Part 1
[email protected] University of Utah Department of Metallurgical Engineering
SYLLABUS Met. E. 5710/6710 High-Temperature Chemical Processing Professor H. Y. Sohn My background for your information: I was born in a beautiful, old dynastic capital of Kaeseong in Korea. B.S., Seoul National University and Ph.D., University of California, Berkeley. Industrial experience: Du Pont Co., Wilmington, DE; technical consultant to many companies and organizations. At the University of Utah since 1974 through the ranks to Distinguished Professor; Honorary Professor of two international universities, and have served as a director of TMS-AIME. Research: Metal nano-powder production and processing, high- temperature chemical metallurgy, and solvent extraction/leaching. Have taught many workshops and given frequent plenary/keynote/invited talks, from Sweden to Asia to Australia to South America to Spain. Over the years, my students’ work has been recognized by several prestigious awards from professional societies. This has allowed me to receive a number of individual awards, but the most meaningful ones are those that my students and I jointly received. My research work has resulted in some 560 technical articles and four monographs. I like sports, both participatory and spectator. I particularly enjoy playing tennis: Tennis anyone? I really enjoy teaching students and particularly, teaching you individually. I encourage, in fact urge/demand, you to come and see me anytime with questions, comments, and arguments. Please, let me know how we (you and I) are doing. I am successful only if you learn well.
Instructors: Lectures --- Prof. Hong Yong Sohn, 403 WBB, 581-5491, [email protected] Office Hours: Any time you can catch me or by appointment Lab --- TA Text: Class Notes prepared by H. Y. Sohn Recommended Book: H.P.C. S. Hayes, Ray, R. Process Sridhar Principles and K. P. inAbraham, Minerals Extraction and Materials of Nonferrous Metals,Production, Affiliated Hayes East-West Publishing, Press Sherwood, Pvt Ltd, Queensland, New Delhi, India,Australia, 2006. Inexpensive1993. on Amazon Other References: P.C.F. Habashi, Hayes, PrinciProcessples Principles of Extractive in Minerals Metallurgy, and Materials Vol. 3 Production,Pyrometallurgy, Hayes Publishing,Gordon and Sherwood, Breach, New Queensland, York, 1986. Australia, 1993. C.B. Gill, Nonferrous Extractive Metallurgy, Wiley, New York, 1980. W.G. Davenport, M. King, M. Schlesinger and A.K. Biswas, Extractive Metallurgy of Copper, Elsevier, 2002. Catalog Description: Fundamentals of commercially important nonferrous and ferrous pyrometallurgical extraction. Thermodynamics and kinetics of high-temperature processes. Fulfills quantitative intensive BS. Prerequisite(s): Met. E. 3620 Metallurgical Thermodynamics II or Equivalent Course Objective: To teach students major high-temperature processes for producing ferrous and nonferrous metals from ores and other raw materials together with the theoretical basis and principles necessary and applicable to the various processes. Lecture Topics 1. Principles involved in High-Temperature Processing Thermal energy and enthalpy Chemical Equilibria Phase diagram 2. Sulfide Smelting and Converting Copper, Nickel, Lead 3. Roasting Processes Types of roasting reactions Types of reactors 4. Iron and Steel Production 5. Refining Processes 6. Aluminum Production 7. Reactive Metals Production 8. Other Topics Class/laboratory schedule: Two 1.5 hour classes and one 3-hour laboratory session weekly Equipment used: Computer software, thermogravimetric analysis unit, fused salt electrolysis unit, high-temperature furnaces. Lab topics and schedule will be given separately.
Contribution of course to meeting the professional component: The course applies mathematics, basic sciences, and thermodynamics knowledge that students learn in their earlier years to the description, understanding and eventual design of ferrous and nonferrous metals production. The students also obtain experience on how certain chemical reactions are actually effected through laboratory experiments and how to analyze and interpret the results. Relationship of course to program outcomes: This course contributes strongly to the development of skills to (1) apply basic mathematics, basic sciences and engineering principles, (2) conduct and interpret experiments, (3) identify, formulate and solve engineering problems, (4) recognize the need for and engage in life-long learning, and (5) exert the effort necessary for job success.
Grading 1 Mid-Term 25%; Final 45%; Homework 10%; Lab work & Report 20%
General Information Materials to be covered should be read before the lecture. It is most helpful to complete some of the lecture outline before coming to class. Homework assignments are due one week after they are given, unless otherwise specified. No make-up examinations will be given in the course, as it is impossible for me to write an examination that will be exactly equivalent. In case of an illness or a dire emergency, one may be excused from an examination if approval is obtained prior to the examination. I will then decide what to do about the missed examination on a case-by-case basis. The University of Utah seeks to provide equal access to its programs, services and activities for people with disabilities. If you will need accommodations in the class, reasonable prior notice needs to be given to the Center for Disability Services, 162 Olpin Union Building, 581-5020 (V/TDD). CDS will work with you and the instructor to make arrangements for accommodations. All written information in this course can be made available in alternative format with prior notification to the Center for Disability Services.
1. Introduction and Principles of High-Temperature Processing
Major Sources General Processing Methods Thermal Energy and Enthalpy Chemical Equilibria Phase Diagram (from Hayes)
From Rosenqvist, "Principles of Extractive Metallurgy" We will develop a quantitative criterion for a spontaneous process applicable when these conditions are satisfied: T(sys)=T(surr); Constant P; Constant T
From Moore, "Chemical Metallurgy," Butterworth, 1990
ȼ These eqs. from the earlier equation on delta G.. Activities at corresponding std. states are unity. Bar underneath denotes 1% std. state.
(Hayes)
Copper Smelting Flow sheet Concentrate (Cu 30~35%) Precipitates Silica, Limestone
Material Storage Wet Charge Dryer Slag Concentrate Dry Charge SmeltingSmelting FurnaceFurnace SO2 Gas (mattemaking furnace) Slag Matte Converter Slag Slag (50~70% Cu) Cleaning Sulfuric Convertingg Furnace Acid Furnace SO 2 Plant Blister Copper Gas (98.5% Cu) Fire Refining Furnace Discard Slag Sulfuric Acid (99.5 % Cu)
Casting Wheel
To Refinery Anode (99.99 % Cu) Process FFlowsheet (Harjavalta Smelter, Finland)
https://www.youtube.com/watch?v=YrJ1J2txL14 Suspension Smelting –Flash : IncoIncon o Flash Smelting Furnace
Suspension Smelting – CycloneCyclone : ContopContop Process
P.J. Mackey and P. Tarassoff, in Advances in Sulfide Smelting: Vol. 2 Technology and Practice, ed. by H.Y. Sohn, D.B. George and A.D. Zunkel, Proceedings of the 1983 International Sulfide Smelting Symposium, TMS -AIME, Warrendale, Pennsylvania, p. 399, 1983. G. Melcher, E. Muller, and H. Weigel, The KIVCET cyclone smelting for impure copper concentrates. Journal of Metals, July 1976. Bath Smelting – Top Jetting Lance : Mitsubishi Process
Oxygen Enriched Air
Concentrate Oxygen Enriched Air Flux(SiO2) Coal C-Slag Flux(CaCO3) C-Slag
S-Furnace Blister Copper (Smelting Furnace) CL-Furnace (Cleaning Furnace) C-Furnace (Converting Furnace)
Bath Smelting – Top Submerged Lance: Ausmelt/Isasmelt/SiromeltAusmelt/Isasmelt//Siromelt/
Lance • Outer pipe for oxygen enriched air • Inner pipe for fuel (oil, coal... ) Bathh Smelting – Top Submerged Lance : AusmeltAusmelt
www.outotec.com/.../OTE_Outotec_Ausmelt_TSL_Process_eng_web.pdf Bath Smelting – Top Submerged Lance : Isasmelt
Air, Oxygen. Oil/Natural Gas
Offgas and Fume
Wet Agglomerated Feed
Submerged Lance
Refractory-Lined Furnace
Frozen Slag Coating
Vigorously Stirred hearth
Taphole Advantages of Ausmelt/Isasmelt • Multiple Applications • ability to run oxidizing or reducing • primary and secondary (scrap smelting) • complex ore smelting • Simple furnace configuration • High specific smelting rate • Flexible fuel type • coal, oils and natural gas • Minimum feed preparation Bath Smelting – Other : Electric Furnace
Reverberatory Furnace: Similar with a Fuel Burner replacing the Electrodes (Davenport et al.)
_ -
Peirce-Smith Converting of Copper Matte
Matte Slag-BlowingggSlag Copper-Blowingpp g Blister Charging (Slagmakingg Skimming (Coppermakingpp Discharging stage) stage)
FeS +1/2 O2 = FeO + SO2 Cu2S + O2 = 2Cu+ SO2
2FeO + SiO2 = 2FeO·SiO2
Mitsubishi CC-Furnace-Furnace
RG Advantages of flash converting compared to PS converting 1. Smelting and converting separated • Smelting and converting can operate separately • Better total on line availability 2. Possibility to use tonnage oxygen
3. Continuous and small off-gas flow rate rich in SO2 • Less gas cooling and cleaning • Smaller investment/operation costs for acid plant • Easier to run • Better process control 4. Closed process
• Smaller SO2 emission • Better working conditions 5. High capacity, small in size, one unit • No converter isle, no cranes • Less maintenance • Lower investment costs 6. Possibility of separate mine-site smelters and market converting and refining facilities • Much like international trade of raw sugar Disadvantage of flash converting compared to PS converting 7. Reduced scrap melting capacity
CaOCaO
CalciumCalcium FFerriteerrite Sag
•Kennecott-Outokumpu Flash Converting Process cf 0.02 %, 0.5 % O for come Peirce-Smith Converting Operation
Refining Furnace (Anode Furnace)
Waiting or Oxidation or Anode Charging Reduction Casting
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OxidationOxidation
200~450 t/batch [S] + O2 ĺ SO2 S in Anode : < 0.003% 2[Fe][] + O2 ĺ 2FeO O in Anode : 0.1~0.2% ReducReductiontion
[O] + CO ĺ CO2 [O] + H2 ĺ H2O
Single-StepSingle--Step- Coppermaking