Mali Gas

Process Gas Handling in Copper Metallurgy
Metals
Engineering & Construction Division
M.A.Cocquerel Vice President Nonferrous Technology Kvaerner E&C San Ramon CA, USA C.Cuadra and T.Moya Pyrometallurgical Specialists Kvaerner E&C Santiago, Chile

Introduction Process Description
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Selection and Design of Gas Handling System Sulfur Recovery from Copper Smelter Gases Conclusion

INTRODUCTION
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Pyrometallurgycal Process Gases (drying, smelting, converting, slag cleaning and fire refining): - contain sulfur dioxide, metallic impurities and particulate materials at elevated temperatures. - must be cooled, cleaned and treated for sulfur recovery - over 40 % SO2 concentration liquid SO2 production - between 8 - 40 % SO2 sulfuric acid production
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INTRODUCTION...
This presentation includes:
- a brief description of the process gas handling system

- a qualitative comparison of this system
- a description of sulfur process recovery

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PROCESS DESCRIPTION Drying - Reduce the copper concentrate humidity from 8-10% to 0.2 % - Indirect Drying (lower process gases, less dust content) - Direct Drying (larger process gases, high dust content)

Typical Drying Process Gases Description Type of dryer Concentrate feed Moisture t/h % Units
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Indirect Drying (*) Direct Drying (**) Kvaerner Steam Dryer 60 - 70 8 9.5 Bag Filter 11000 - 15000 125 - 133 n.a. Fluid bed 60 - 90 6.5 9.5 Cyclone/Bag filter 80 000 100 000 125 - 135 n.a
Type of dedusting 3 Inlet gas flow Nm /h Inlet gas temp. C 3 Inlet dust loading g/Nm

Typical Drying Process Gases Description Type of dryer Composition SO2 H2O CO2 O2 N2 (*) (**) Units
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Indirect Drying (*) Direct Drying (**) Kvaerner Steam Dryer Fluid bed
Vol.% Vol.% Vol.% Vol.% Vol.%
0 50 0 10 40
1 (SO2 + CO2) 8 1 (SO2 + CO2) 19.5 79.5
Operational Data from Chagres Smelter, Disputada Las Condes, Chile Data from Caletones Smelter, CODELCO, Chile
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Smelting / Converting
- Outokumpu Flash Furnace
- Inco Flash Furnace
- Noranda Furnace
- Teniente Furnace
- Mitsubishi Smelting Technology

- Peirce-Smith Converter
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Outokumpu Flash Furnace

Flue Dust Dry Concentrate + Flux Waste Heat Boiler To Acid Plant Electrostatic Precipitator
Enriched Air
Settler
Reaction Shaft
. . .. .. : .. . . .
Gases Shaft
Drag Conveyor
Drag Conveyor
Matte Settler
Slag
Flue Dust to FSF Feed System
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Noranda Reactor
Ele ctro static Preci pita to r to Acid Pla nt
s se d a G oo H
Nora nda Fur na ce
Co oli ng Ch ambe r
Bal loo n Flue
Ele ctro static Preci pita to r
He at Excha ng er Ho od Co ol ing Water System Dra g Co nveyo r
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Teniente Converter
Rad iant Coo ling E lectr ost atic P re cipita tor to A cid P lant
s se d a G oo H
T enie nte Con ver ter
Coo ling Cha mb er
B alloon Fl ue
E lectr ost atic P re cipita tor
Hea t E xcha ng er Hoo d Co oling Wat er syste m Dra g Co nve yor
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Proceso Mitsubishi
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Convertidor Peirce-Smith

Facility Gas Vol. (Nm3/h) Gas Temp. (C) SO2 in off gas (%) Dust Loading 3 (g/Nm )
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Configuration of Various Smelter Off-Gas System Gas Cooling Gas Cleaning
Asarco, Hayden P.D.,Chino
12,600
1200
80 70 75 70 80 70 80
350
Settl.Ch./ Spray Cooler Settl.Ch. / Wash Tower Settl.Ch. / Wash Tower Quench Chamber Vert./Horiz. Boiler Horizontal Boiler
ESP
15,800
1200
270
Scrubber
Inco (Copper) Inco (Bulk conc) Asarco, El Paso P.D.Hidalgo
12,600
1200
390
Scrubber
18,900
1320
200
Scrubber
15,800
1350
20
70
ESP
83,600
1300
22
180
ESP

Facility Gas Vol. (Nm3/h) Gas Temp. (C)
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Configuration of Various Smelter Off-Gas System SO2 in off gas (%) 25 50 Dust Loading 3 (g/Nm ) Gas Cooling Gas Cleaning
Harvajalta
19,700
1370
250
Horizontal Boiler Horizontal Boiler Horizontal Boiler Horizontal Boiler Spray Cooler Vertical Boiler
ESP
Tamano
48,900
1000
13.5
90
ESP
Kidd Creek
31,500
1200
25
70
ESP
Kennecott
126,200
870
22
40
ESP
Noranda, Horne Kivcet, Sardinia
116,700
870
22
100
ESP
141,900
1260
25 - 30
50 - 70
ESP

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Selection and Design of Gas Handling Systems Design Parameters: - Gas and particulate capture (hood design) - Gas cooling - Gas cleaning - Dust build - up - Pressure drops (fans and stack draft) - Ductwork material - Contaminant dispersion from stack
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Gas Cooling Methods: - Waste Heat Boiler - Evaporative Coolers - Radiant Coolers - Quench Coolers - Gas to Air Heat Exchanger
Process Gas Handling in Copper Metallurgy Waste Heat Boiler
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For continuous large gas flow, with steam production. Design must consider: - feed water system - water circulation - high pressure steam production Disadvantage: The downtime required for maintenance and change of damaged walls or panel tubes
Process Gas Handling in Copper Metallurgy Evaporative Cooler
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- Horizontal or vertical, continuous or discontinuous large gas flow, with spray water addition. - The evaporated water increases the gas flow and water content sent to the sulfuric acid plant, affecting the heat balance. - Operation decreases the gas temperature, but does not decrease the heat content of the gases.
Process Gas Handling in Copper Metallurgy Radiant Cooler
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- Cooling the process gases by conduction,
convection or radiation
- No energy recovery - Horizontal Chamber with a Pack of Tubes
Process Gas Handling in Copper Metallurgy Quench Cooler
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- fast cooling of the gases to lower the actual
off gas volume

- minimize the corrosion effect of extended wet / dry interfaces - size decreasing of all ducting and subsequent handling equipment
- very short residence time minimizes the

oxidation of SO2 to SO3
Process Gas Handling in Copper Metallurgy Gas to Air Heat Exchanger
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Similar to the radiant cooler, but it is used for
batch operation with high air infiltration.
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Gas Cleaning Methods

- Cyclones - Wet Scrubbers - Electrostatic Precipitators - Baghouses
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CYCLONES
Pre-cleaning equipment to handle heavy dust with above 90 % efficiency. e.g. Fluxflow Technology in the Isasmelt copper process

Fluxflow Technology
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Process gas out T = 150900C Dust 120 g Nm3
Water / steam / air Riser
Cyclone
Water / air
Solids recycle Mixing chamber T = 200900C
Dust out
Process gas in T = 6001800C Dust, droplets, vapor 10500 g/Nm3
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Wet Scrubbing They use mechanical means to create fine water droplets to contact them with the dust laden gas. The dust is separated out in a second stage centrifugal, inertial or wet electrostatic separator.
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Electrostatic Precipitator
A high voltage electrode ionizes the gas. The positive ions being attracted to the discharge electrodes and the negative charged particles migrate towards the collecting plate to which they adhere while being discharged. These particles build-up a layer of dust on the plate surface which is dislodged by rapping.
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Schematic Drawing of Electrostatic Precipitator

Basic Arrangement of Electrostatic Precipitator
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Type F precipitator with pyramidal hoppers and two central inlet transition pieces each incorporating three vertical gas distribution screens
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Baghouses
Dust and fume are collected on a fabric filter, which are increasingly used in concentrate drying application and fugitive gas cleaning. Some copper smelter use fabric filter after ESP to collect dust high in Zn and Pb.

Bagfilter (Pulse Jet Collector)
Double Diagram Valve Walk in Access Pulse Header Clean Air Plenum Pulse Manifold Pipe
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Clean Floor Design
Filter Bags
Heavy Duty Hopper Construction Dust Discharge
Inlet With Gas Distribution Baffle
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Process Parameters Affecting Hot Gas Cleaning Equipment Process Parameter Cyclic temperature Process Source Effect on Gas Cleaning Peirce Smith Converter. Design must allow freedom of expansion for structural and internal components. Dust builds up in flues at low flow. High collection efficiencies required and adequately sized dust conveying equipment.
Cyclic gas flow High dust loads
Peirce Smith Converter. Continuous smelting processes.
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Process Parameters Affecting Hot Gas Cleaning Equipment Process Parameter Chemically reactive dust Process Source Effect on Gas Cleaning Chemical reaction within the gas cleaning equipment to form hard sulfates. Dust very difficult to collect with electrostatic precipitators.
Concentrate feed processes.
High resistivity dust
Copper smelting/converting processes with high lead and zinc content in the concentrate. Occurs in case where dust is returned to the process, it quickly builds up a high-recirculated load.
Recirc. dust load
Collected dust may have to be treated separately or returned to a different smelter furnace.

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Sulfur Recovery from Copper Smelter Gases
Acid Plant
Liquid SO2
Elemental sulfur
Dilute gas treatment
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Flowsheet for Producing H2SO4 from Smelting and Converting gases
Smelting and Converting 1200C Gas Cooling and Dust Removal 300C
Electrostatic Precipitation of Dust

300C
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from EP of Dust 300C Gas Scrubbing and Cooling with water 35 - 40C Electrostatic Mist Precipitation 35 - 40C 5-7% H2O
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Gas Drying with 93% H2SO4 O2/S2 ratio=1.1 410C Catalytic Oxidation of SO2 to SO3 ~ 200C
Absorption of SO2 in 98% H2SO4

Tail gas (~80C) to stack or scrubbing with basic solution
98% H2SO4, 2% H2O

Flowsheet for Producing liquid SO2
>80%SO2 40-65C Mist Precipitator
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SO2 compression (7 - 10 atm)
SO2 condensation
Liquid SO2
Process Gas Handling in Copper Metallurgy Elemental Sulfur
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Process gases must contain more than 10 % SO2 SO2 reduction with carbon or hydrogen gas high cost of reductants
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Weak Gas Streams Treatment

Flue Gas Desulfurization
Regenerative Absorption (MgO concentration system, USBM citrate process, Flakt-Boliden citrate process, Cominco ammonia scrubbing system, Wellman-Lord Process) Non-regenerative system(Onahama lime/gypsum, Palabora process, Sodium carbonate process, Aqueous carbonate process, double alkali and Chidoya Thoroughbred 101 process)
Process Gas Handling in Copper Metallurgy CONCLUSIONS
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Gas handling and cleaning represent today a substantial part of plant capital and operating cost.
The gas cooling and cleaning systems must be designed to avoid downtime, build-up, corrosion and other typical problems. The harmful effects of sulfur dioxide on the environment has and will continue to lead to the imposition of more stringent air pollution control regulations in all the smelting industry.
Process Gas Handling in Copper Metallurgy CONCLUSIONS...
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The tendency in the copper industry is to maximize the production of a continuous flow of high strength gas from the primary smelter furnace. The recovery of sulfur as sulfuric acid is the accepted control approach in the industry.
The use of a double absorption acid plant, scrubbing of acid plant tail gas, collection and scrubbing of fugitive emissions permit better than 99 % sulfur fixation.
Process Gas Handling in Copper Metallurgy CONCLUSIONS...
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The tendency in the copper industry is to maximize the production of a continuous flow of high strength gas from the primary smelter furnace. The recovery of sulfur as sulfuric acid is the accepted control approach in the industry.
The use of a double absorption acid plant, scrubbing of acid plant tail gas, collection and scrubbing of fugitive emissions permit better than 99 % sulfur fixation.

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Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

This presentation includes:

- a brief description of the process gas handling system

- a description of sulfur process recovery

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Vol.% Vol.% Vol.% Vol.% Vol.%

1 (SO2 + CO2) 8 1 (SO2 + CO2) 19.5 79.5

Process Gas Handling in Copper Metallurgy

- Mitsubishi Smelting Technology

Process Gas Handling in Copper Metallurgy

Outokumpu Flash Furnace

Flue Dust to FSF Feed System

Process Gas Handling in Copper Metallurgy

Bal loo n Flue

Ele ctro static Preci pita to r

He at Excha ng er Ho od Co ol ing Water System Dra g Co nveyo r

Process Gas Handling in Copper Metallurgy

Coo ling Cha mb er

E lectr ost atic P re cipita tor

Hea t E xcha ng er Hoo d Co oling Wat er syste m Dra g Co nve yor

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Configuration of Various Smelter Off-Gas System Gas Cooling Gas Cleaning

Asarco, Hayden P.D.,Chino

Inco (Copper) Inco (Bulk conc) Asarco, El Paso P.D.Hidalgo

Process Gas Handling in Copper Metallurgy

Noranda, Horne Kivcet, Sardinia

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy Waste Heat Boiler

Process Gas Handling in Copper Metallurgy Evaporative Cooler

Process Gas Handling in Copper Metallurgy Radiant Cooler

- Cooling the process gases by conduction,

Process Gas Handling in Copper Metallurgy Quench Cooler

- fast cooling of the gases to lower the actual

off gas volume

- very short residence time minimizes the

Process Gas Handling in Copper Metallurgy Gas to Air Heat Exchanger

Similar to the radiant cooler, but it is used for

batch operation with high air infiltration.

Process Gas Handling in Copper Metallurgy

Gas Cleaning Methods

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process gas out T = 150900C Dust 120 g Nm3

Water / steam / air Riser

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Schematic Drawing of Electrostatic Precipitator

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Process Gas Handling in Copper Metallurgy

Clean Floor Design