Kennecott Utah Copper Corporation

Kennecott Corporation

Kennecott Copper Corporation

Kennecott Holdings Corporation

Union Carbide Corporation

Praxair Technology, Inc.

Kennecott Holdings Company

David B George

Philip J Gabb

John F Castle

Eugene You

Torstein Utigard

Keming Zhou

Antonio Berges-Dreyfous

William John Mahoney

Daniel Kang Kim

Ian F Masterson

Adrian Christian Deneys

Jesse E Cates

Stephen A Manley

Kevin W Albrecht

Arsenio C Enriquez, Jr

Jesus A Sepulveda

Frederick A Rudloff

Kenneth J Richards

John R Knoepke

Leonard K Bailey

Minyan Ruan

Anthony J Weddick

Anthony G Storey

David Arana

Ian Francis Masterson

Roger Roth

Eugene Yanjun You

Kevin Albrecht

A method and system for the copper anode refining is provided in which coherent jet technology is employed to heat the molten blister copper and/or melt scrap copper charges using a melting flame, oxidize the sulfur in the molten blister copper, and reduce the oxygen in the molten blister copper using top-blown coherent jet gas streams from one or more multi-functional, coherent jet lance assemblies. The present system and method employs a microprocessor-based controller operatively controlling the flow of an oxygen-containing gas, an inert gas, a reducing agent and a fuel to the coherent jet lance. The disclosed copper anode refining system and method greatly improves copper production while lowering oxidation/reduction cycle times and minimizing NOemissions.

Copper anode refining system and method

A system, device, and method include a cell-powered first electronic device powered using electrical potential imposed across an electrolytic cell. The potential is voltage-boosted to accomplish this task. If the electrical potential imposed the cell is insufficient, the device can also be battery-powered. In any event, this device is in communication with one or more sensors in the electrolytic cell, as well as a second electronic device, and the first and second electronic devices wirelessly communicate. More specifically, the first electronic device wireless transmits data signals to the second electronic device, which receives the same. The first and second electronic devices are physically remote from one another, and they communicating over a private or public network, preferably using spread spectrum technology. In addition, the second electronic device also preferably transmits data signals to a computer for further processing of the data signals, and these arrangements can be used, for example, when producing copper.

Wireless electrolytic cell monitoring powered by ultra low bus voltage

For an electrolytic cell, an apparatus and method are described that use one or more sensors to measure magnetic field strength about a conductor carrying electrical current. A processor is in electrical communication with the sensors and determines a compensated magnetic field strength based on the magnetic fields of other conductors that also carry electrical current to or from the electrolytic cell. The processor uses this compensated magnetic field strength to determine the cathode electrical current carried by the conductor and to identify open and short circuits between the anodes and cathodes of the cell. The described apparatus and method account for interactions between the magnetic fields of the neighboring cathodes.

Monitoring electrolytic cell currents

In a copper converting furnace, the (i) reduction of copper oxide in and the removal of copper metal from the slag, and (ii) conversion of copper sulfide in and the elimination of mineral waste from the blister copper is enhanced by introducing a gas, e.g. nitrogen, into at least one of the blister copper and slag such that the gas increases the turbulence or mixing at the blister copper/slag interface and promotes a lowering of the sulfur dioxide equilibrium pressure within the blister copper and slag phases. In one embodiment, the gas is introduced into both the molten blister copper and slag through a porous-wall injector.

Enhanced phase interaction at the interface of molten slag and blister copper, and an apparatus for promoting same

Copper matte is processed to anode copper without oxidizing blister copper in an anode furnace. Copper matte, in either molten or solid form, is fed to a continuous copper converting furnace in which it is converted to blister copper and slag. The blister copper and slag collect in the settler region of the furnace and separate into two phases, a blister copper phase and a slag phase (the latter floating upon the former). The converting furnace is equipped with means for stirring or agitating the interface of the blister copper and slag phases such that the sulfur content of the blister copper phase and the copper content of the slag phase are reduced.

Process and apparatus for the continuous refining of blister copper

A metallurgical furnace, preferably a metallurgical furnace for the production of copper, is equipped with a forebay. The forebay is in open communication with the settler of the furnace by a passageway that allows for the continuous removal of both slag and metal product, e.g. matte, blister copper, etc. The slag and metal product maintain their phase-separated relationship as they enter the forebay. The forebay is equipped with a weir that divides the forebay into a slag skimming chamber and a riser chamber. The slag skimming chamber has at least one slag overflow notch on at least one sidewall. The notch is located at an elevation on the sidewall such that only slag enters and is removed from the forebay. The notch is above the top surface of the metal product, i.e. it is above the interface between the slag and metal product layers. The weir is located downstream from the slag overflow notch, and it is positioned such that it acts as a dam to the slag but not the metal product, the latter of which underflows the weir and flows into the riser chamber. The molten metal product continuously overflows the end wall of the riser chamber through at least one metal product overflow notch into any means, e.g. a launder, tundish, etc. for transfer to another vessel (e.g. a holding furnace, an anode furnace, etc.).

Forebay for am Metallurgical furnace

Solidified copper matte is used as a coolant to moderate or reduce the temperature of a bath of molten blister copper resident within a continuous, top-blown converter. In one embodiment, the addition of solidified copper matte to a bath of molten blister copper resident within a continuous, top-blown converter increases the throughput of the converter.

Method of moderating temperature peaks in and/or increasing throughput

Molten matte or slag is water granulated by feeding molten matte or slag through a launder to a granulator tank. The tank includes sloping walls and is equipped with adjustable overflow weirs and one or more of spray nozzles. These nozzles are positioned such that the water that they emit impacts on substantially all of the molten matte or slag that is fed to the granulator tank. The granulation tank is optionally coated with a polymeric material to reduce the potential for phreatic explosions. The granulator is also optionally equipped with a gas offtake which can be connected directly to a quench tower which in turn can be connected to an induced ventilation system.

Apparatus for and process of water granulating matte or slag

Metal, e.g. copper, is electrolytically deposited within the recess formed over a plugged hole of a component of a pyrometallurgical vessel, e.g. a cooling block, to form a seamless seal with the surface of the component. The method comprises the steps of inserting a mechanical plug into a channel opening of the component such that a recess is formed between the external surface of the plug and the outer surface of the component; positioning an anode adjacent the recess; providing an aqueous solution containing metallic ions, e.g. a solution of copper sulfate, between the anode and the mechanical plug; and creating an electric potential across the anode and the mechanical plug such that metal is deposited within the recess, preferably until the recess is filled with the electrodeposited metal. In alternative embodiments, the process can be used to secure fittings and the like to the components or to repair ruptured or weakened areas along the perimeter of such fittings.

Method of sealing cooling blocks using electrodeposited metal

A cooled elongated, preferably threaded and, tapered, metallurgical taphole plug and a method for using it are described. The plug is inserted into a taphole to cause a plug of molten material to freeze in the taphole such that molten material flow within the taphole is stopped. In one embodiment, the plug is comprised of an externally threaded, elongated member having a first end and a second end with a taper extending at least partially therebetween. The first, narrower end, which is inserted into the taphole, is cooled by a fluid flowing through an internal passage extending at least partially between the first and second ends. As the first end is cooled, the molten material adjacent the first end freezes around the tip of the first end, effectively plugging the taphole. The device is removed by discontinuing fluid flow and applying a rotational moment about the second end such that the threaded, tapered device backsout of the taphole.

Cooled tapping device

Fire-refined blister copper is produced from copper concentrate by a process comprising:

Apparatus and process for the production of fire-refined blister copper

A process for heating a molten material by injecting oxygen and a fuel into a molten bath of the material at a bath temperature above the spontaneous combustion temperature of the fuel, at least a portion of the fuel forming a shroud around the oxygen, and combusting the fuel to provide heat to the molten material. Where the molten material is impure copper the amount of oxygen and fuel injected may also be controlled to alternately oxidize and reduce the copper impurities and remove them from the bath. Solid material may be melted in the bath during any stage of heating or refining. In a preferred embodiment, a portion of the fuel forms a shroud around the oxygen during injection, and the oxygen forms a shroud around the remaining fuel.

Submerged combustion in molten materials

Copper sulfide ores are processed by a unique series of steps to produce blister copper, while attaining long sought advantages. An initial smelting step is carried out in any desired manner, e.g. according to conventional practice, to produce a molten, copper sulfide matte or white metal. This matte or white metal is then solidified and subjected to a size-reduction step to produce solid particles capable of being injected into a converting vessel in a stream of oxygen, either pure oxygen or air significantly enriched with oxygen. With the matte or white metal injected in this manner, the converting reaction may be carried out on an autogenous basis, with continuous evolution of substantially undiluted SO.sub.2 gas capable of being liquified for use in the production of elemental sulfur or sulfuric acid or for disposal so as to avoid atmospheric contamination. The usual fugitive gas emissions resulting from the handing and transporting of molten matte in conventional ways are almost completely avoided, and continuous optimized operation of the converting vessel is achieved independently of operation of the smelting step, making it possible to eliminate the often-resorted-to close coupling of smelting and converting furnaces and affording unusual freedom in plant layout.

Solid matte-oxygen converting process

A method of pyrometallurgical refining of crude silver to remove base metal impurities, particularly bismuth, by treatment with sulfer hexafluoride gas. The crude silver is melted and maintained at about 1000.degree. C. while it is treated concurrently with sulfur hexafluoride and an oxidizing gas, such as air. Base metal fluorides are formed and are removed from the silver, after which the molten bath is treated with a reducing agent, such as hydrogen gas.

Process for removal of base metal impurities from molten silver with

A gas sampling probe for industrial furnaces, such as reverberatory furnaces used in extractive metallurgy, is constructed with a sample tube concentrically disposed within a shield tube and spaced therefrom to provide an annular passage for a coolant fluid, such as steam or water vapor, which is discharged from the shield tube through ports therein located, for example, above the open lower end of the sample tube, as well as through the lower open end of such shield tube. The shield tube extends below the lower open end of the sample tube as a protection against accretion build-up, and an annular partition plate which is secured to the shield tube but terminates short of the sample tube permits free expansion and contraction of the sample tube while limiting discharge of the coolant fluid through the lower open end of the shield tube.

Growing community of inventors

Salt Lake City, UT, United States of America

David B George