelling was carried out using thermochemical software package MTDATA, which enables thermodynamic and physical properties of the matte, slag and gas phases to be calculated in a wide range of temperatures, pressures and chemical compositions.
It was found that the copper content in the slags may vary significantly depending on the location of slag sampling. Analysis of microstructure and phase composition showed that major phase found in the samples is fayalite, while other phases are complex spinels, different sulphides and an amorphous phase. Thermodynamic calculations demonstrated the presence of these phases, their compositions and optimal ranges of operating conditions. Potential ways of improving the matte grade and optimising the smelting process were suggested on the basis of the calculations.

In order to improve lead and zinc recovery rate and comprehensive recovery of lead and zinc bearing materials produced in copper smelting, JiangCopper company started up its KIVCET furnace along with a state-of-the-art slag fuming furnace and a continuous drossing furnace for bullion in March 2012. This paper focuses on a briefly description of the first introduction Kivcet process in China and a preliminary discussion of critical control points and problems happened in some main processes.

Formation of accretions is one of the main disadvantages of the processes which are carried out in Waelz kilns (productivity falls, chemistry of the process is violated). <br />Analysis of the accretions formation process reveals that the main causes of their growth are:<br />- Chemical composition of charge mixture (as it contains slag-forming compounds - CaO, SiO2, FeO);<br />- The kiln rotation speed;<br />- Feed material quantity;<br />- Temperature conditions;<br />- Grain size composition of charge mixture. <br />Setting operating conditions of the Waelz kiln in accordance with charge material composition makes it possible to avoid accretion formation. <br />At the same time, it is necessary to form skull in the kiln as a means of the furnace refractory protection from chemical and thermal "corrosion".<br />It is suggested to operate the Waelz kiln in the regime of variable silica ration in the interval from 0.4A·0.6 to 1.4A·1.6 that gives an opportunity for charge mixture consisting mainly of zinc cakes to exclude furnace shutdown for accretions removal and to increase in-service life of refractory protection at the expense of skull.

Due to the worldwide problems with CO2 and reduced quantity of primary energy resources in the future, the plant-management in the metallurgical industry has to utilise the full energy potential of their plants.
In many of the pyro-metallurgical plants the utilisation of the process waste heat by means of heat-ing-usage, drying of process components or the recuperation of heat is limited. The power genera-tion from waste heat is probably one solution to avoid the loss of this energy and to save the global resources. In the new planned metallurgical plants and in many of the existing applications the primary process gas treatment downstream furnaces is done by waste heat boilers. These waste heat boilers produce steam at a middle pressure-level of 40 - 60 bar. The generated steam can be used for the power generation to improve the energy efficiency of the plant.
Oschatz designs and manufactures waste heat boilers for the metallurgical industry but also the industrial and municipal turn-key power stations for different wastes. The idea is to use this experience for the power generation in the non-ferrous industry.
The presentation describes existing furnace technologies with the corresponding waste heat boilers and shows the possible waste heat boiler concepts that could be realised in the non-ferrous industry. The main focus is to introduce the different possibilities of electrical energy production from the middle-pressure steam generated by the waste heat boilers. The presentation will give a preview for improvements and further developments which could be possible.

All modern processes for smelting of primary lead raw materials, including those which are not industrially applied, may be divided into two main types: smelting in liquid bath and flash smelting. The paper provides the review of interconnections of technical organization and technological capabilities of the above mentioned processes in terms of objective natural regularities. The paper describes the way and the reasons of impact of lead smelting conditions on limitations of quality and process parameters of lead raw material smelting. It is focused on specific features of KIVCET process, which allow lead smelting using unsurpassed range of lead-bearing materials, including the resistant materials such as highly ferrous residues from zinc electrolysis, complex lead-zinc and lead-copper-zinc concentrates, etc. The main founding of the review is availability of objective physical and chemical regularities of lead and lead compounds behavior stipulating technological capabilities of lead smelting processes. Consideration of such specific features in KIVCET process allows, first of all, adjusting the process to conditions of deficiency of high-grade lead materials in global market, and making it the most appropriate for usage in integrated metallurgical plants, incorporating lead, zinc and in some cases even copper productions.

Portovesme has been applying the Kivcet technology at its industrial site since 1987. Different scenarios in the lead market occurred over the past three decades and Portovesme adapted the design of the furnace in order to be able to treat different kinds of lead bearing materials. This paper provides an overview of Portovesme's Kivcet design and experience in smelting various lead concentrates, as well as lead recycles and Zn leaching residues coming from different sources. The success of the Kivcet process is proven when installed within an integrated zinc-lead complex like Portovesme. It is in fact possible to optimize the recovery of metals inside the plants and consequently minimize the volume of residues dumped. The last changes made in 2012, coupled with a new Continuous Drossing Furnace (CDF), increased the feed flexibility and the Kivcet at Portovesme is nowadays smelting a wide range of complex materials, while keeping the same ability to recover all of the valuable metals into saleable products.

The article concerns the most recent and innovative aspects of the engineering of Kivcet furnace, utilized as lead smelter.
Some of these details have already been tried on the working plants; others are in a studying phase.
The four main topics examined in the article are:
• The hearth of the furnace, especially with reference to the design, to the refractory materials and to skewbacks with the contrast springs
• The water cooled copper jackets with particular reference to the necessary tests for their acceptability, to refractory tiles of protection and to heat fluxes that can be reached in the different zones of the furnace
• The sulphurous gas boiler and electrothermic gas boiler with particular reference to the design, cleaning devices and to protection against corrosion of the heat transfer surfaces
• The lead tapping copper jackets especially with reference to design of the tapping block and its protection with refractory lining; besides it will be described and highlighted the necessity of mounting a tapping machine and a continuous control of the temperatures of the copper jackets to monitor all conditions of wear and so of possible danger.
Also with the implementation of these executive details, the Kivcet furnace, utilized as lead smelter, has reached a very good operative reliability and an interval from big maintenances between 2,5 and 3 years.

The article concerns the most recent and innovative aspects of the engineering of Kivcet furnace, utilized as lead smelter.
Some of these details have already been tried on the working plants; others are in a studying phase.
The four main topics examined in the article are:

•The hearth of the furnace, especially with reference to the design, to the refractory materials and to skew backs with the contrast springs
•The water cooled copper jackets with particular reference to the necessary tests for their acceptability, to refractory tiles of protection and to heat fluxes that can be reached in the different zones of the furnace
•The sulphurous gas boiler and electrothermic gas boiler with particular reference to the design, cleaning devices and to protection against corrosion of the heat transfer surfaces
•The lead tapping copper jackets especially with reference to design of the tapping block and its protection with refractory lining; besides it will be described and highlighted the necessity of mounting a tapping machine with a continuous control of the temperatures of the copper jackets to monitor possible conditions of wear and so of possible danger.
Also with the implementation of these executive details, the Kivcet furnace, utilized as lead smelter, has reached a very good operative reliability and an interval from big maintenance between 2,5 and 3 years.

A new method of nickel-containing copper matte continuous converting to blister copper and dump slag was developed at Gipronickel Institute as an alternative to the previously created technology of continuous converting in Two-zone Vaniukov Furnace to blister copper and recirculating slag, the latter being delivered to nickel production site for further processing. The new process differs from the previous one in that the slags formed during oxidising smelting of nickel-containing copper matte to blister copper are subject to deep cleaning by copper, nickel and cobalt to get dump slag. The target is achieved through successive running of the converting and slag cleaning stages in a train of two One-zone Vaniukov Furnaces. In the first Furnace, converting to blister copper and slag rich in copper, nickel and cobalt oxides take place, the latter being delivered to the second Furnace where its cleaning is performed in the presence of carbon-based fuel and coal. The process of reduction results in formation of dump slag and copper-nickel alloy containing some iron as an impurity. Cu/Ni ratio contained in the metallic melt formed in the second Furnace makes ~3-4/L, which corresponds to the Cu/Ni grade ratio in German silver, a valuable and widely used copper-nickel alloy. The produced copper-nickel alloy is further subject to oxidising refining to get the marketable product. One of the advantages of the new process flow-sheet is a substantial decrease of price of German silver produced from the continuous converting by-product as compared to that traditionally produced from pure metals.

The development of primary lead metallurgy is connected with application of modern metallurgical processes, including Vanyukov process. The history of creation and development of this way of Vanyukov process is described together with its following advantages:
-absence of strict requirements to composition and quality of raw materials;
-possibility of raw materials processing without drying and complex smelting preparation;
-possibility of using oxygen-containing blowing with various oxygen content;
-obtaining gases with high content of sulfur dioxide;
-combination of smelting with in-furnace refining of lead bullion;
-possibility of usage of various fuel types.
Vanyukov furnace allows to carry out the continuous consecutive oxidative and reduction processes in one unit. As the need arises, the furnace allows to carry out these processes by consecutive cyclical runs. The basic physical-chemical smelting parameters are described. Nowadays, new ways of lead raw material smelting are developed: processing of complex raw materials, containing copper and zinc; processing of semi-products, containing copper, lead and zinc; and processing of raw materials with high content of noble metals.

It is rather difficult to keep stability of lead production under conditions of lead market recession and rather low production profitability. The problem could be solved by addition of gold-bearing ores and concentrates to charge of primary lead production facilities, which allows providing high added value of products due to additional production of gold as Dore or refined metal. This solution is possible due to high level of gold recovery into lead (99-99.5%), which is higher than the recovery values of any other gold-bearing raw material process, and due to well-proven methods of gold recovery from lead bullion in the existing refineries. Experience of addition of gold-bearing concentrates and gold-bearing silica ores as fluxes to lead smelting charge has been known for a long time. However, the amount of addition of such materials to charge, and, respectively, gold concentration in charge is very limited due to limitations for minimum lead content in charge, which are common for most of lead smelting processes. Such limitations are minimized in flash smelting processes. The paper provides the results of studies of gold behavior during smelting of gold-bearing lead raw materials in KIVCET plants, demonstrating the perceptiveness of KIVCET process application for integrated processing of lead and gold-bearing raw materials.

The construction of the computer 3D and 4D models of phase diagrams (PD) of metals' A-B-C-D and oxide-fluoride slags' A,B,C||F,O systems on the basis of experimental data is aimed for the elaboration of new technologies to obtain alloys and coatings. To solve such practical problems, it is important to develop new methods of studying phase transitions in three-dimensional (3D) and four-dimensional (4D) spaces with T-x-y and T-x-y-z PD (including reciprocal systems with reactions of exchange), using computer-aided design of the boundaries of the phase regions with further assembling of spatial models. They help to obtain high-quality visualization (the rotation of 3-dimensional figures, projections, construction of arbitrary given sections), to predict the crystallization schemes for any composition, to calculate the mass balances of coexisting phases at any temperature, and, taking into account the stages of their formation, to be the source of additional information about the microstructure formation. It is also allowed to estimate the phases relationship for given concentration. Such comprehensive study of system properties establishes the theoretical basis for experimental work. The schematic variants of computer models of alternative phase diagrams (which will be updated with the obtaining of new experimental and theoretical data) are analyzed for real systems. Such complex investigation of the properties of metal and reciprocal oxide-fluoride systems will optimize the SHS processes, which are used to develop new alloys and coatings, as well as to create a theoretical basis for experimental work at the refining of phase equilibria parameters. After the triangulation of 3-dimensional prisms of quaternary reciprocal A,B,C||F,O systems into the tetrahedrons, the 4D computer model of T-x-y-z diagrams of these subsystems are assembled. They permit to obtain the full description of each system, which is suitable for the elaboration of optimal compositions with given properties. For each system, the concentration fields with different crystallization schemes are analyzed and confirmed by mass balances and the series of isothermal sections and isopleths are produced. Detailed report for PD contains: - initial data for model (coordinates of binary, ternary and quaternary points on the liquidus surfaces; coordinates of compounds); - scheme of uni- and invariant equilibria; - visualization of PD in space and projections; - list of surfaces and phase regions; - horizontal and vertical sections (if there are experimental or calculated thermodynamic methods sections, then they will be compared); - tables with the list of phase transformations and elements of microstructure for concentration fields; - diagrams of mass balances for given concentrations containing the information about crystallization stages and the ratio of phase portion evolved in different parts of phase regions. In addition, such computer model of phase diagram makes possible to calculate the tie-lines and crystallization paths, to identify the effect of change of phase reactions type. It permits to obtain data about the studied system at the user's request, which significantly reduces the amount of experimental work. The work was partially supported by the Russian Foundation for Basic Research (projects 14-08-00453 and 14-08-31468).

This work presents the results from investigations concerning the structure and chemical composition of the crystallized matter containing 50 to 60 % of Cu that was precipitated during the process of autogenous smelting of copper and zinc concentrates (14 – 18 % of Cu) in Vanyukov's furnace. XRD analysis revealed that the main phase content of the samples was that of bornite, copper sulfide and an insignificant amount of magnetite. The elemental composition of the phases was investigated by optical and electron microscopy and X-ray microanalysis. Phase dispersion was defined and the distribution of impurities (Sn, Sb, Zn, Pb, Ag, Ni, Co, As and Au) therein was identified. The temperatures of phase transition and melting of the mattes and the onset of oxidation and content of the derived precipitate were established under thermal analysis in argon and air flow. It is proposed that the derived results be used for the development of continuous mattes conversion technology.

Teck Metals Ltd. operates an integrated zinc-lead complex at Trail, British Columbia, Canada. Since 1997, KIVCET flash smelting technology has been utilized for the treatment of zinc plant residues and lead concentrates. A review of the first 18 years of operation with respect to furnace integrity is presented with focus on challenges and successes associated with increasing furnace component reliability to increase process safety and campaign life between cold shutdowns.

Depending on the process conditions, considerable amount of copper (between 0.7 and 2.3% Cu) is lost to slag in copper matte smelting stage. Temperature is one of the factors affecting the copper losses to slag during this step. Therefore, in this study, temperature effect on copper losses to slag with colemanite (a boron compound; 2CaO.3B2O3.5H2O) addition as flux were investigated at controlled partial pressure of oxygen obtained by mixture of CO-CO2 gasses. A series of experiments were performed with flash furnace slag (FFS) and matte (FFM) provided by Eti Copper Co. (EBI) at 1200oC, 1250oC and 1300oC for 2 hours at fixed Po2 of 10-9 atm. With an increase in temperature of the system, a decrease in the viscosity of slag which led to the speeding up of settling rate of matte particles in the slag was expected. Experimental results indicated that increasing not only the temperature but also colemanite additions caused a decrease in copper content of slag down to 0.29%.

Theoretical foundations of sulfide raw material smelting in liquid bath developed at Moscow Institute of steel and alloys (MISA) in the department of non-ferrous metals metallurgy, led by Professor A.V. Vanyukov. Pilot tests and industrial development process is carried out at the Balkhash and Norilsk plants and Ryazan plant of Gintsvetmet Institute (Moscow) with his direct leadership. The process was proposed by A.V. Vanyukov in 1949 and for many years it has been learnt and improved. Since 1988, the melting process in liquid bath is called "Vanyukov process", oven for its implementation "Vanyukov furnace" with the abbreviation "VF".<br />Pilot tests of VF were first conducted at Balhash copper plant in 1974. In testing, employees of the Moscow Institute of Steel and Alloys, Institute of Metallurgy and Beneficiation (IMB) of the Academy of sciences Kazakh USR, Kazakh USR Ministry of metallurgy were involved. During the VF tests between 1974 and 1979 basic elements of furnace construction were developed. Also, basic technological characteristics of melting were defined and initial data to "Giprotsvetmet" institute for the design of industrial furnace were given.<br />The industrial development of melting process of high-iron copper concentrates in liquid melt bath - Vanyukov process was started at the Balkhash smelter in 1985-1987, when in industrial operation VF-1 and VF-2 complexes were put with involvement of scientists of MISA, IMB and Gintsvetmet. From 2004, Balkhash copper plant used only Vanyukov technology, which provided significant increment production of blister copper from low-grade copper concentrates.<br />Today in , Kazakhstan and China, there are several large complexes VF, whose work fully confirms the fundamental technological and design advantages of modern VF autogenous processes of copper and lead production from various raw materials.

The present study determines conditions for titanium magnetite concentrate processing with fairly complete titanium conversion to the slag and iron and vanadium separation in the hot metal.
It is quite difficult to process titanium magnetite concentrate in the blast furnaces due to low fusibility of charge and direct electrical melting causes process instability. The present work is devoted to the development of concentrate double stage smelting process with little soda additions, including solid-phase recovery at the first stage using specific coke as a reductant, avoiding concentrate oxidation and including its preliminary thermooxidation.
Mix charge made of concentrate, soda and specific coke was granulated in water, dried at 130A°C, pellets were placed in graphite crucible and later on it was set up in the centre of the furnace in alundum crucible. The temperature regimen was fixed under the following parameters: temperature at the first stage is 1250A°C; soaking time is 50 minutes; temperature at the second stage is 1500 - 1650A°C; soaking time is 35min.
It is established that little soda additive (estimated 3-4% Na2O) to the charge of titanium magnetite concentrate recovery smelting performs as coagulant during briquetting, as catalyst in course of solid-phase recovery, as inhibitor of DRI briquettes secondary oxidation as slag thinner during smelting. In course of titanium magnetite concentrate reduction smelting process soda interacts to SiO2, Al2O3, TiO2 oxides forming sodium silicates and titanates.
Double-stage technology of titanium magnetite concentrate reduction smelting both with soda addition and without oxidation and preliminary iron oxidation of titanium magnetite concentrates till hematite was developed. Optimal process parameters were determined.
Following parameters were obtained: hot metal yield was ~55% out of concentrate weight, slag yield - 23.3-25.8%, carbon-free slag content, wt%: Fe=1,0-1,6; TiO2=62,7-61,9. TiO2 yield in the slag is 89,6-94,1%. Hot metal contains, %: 5,51 C; 0,36 Ti; 0,35 Mn; 0,04 Si; 0,23 V. Vanadium yield in iron was 53.0%.

Rotary bevel drum-type furnace, mainly represented by Kaldo furnace and TROF-converter, are not widely distributed in Russia. There are only two units, one of them located in Kishtim, and another one in Velikiy Novgorod. TROF-converter as Kaldo furnace is not an autogenous smelting process; it may process either molten or solid materials. Particularly in Kishtim, it is being used for slag reduction. The main advantage of this type of furnace is strap slag processing possibility, while recycling copper containing materials such slag is formed and because of high zinc and tin containment such slags have high viscosity. The ability to mix producing slag allows to receive waste slag with low copper containment. It may be used as converter unit, with use of unsubmerged blowing. Due to unsubmerged blowing and rotating smelting chamber, the material flow trajectory is very difficult to predict. For the better understanding of TROF-converter operation and to find possible ways for hydrodynamics improvement, cold and numerical simulation had been carried out. The obtained results permitted to calculate energy balance. By means of it, we revealed that only 43% of the energy provided by blowing uses for mass transfer process. Moreover, we determined the relationship between air flow penetration depth and air flow rate. We also detected a number of dead zones in furnace molten bath. TROF-converter cold model was constructed of plexiglass in scale of 1:10 to real furnace and equipped with steel lance. Model construction may simulate furnace rotation and has an ability to set angel of furnace drum and lance independently. Blowing was performed by compressed air with rate 145 l/min. The results were obtained by means of video recording using two 100 fps cams. The liquids used were water and different oils. Series of experiments were conducted. The obtained data had been used for CFD modeling of the process. During the experiments, we varied angle of model body, lance angel and position, volume of liquid in model and air blow rate. We measured pressure at the inlet and outlet of lance. By means of video recording, we determined torch size, its penetration depth and volume of displaced liquid, calculated Reynolds. Among valuable statistical data to use in future detailed modeling, the following facts were noted:
1. Potential and kinetic energies were calculated for different blowing conditions. Blowing intensity varied from 30 to 249 l/m. The potential energy varied from 0.002 to 0.246 N, while the kinetic energy varied from 1.7 to 223 N;
2. The relationship between air pressure and distance from lance tip to bath surface was measured. It showed that small (from 0 to 5 mm) change in distance does not have any significant effect on pressure at the state flow rate;
3. Flow trajectories in liquid bath were found using solid indicators and video capture. They will be used for computational modelling of bath mixing later;
Our next step is the examination of slag composition influence on its physical properties in conditions of TROF-converter slag treatment. Then, this data will be combined with modeling results and will provide us with prediction model for industrial process optimization.

Currently, three Vaniukov Furnaces are operating at Norilsk Nickel's plants. Two Furnaces are installed at the Norilsk Combine's Copper Plant and are used for copper ore concentrates processing to ~60% Cu grade matte. The third Furnace is operating at the Norilsk Combine's Nadezhda Metallurgical Plant; it processes copper concentrate from high-grade matte separation to produce rich copper matte, i.e. ~70% Cu grade white matte. Approach to and methods of both technological and technical improvement of the existing Furnaces are presented. Also, new technological trend is described, namely Two-zone Vaniukov Furnace application. The results of pilot testing of various methods of copper and nickel raw material processing in Two-zone Vaniukov Furnace are presented. Possibilities of the Furnace's use for processing of laterite ores, lead concentrates, industrial and household wastes, as well as for coal combustion, are described.

Special double-chamber Vanyukov furnace was designed in 2004 at Southern Urals Nickel Plant, for the purpose of laterite ore (~1% of Ni) matte smelting. The following operations were carried out during full-scale tests and application of new smelting complex:
-use of controlling methods of smelting stage temperature modes in first furnace chamber, and reduction-sulfiding processing of slag melt in second chamber;
-use of regulation methods of nickel mate composition, continuous loading of charge and reagents, and output of slag and matte.
The basic production data of new technology is given. The technological peculiarities of cokeless smelting of laterite ores in Vanyukov furnace are set, showing the wide prospects of its industrial application.

Nowadays, more than a half amount of lead is produced from secondary raw materials. Basically, the production is carried out in developed countries, which have strict economic requirements. The absence of noble metals in raw materials leads to reduction of industrial and capital costs. Vanyukov furnace meets these requirements because of its high production capacity and its blowing-based operation with high oxygen concentration. Besides, the furnace does not require the complex preparation of raw materials to smelting process. The smelting development history started in 1980-s (when the first works were carried out under the direction of Professor Andrey V. Vanyukov, with participation of VNIITsvetmet Institute), and continues nowadays with modern offers of creation of secondary lead production. The basic physical-chemical regularities of secondary raw material smelting and the influence of various parameters on Vanyukov process indicators are considered. Basic production indicators are described together with their possibilities and prospects.
Key words: chemistry, secondary lead, Vanyukov furnace, antimony, tin, arsenic, refining, ecology, silicate slag, sulfur.

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