Saint Petersburg Mining University of Empress Catherine II (Saint Petersburg, Russia)

L. V. Krupnov, Associate Professor of the Department of Metallurgy, Candidate of Technical Sciences, Krupnov_LV@pers.spmi.ru

The current state of mining and metallurgical complexes processing sulfide copper-nickel raw materials is characterized by the depletion of high-grade ore deposits. This necessitates the processing of previously accumulated technogenic materials, which in some cases account for 30% or more of the feed to smelting furnaces. As a result, atypical smelting products, namely an intermediate layer and refractory accretions, form in different zones of the furnaces. This paper presents the results of studies on atypical smelting products formed during the processing of low-energy raw materials in autogenous smelting units. It is demonstrated that the main phases of these products are refractory compounds, including aluminosilicates with a wide range of compositions and spinels. The results of thermodynamic calculations of the conditions under which the refractory phases forming the basis of these products develop are presented. Based on these calculations, a mechanism for the formation of the intermediate layer and refractory accretions is proposed. The main factors affecting this process are identified. It is demonstrated that the primary cause of process disruptions during the smelting of low-energy raw materials is a heat balance deficit. Comparative calculations of the heat balances of smelting operations involving different types of raw materials are presented, based on actual heat consumption data obtained during the operation of industrial units, namely a flash smelting furnace and a Vanyukov furnace. The advantages of the bath smelting process (Vanyukov furnace) are substantiated. Industrial trials involving the processing of low-energy copper-nickel raw materials have confirmed the calculations and conclusions.
The author expresses his gratitude to S. S. Ozerov, Candidate of Technical Sciences, and V. A. Popov, Candidate of Technical Sciences, as well as to the employees of the Copper Plant of the Polar Branch of PJSC Norilsk Nickel MMC and LLC Gipronikel Institute, who took part in preparing the materials.

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