Improved copper production method

专利摘要:
What is disclosed is a process for the production of a crude solder product and a copper product comprising the steps of a) providing a black copper containing> = 50 wt% copper together with> = 1.0 wt% tin and / or> = 1.0% by weight of lead, and (i) refining a first portion (1) of the black copper to obtain a refined copper product (9) together with at least one copper refining slag (3, 6, 8), (ii) recovering a first raw solder product (18, 26) from the copper refining slag (3, 6, 8), thereby forming a solder refining slag (19, 27) that is in equilibrium with the first raw solder product, wherein the method further comprising: f) contacting (700, 1100) another portion (50, 55) of the black copper with the solder refining slag (19, 27) whereby an exhausted slag (20, 28) and a metal on lead-tin base (10, 29) are formed, followed by separation of the spent slag from the lead-tin base metal.
公开号:BE1025771B1
申请号:E2018/5874
申请日:2018-12-10
公开日:2019-07-08
发明作者:Bert Coletti；Jan Dirk A. Goris；Visscher Yves De；Charles Geenen；Walter Guns；Niko Mollen；Andy Breugelmans；Steven Smets
申请人:Metallo Belgium；
IPC主号:

专利说明:

FIELD OF THE INVENTION
The present invention relates to the production of non-ferrous metals by pyrometallurgy, in particular the production of copper (Cu) and so-called solder products. More particularly, the invention relates to an improved process for the co-production of copper and solder currents from primary and secondary base materials, as high-quality products for further upgrading to metal products with commercially desired purities. Solder currents often belong to the family of metal compositions or alloys that contain significant amounts of tin (Sn), usually but not necessarily together with lead (Pb).
BACKGROUND OF THE INVENTION
The non-ferrous metals can be produced from new ores as the starting materials, also called primary sources, or from recyclable materials, also called secondary base materials, or from a combination thereof. Recyclable materials can for example be by-products, waste materials and materials at the end of their life. The recovery of non-ferrous metals from secondary base materials has, over the years, become an activity of the highest importance. The recycling of non-ferrous metals after use has come to play a key role in the industry, due to the continued high demand for such metals and the decreasing availability of new high-quality metal ores. Especially for the production of copper, its recovery from secondary base materials has acquired a considerable interest in the industry. In addition, the decreasing availability of new high-quality metal ores has also led to an increase in the importance of recovering non-ferrous metals from lower-quality metal base material. For example, the lower-grade metal base materials for copper recovery may contain significant amounts of other non-ferrous metals. These other metals may in themselves have significant potential commercial value, such as tin
BE2018 / 5874 and / or lead, but these primary and secondary base materials may contain other metals with a lower or no economic value at all, such as zinc, bismuth, antimony, arsenic or nickel. These other metals are often undesirable in the high-quality commercial non-ferrous metal products, or are only permissible in very limited amounts.
The materials that are available as basic material for copper production therefore generally contain a multitude of metals. Secondary copper base materials are, for example, bronze, essentially an alloy of copper and tin, and brass, an alloy of primarily copper and zinc.
These different metals must be separated from the copper in the production process. The base materials may additionally contain small levels of a range of other elements, including iron, bismuth, antimony, arsenic, aluminum, manganese, sulfur, phosphorus and silicon, most of which have limited acceptability in a high-quality, high-volume commercial metal product .
Secondary basic materials that contain copper can also be electronic and / or electrical components at the end of their service life. In addition to copper, these basic materials generally contain the soldering components, mainly tin and lead, but usually also contain additional metals such as iron and aluminum, plus occasionally small quantities of precious metals, and also non-metallic parts such as plastics, paint, rubber, glue, wood , paper, cardboard etc .... These basic materials are generally not clean, and therefore usually also contain additional impurities such as dirt, grease, wax, soil and / or sand. Many metals in such base materials are often also partially oxidized.
Because the base materials with lower purities and higher levels of contaminants, both primary and secondary base materials, are much more widely available, there is a need for a broadening of the possibilities of non-ferrous metal production processes to increase the permissibility of such
BE2018 / 5874 low-grade raw materials as part of the basic materials for the recovery or production of non-ferrous metals such as copper.
The non-ferrous metal production processes generally comprise at least one, and usually a plurality of pyrometallurgical process steps. A very common first pyrometallurgical step for recovering copper from low-grade secondary materials is a smelting step. In a smelting furnace, the metals are melted, and organic substances and other combustible materials are removed by incineration. In addition, various chemical reactions take place between many of the other components that are introduced into the smelting furnace. Metals with a relatively high affinity for oxygen are converted to their oxides and collect in a lower-density slag phase that floats to the surface of the molten metal phase. More volatile metals can escape from the liquid phase to the gas phase and leave the furnace with the exhaust gases, together with any carbon oxides and / or SO 2 that may have formed. The metals with a lower affinity for oxygen, if present in an oxidized state, rapidly reduce to their elemental metal form and move to the heavier underlying metal phase. If they are not oxidized, these metals remain present as elemental metal and remain in the bottom of the smelting furnace in the liquid metal phase with higher density. In a copper production step, the smelting step can be carried out in such a way that most of the iron ends up in the slag, while copper, tin and lead end up in the metal product, a stream commonly referred to as "black copper". Most of the nickel, antimony, arsenic and bismuth will also become part of the black copper product.
U.S. Pat. No. 3,682,623, and its counterparts AU 505015 B2 and AU 469773 B2, describe a copper refining process that begins with a melting step leading to a black copper stream followed by the further stepwise pyrometallurgical refining of this black copper to a current of copper of anode quality, suitable for being cast into anodes for electrolytic refining. The refining of the black copper in US 3,682,623
BE2018 / 5874 led to the formation of a number of successive copper refiner slags, with the early slag rich in zinc, the middle slag rich in lead and tin, and the end slag rich in copper. The different refining slags were brought together and collected together, and transferred to a slag re-treatment furnace for recovery of the copper, lead and tin present in those slags. In a first slag reprocessing step, the collected copper refining slag was partially reduced by adding copper / iron scrap, copper / aluminum alloy and quicklime, so that a metal stream could be separated (Table XIV) with which about 90% of the copper and about 85% of the nickel was recovered in the oven. This tapped metal stream is referred to as "black copper" in US 3,682,623 and was recycled to the refining furnace, where it was mixed with the pre-refined black copper from the melting furnace and with radiators (Table VI). After draining this black copper, an extracted slag remained in the furnace, this slag being further reduced in a subsequent step by loading the furnace with an amount of 98% iron scrap. This second reduction step yielded a lead / tin metal (i.e., a kind of "crude solder") that was drained for further processing, along with an exhausted slag (Table XV), which was presumably disposed of. The solder metal product contained 3.00% by weight of iron, 13.54% by weight of copper and 1.57% by weight of nickel, i.e. 18.11% by weight in total. The spent slag contained 0.50% by weight of tin and the same amount of lead, and 0.05% by weight of copper. Because the total amount of snail used up was very high, these low concentrations represent economically large quantities.
The method according to US 3,682,623 provides, for the black copper obtained as the high-quality product from the upstream melting step, one access point to the refining furnace, i.e. at the beginning of the sequence of the copper refining process (Table VI). The upstream melting step accepts complex base materials and base materials of low quality, such as slag, scrap and ash. The black copper obtained from the melting step is therefore based on materials that have little or no other escape, and is therefore available
BE2018 / 5874 meet very attractive economic conditions. It would therefore be interesting to be able to process as much black copper as possible from the upstream melting step.
However, for a given volumetric capacity of the copper refining furnace in US 3,682,623, supplying more black copper to the first step in the copper refining process sequence would require a reduction in the input of other feeds to that first step, ie the "radiators," and also from fresh feeds to the further steps in the copper refining process sequence. The metal stream that is recycled as "black copper" from the downstream impact re-treatment furnace (Table XIV) has no other way out, and therefore must indeed remain part of the feeding to the first step of the copper refining process sequence (Table VI). The supply of more black copper feed to the copper refining sequence in the U.S. Pat. No. 3,682,623 would thus be at the expense of other fresh base materials, to the first and to the following copper refining steps.
Consequently, there remains a need for a pyrometallurgical copper production process capable of handling larger quantities of black copper from an upstream smelting furnace step, without having to reduce the volume of other fresh base materials that can be added to the first and / or the subsequent steps of the copper refining process sequence.
It is an object of the present invention to eliminate or at least alleviate the problem described above, and / or to provide improvements in general.
SUMMARY OF THE INVENTION
According to the invention, a method is provided as defined in any of the appended claims.
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In one embodiment, the present invention provides a method for the production of a crude solder product and a copper product comprising the step of
a) providing a black copper composition comprising at least wt% copper together with at least 1.0 wt% tin and at least 1.0 wt% lead, the method further comprising the steps of (i) ) refining a first portion of the black copper composition obtained from step a) to obtain a refined copper product together with at least one copper refining slag, (ii) recovering a first raw solder metal composition, as a first raw solder product from the at least one copper refining slag, thereby forming a second solder refining slag in equilibrium with the first raw solder metal composition, characterized in that the method further comprises the step of
f) contacting a second portion of the black copper composition from step a), different from the first portion, with the second solder refining slag, thereby forming a second spent slag and a second lead-tin-based metal composition by separating the second spent slag from the second lead-tin-based metal composition.
The applicants claim that a method according to the preamble of claim 1 is known from US 3,682,623, AU 469773 B2 and AU 505015 B2. Example 1 in each of these documents describes how the melting step plus its final reduction step are capable of providing a black copper composition as indicated in step a) (Table VIII). A number of further oxidation steps, with details in Tables IX, X, XI and XII, describe the refining of black copper, as indicated in step (i), to the refined copper product of Table XII, together with a number of slags that are decanted and put into the slag re-treatment furnace is introduced at the beginning of Example 2. Example 2 describes the recovery of one
BE2018 / 5874 raw solder metal composition (Metal in Table XV) from these slags, thereby also forming a solder refining slag (Snails in Table XV). Thus, in the prior art, at least one method is prescribed for obtaining the components that are essential to enable step f).
The second solder refining slag which enters in step f) contains valuable solder metals, i.e. Sn and / or Pb, some of which are in the form of their oxides, and some of which are also entrained in their elemental metal form. The black copper that enters in step f), optionally together with other fresh feed elements that can be added at this stage, contains at least the copper content prescribed as part of step a). The black copper also contains some tin and lead, usually together with other metals that have a higher affinity for oxygen under the conditions of the process than copper, tin and / or lead.
Applicants have found that contacting the black copper with the second solder refining slag in step f) leads to an extraction by the copper of Sn and / or Pb from the slag phase and into the molten metal phase, and a reaction of oxides of Sn and / or Pb with metals in the black copper with a higher affinity for oxygen than copper, tin and / or lead, such as for example Fe or Zn. Applicants have determined that these mechanisms are capable of taking place without causing an unacceptable loss of copper in the spent snail produced in step f).
The method according to the present invention surprisingly entails the advantage that the method is capable of processing a much larger amount of black copper base material than the sequence of successive copper refining steps for producing a refined copper product enriched in copper and copper. possible to anode quality, is able to record. Applicants have found that this can make it possible to significantly increase black copper processing capabilities of the global process, compared to the sequence of successive copper refining steps
BE2018 / 5874 for producing a refined copper product, possibly and even preferably of anode quality, is capable of incorporating into its first step.
In order for a concentrated copper stream or a concentrated copper product to have anode quality or to be of anode quality, the applicants prefer that the product comprises at least 98.0% by weight of copper, preferably at least
98.5% by weight, more preferably at least 99.0% by weight, even more preferably at least 99.5% by weight, even more preferably at least
99.8% by weight of copper.
In addition to the advantage of being able to process much higher volumes of black copper from an upstream process step, the applicants have surprisingly determined that the method of the present invention is capable of incorporating black copper with a lower copper content and a higher content of other valuable metals, in particular of the solder metals tin and / or lead, preferably tin and optionally also lead.
This entails the advantage that the process of the present invention is much more tolerant to elements other than copper, most of which are elements that have a higher affinity for oxygen than copper under the conditions of the process, and possibly even higher than tin and lead. This advantage creates the possibility of producing a larger amount of tin for the same amount of copper production, which provides a considerable economic advantage for the person carrying out the process.
The applicants point out that the method according to the present invention in step f) produces a used-up slag,
i.e., a slag that is removed from the process. The purpose of step f) is to recover most of the tin and lead present in the furnace in the lead-tin-based metal composition, a stream that is well suited to be recycled to a process step upstream of step f). This embodiment of step f) entails the advantage that the majority of the copper and nickel present in the furnace, since copper and nickel are even lower in the conditions of the process.
BE2018 / 5874 have an affinity for oxygen than tin and lead, also ends up in the lead-tin-based metal composition, and is therefore easily recycled and thus becomes available for recovery as part of a high-quality product from the global process. This embodiment of step f) further has the advantage that most of the metals and other elements which, under the conditions of the process, have a higher affinity for oxygen than tin and / or lead, react with oxides of metals with a lower affinity, such as tin and / or lead, and thus become part of the spent snail. This applies to elements selected from the list of zinc, iron, aluminum, manganese, sulfur, phosphorus and silicon. Most of these "less noble" metals have a much lower commercial value than copper, tin and lead. The method of the present invention easily removes most of these "less noble" metals, when introduced as part of the portion of the black copper supplied to step f), immediately from the method as part of the spent slag which is obtained in step f).
Applicants have determined that step f) is preferably carried out as an additional reduction step f). Performing the step f) for treating the second solder refining slag allows the recovery of most of the solder metals from that current, and causes a substantial reduction in the amounts of solder metals lost with the second spent slag produced in step f). Applicants have found that this additional recovery of valuable metals from the second solder refining slag makes it possible to obtain in the downstream step a first raw solder metal composition that is richer in the desired solder metal tin and / or lead, and therefore poorer in the metals that are undesirable as part of the soldering product, and therefore must be removed. The removal of these other metals from the raw solder metal composition requires chemicals, in particular when the refining process comprises the treatment with silicon metal, as set forth in patent DE 102012005401 A1 for treating the raw tin product. Obtaining a raw solder metal composition that
BE2018 / 5874 contains fewer undesirable other metals, thus brings considerable economic benefits for the downstream refining of that raw solder metal composition.
The applicants have further established that, coupled with a higher production of crude solder product in an upstream pyrometallurgical step, and provided that the second solder refining slag is kept in the same furnace, more furnace volume becomes available for adding more black copper to the furnace charge of step f). The present invention therefore entails the advantage that more black copper can be processed as part of step f). More space for extra black copper in step f) means more space for additional copper, which allows a higher recovery of tin and / or lead in step f) and a lower presence of tin and / or lead in the spent slag from step f ).
Applicants have found that the present invention also considerably eases the acceptability criteria for the black copper introduced in step f). This advantage considerably reduces any need for pre-refining before the black copper can be used as starting material for pyrometallurgical copper refining steps, as described in US 3,682,623. This advantage also broadens the acceptability criteria for the raw materials used in the upstream production of the black copper, usually in a smelting furnace step. The upstream step is therefore able to incorporate many more low-quality raw materials, which are generally more widely available under more economically attractive conditions.
Applicants have found that the addition of a significant amount of copper in step f), for example as part of the black copper composition being introduced, brings a significant advantage as the copper can act as an excellent extraction agent for any other valuable metals remaining in the second solder refining slag from step (ii), and that this advantageous extraction step can be carried out without loss of
BE2018 / 5874 significant amounts of copper in the second spent snail produced in step f).
The applicants have further established that the part of the second part of the black copper composition that can be added in step f) may contain significant amounts of other valuable metals, in particular of zinc, nickel, tin and / or lead. The applicants have found that, especially when sufficient copper is made available in step f), the losses of in particular tin and / or lead in the second spent slag can be kept very low and therefore do not entail any risk for the possible further use or trajectory of this second spent snail.
Applicants have found that in step f) a substantial amount of the black copper provided in step a) can be added in step f) to extract more valuable metals from the second solder refining slag obtained from step (ii) without excessive loss of extra valuable metals in the second spent snail from step f). Applicants have found that the amounts of such black copper from, for example, an upstream smelting furnace step that are acceptable in step f) are very substantial, even on the order of the amount of black copper that can be fed to the first step of the copper refining sequence. Applicants have found that incorporating step f) into the process of the present invention considerably increases the capacity to process smelting furnace type black copper, and therefore to process larger quantities of lower quality raw materials in which valuable metals are used at base material value provided and therefore with a high potential for upgrading. The applicants have found that this entails the additional advantage that a substantial portion of the black copper can be processed from the upstream smelting furnace step without all of that black copper having to go through the first step of the copper refining (i). Any metals present in the black copper feed to step f) which have a higher affinity for oxygen under the conditions of the process
BE2018 / 5874 then copper, tin and / or lead are most likely already removed before the copper introduced with this fresh black copper feed to step f) can find its way into the step sequence of the copper refining process (i).
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a process flow diagram of a preferred embodiment of the method according to the present invention.
DETAILED DESCRIPTION
The present invention will be described below in specific embodiments and with possible reference to specific drawings; however, it is not limited to that, but is only determined by the conclusions. The described drawings are only schematic and are non-limiting. In the drawings, the size of some elements for illustrative purposes may be magnified and not drawn to scale. The dimensions and relative dimensions do not necessarily correspond to actual practical embodiments of the invention.
Furthermore, the terms first, second, third, and the like, in the description and claims, are used to distinguish between similar elements, and not necessarily to describe a sequential or chronological order. The terms are interchangeable under appropriate conditions, and the embodiments of the invention may function in sequences other than described or illustrated herein.
Furthermore, the terms upper, lower, top, bottom, and the like, in the description and the claims, are used for descriptive purposes, and not necessarily to describe relative positions. The terms thus used are interchangeable under appropriate circumstances, and the embodiments of the invention described herein may function in orientations other than described or illustrated herein.
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The term "comprising", used in the claims, should not be interpreted as being limited to the means listed in its context. It does not exclude other elements or steps. The term is to be interpreted as the required presence of the stated properties, numbers, steps or components, but does not exclude the presence or addition of one or more other properties, numbers, steps or components, or groups thereof. The scope of the expression "an item comprising means A and B" should therefore not be limited to an object composed solely of components A and B. It means that for the subject matter of the present invention, A and B are the only relevant components. Accordingly, the terms "include" or "enclose" also include the more restrictive terms "consist essentially of" and "consist of". Therefore, when "include" or "contents" is replaced with "consist of," these terms represent the basis of preferred but narrowed embodiments, which are also provided as part of the contents of this document relating to the present invention.
Unless otherwise specified, all values specified in this document include the range up to and including the end points indicated, and the values of the components or components of the compositions are expressed in percent by weight, or percent by weight, of each ingredient in the composition.
In addition, each compound used in this document can be interchangeably discussed based on its chemical formula, chemical name, abbreviation, etc.
Within the context of the present invention, the term "at least in part" includes its end point "complete". With regard to the extent to which a particular oxidation or reduction step of the process is carried out, a typical preferred embodiment is a partial implementation. With regard to the addition or recycling of a process stream in a particular process step, a typical preferred embodiment is the operating point "fully" within the range covered by the term "at least partially".
BE2018 / 5874
In the context of the present invention, "smelter", "melting", "melting" or similar "melting" derivative means a method that involves much more than just changing the aggregation state of a substance from solid to liquid. In a pyrometallurgical smelter step, various chemical processes also occur that convert certain chemical compounds into other chemical compounds. Important of these conversions can be oxidations, whether or not accompanied by the formation of an oxide, or reductions, whereby the oxidation state of some atoms change.
In the context of the present invention, "scratch" or "scratch" means an often pasty substance that forms as a result of an operational step, and which separates from another liquid phase, usually under the influence of gravity, and usually comes to the surface. The scratch or scratches are therefore usually mechanically scraped or removed from the underlying liquid.
By "the solder", or also "the solder", is meant in the context of the present invention a metal composition that is rich in tin and / or lead, but which may also contain other metals. Solder typically has a relatively low melting temperature, which makes the composition suitable for being able to form a metal connection between two other metal parts, the so-called "soldering" after cooling to a relatively limited temperature.
In this document, unless otherwise stated, quantities of metals and oxides are expressed in accordance with current practice in pyrometallurgy. The presence of each metal is generally expressed as its total presence, regardless of whether the metal is present in its elemental form (oxidation state = 0) or in any chemically offered form, typically an oxidized form (oxidation state> 0) . For the metals that can be relatively easily reduced to their elemental form, and that can appear as molten metal in the pyrometallurgical process, it is quite common to express their presence in terms of their elemental metal form, even when the composition of a slag is indicated,
BE2018 / 5874 while the majority of such metals may in fact be present in oxidized form. For this reason, the composition of Fe, Zn, Pb, Cu, Sb, Bi is specified as elemental metals in the composition of a slag. Less noble metals are more difficult to reduce under non-ferrous pyrometallurgy conditions and usually occur in oxidized form. These metals are usually expressed in terms of their most common oxide form. Therefore, in slag compositions, the Si, Ca, Al, Na content is generally expressed as SiO 2, CaO, Al 2 O 3, Na 2 O, respectively.
Unless otherwise specified or for aqueous compositions, the concentrations in this document are expressed in relation to the dry weight of the total composition, and therefore without any water or moisture present.
Applicants have found that the results of a chemical analysis of a metal phase are considerably more reliable than those of an analysis of a slag phase. In this document, when values are derived from a material balance over one or more process steps, applicants prefer to base such calculations, if possible, on as many metal phase analyzes as possible, and to minimize the use of slag analysis . For example, applicants prefer to calculate the recovery of tin and / or lead in the first copper refining slag from step b) on the basis of the amount of tin and / or lead in the combined feed to step b) that is no longer recovered in the first enriched copper metal phase from step b), rather than based on the concentration of tin and / or lead reported for the first copper refining slag.
The applicants have furthermore found that an analysis of a slag phase that is further processed can often be corrected by drawing up a mass balance over the downstream process step or steps, and by calculating, using the quantities of the products obtained from the downstream step in combination with the analysis of these products,
BE2018 / 5874 of which at least one is preferably a liquid metal product, which yields much more reliable analytical results. Such a recalculation can be performed individually for several of the relevant specific metals, and can make it possible to draw up reliable material balances over most individual steps of the method according to the present invention. Such a recalculation can also be useful in determining the composition of a liquid metal stream where it can be particularly difficult to obtain a representative sample from it, for example a molten solder metal stream containing large amounts of lead together with tin.
Applicants prefer the use of X-ray fluorescence (X-ray fluorescence, XRF) for analyzing a metal phase in the context of the present invention. For this analysis, the applicants prefer to take a sample of the molten liquid metal, and the applicants preferably use a sampling device for immediate analysis in the copper refining of the Heraeus Electro Nite company, which rapidly produces a solid and cooled sample. provided for further processing. A surface of the cold sample then undergoes suitable surface treatment before the analysis is performed using an XRF probe. However, the XRF analysis technique does not provide an analysis of the oxygen content in the sample. Therefore, if necessary, to determine the complete composition of a metal phase including the oxygen content, the applicants prefer to measure the oxygen content of the metal in the molten liquid metal present in the furnace separately, preferably using a disposable electrochemical sensor for single-use batch processes in the copper refining offered by Heraeus Electro Nite. The analytical result of the analysis of the metal phase by XRF, as described above, can then be adjusted if desired for the oxygen content obtained from the individual oxygen analysis. The compositions mentioned in the Example of this document have not been adjusted to take into account their oxygen content.
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The present invention mainly deals with the recovery of the intended metals copper, nickel, tin and / or lead in product streams that are suitable for deriving high quality purity metal products therefrom. The process of the present invention comprises various process steps and these process steps can be categorized either as an oxidation step or as a reduction step. With this category, applicants want to indicate the chemical reactions to which these target metals can be subjected. Thus, a reduction step involves reducing at least one of these target metals from at least one of its corresponding oxides to its elemental metal form for the purpose of causing that metal in the furnace to pass from the slag phase to the metal phase. Such a reduction step is preferably stimulated by the addition of a reducing agent, as explained in various places in this document. The reduction steps are the process steps with reference numbers 400, 600, 700, 900, 1000 and 1100. In an oxidation step, the main objective is the conversion of at least one of the targeted metals to at least one of its corresponding oxides, with the aim of forming that metal in the furnace from the metal phase to the slag phase. The oxygen for that conversion can be supplied in the context of the present invention from various sources. The oxygen does not necessarily have to come from air or oxygen that can be blown into the liquid bath. The oxygen can also be supplied by introducing a slag phase obtained from another process step and in which the oxygen is bound in an oxide of at least one other metal. Thus, an oxidation step in the context of the present invention can optionally be performed without any injection of air or oxygen. The oxidation steps are therefore the process steps with reference numerals 100, 200, 300, 500, 800 and 1200.
Among the intended metals recovered by the present invention, Sn and Pb are considered "the solder metals". These metals are distinguished from the other targeted metals, copper and nickel, because mixtures that contain large amounts
BE2018 / 5874 of these metals usually have a much lower melting point than mixtures containing large amounts of copper and / or nickel. Such compositions were already used millennia ago to create a permanent bond between two pieces of metal, by first melting the solder, applying it, and allowing it to cure. The solder therefore had to have a lower melting temperature than the metal of the pieces that were connected to it. In the context of the present invention, a solder product or solder metal composition, two terms that are used interchangeably in this document, means metal compositions in which the combination of the solder metals, and thus the content of Pb plus Sn, represents most of the composition , ie at least 50% by weight and preferably at least 65% by weight. The solder product may further contain small amounts of the other target metals copper and / or nickel, and of non-target metals, such as Sb, As, Bi, Zn, Al and / or Fe, and / or elements such as Si. Because the method is aimed at the production of a crude solder product and a copper product, it is expected in the context of the present invention that the crude solder product or raw solder metal composition is obtained using the method in steps e) and / or n) contains a measurable quantity of at least copper, but only as an unavoidable impurity.
The refined copper product obtained in step (i) is obtained by refining the first portion of the black copper composition. Consequently and inherently, the refined copper product obtained in step (i) must necessarily have a higher copper content than the black copper composition from which it was derived by at least one refining step.
In an embodiment of the method according to the present invention, step f) comprises adding a third reducing agent to step f).
Applicants have found that the third reducing agent makes it possible to steer the result of reduction step f) in the direction of the desired separation of valuable metals in
BE2018 / 5874 the second metal composition on lead-tin basis and to leave metals to be rejected in the second spent slag. Applicants have found that the third reducing agent can be a gas, such as methane or natural gas, but can also be a solid or a liquid, such as carbon, a hydrocarbon, even aluminum or iron.
In an embodiment of the method according to the present invention, the third reducing agent comprises a metal, and the third reducing agent is preferably a metal which, under the conditions of the method, has a higher affinity for oxygen than tin and lead, copper and nickel , preferably iron metal, more preferably scrap iron. Applicants preferably use iron, preferably scrap iron, as the reducing agent, due to their high availability at economically attractive conditions. Applicants have found that the addition of the solid reducing agent may entail the additional advantage that the furnace requires less additional heating to maintain or reach its desired temperature. Applicants have found that this positive effect can be large enough for additional heating by burning a fuel with the aid of air and / or oxygen to remain limited, or even hardly necessary to achieve the desired temperature. The applicants have furthermore determined that step f) may furthermore be positively effected by the addition of silica, as explained elsewhere in this document.
Applicants prefer to add to step f) an amount of a third reducing agent that is rich in iron, preferably as a multi-metal material, because such multi-metal material is more readily available under more favorable conditions than higher purity tin, copper of higher purity or iron of higher purity. Another suitable material could be electric motors, preferably such motors after use, because of their high iron content for the cores and copper for the windings. Applicants have found that the copper and / or tin can easily be kept in the metal phase and prevented from entering
BE2018 / 5874 to go into the slag phase, while the iron present in this copper-containing fresh feed easily passes to the slag phase as iron oxide, while contributing to the chemical reduction of other metals that have a lower affinity for oxygen under the conditions of the process iron.
In an embodiment of the present invention, the method further comprises the steps of (iii) recovering a second raw solder metal composition, which differs from the first raw solder metal composition, as a second raw solder product, from the at least one copper refining slag, whereby a fifth solder refining slag is formed in equilibrium with the second raw solder metal composition, and
o) contacting a third part of the black copper composition obtained from step a), which differs from the first part and the second part, with the fifth solder refining slag, a third spent slag and a third metal composition lead-tin based, followed by separation of the third spent slag from the third lead-tin-based metal composition.
Applicants have found that it may be advantageous to also recover a second raw solder product, different from the first raw solder product, from the at least one copper refining slag obtained by refining the first portion of the black copper composition obtained was from step a). The applicants have found that this has the positive effect that the separation can take place better between the refined copper product on the one hand and the first and the second crude solder product on the other hand. Applicants point out that this advantage, and how it is obtained, is explained in more detail in patent EP-A17207370.2.
The method of the present invention comprising step (iii) also produces the fifth solder refining slag. The applicants have determined that this fifth is advantageous
BE2018 / 5874 solder refining slag also to be brought into contact, ie including reacting and extracting, with a third part of the black copper obtained from step a), the third part different from the first and the second part of black buyer.
The method according to the present invention comprising step o) surprisingly further enhances the advantage that the method is able to process a much larger amount of black copper base material than the sequence of successive copper refining steps to produce a refined copper product that has been enriched is up to the buyer and possibly to anode quality. Applicants have found that this can make it possible to further significantly increase black copper processing capabilities of the global process compared to the sequence of successive copper refining steps to produce a refined copper product, possibly and even preferably of anode quality, is able to include it in its first step.
In addition to the advantage that it is capable of handling much higher volumes of black copper from an upstream process step, the applicants have surprisingly determined that the method of the present invention is capable of incorporating black copper with a lower content to copper and a higher content of other valuable metals, in particular to the soldering metals tin and / or lead, preferably to tin and optionally also to lead.
This entails the advantage that the process of the present invention is even more tolerant to elements other than copper, most of which are elements that have a higher affinity for oxygen than copper under the conditions of the process, and possibly even higher than tin and lead. This advantage further broadens the possibility of producing a larger amount of tin for the same amount of copper production, which provides a considerable economic advantage for the person carrying out the process.
Applicants point out that the method according to the present invention in step o) is the third spent snail
BE2018 / 5874, i.e. a slag that is removed from the process. The purpose of step o) is to recover the majority of the tin and lead present in the furnace as part of the third lead-tin-based metal composition, a stream that is well suited to be recycled to a process step upstream of step o). This embodiment of step o) entails the advantage that the majority of the copper and nickel present in the furnace, since copper and nickel have an even lower affinity for oxygen than tin and lead under the conditions of the process. the third metal composition is lead-tin based, and therefore easily recycled and thus becomes available for recovery as part of a high-quality product from the global process. This embodiment of step o) furthermore has the advantage that most of the metals and other elements which, under the conditions of the process, have a higher affinity for oxygen than tin and / or lead, become part of the third used up snail. This applies to elements such as zinc, iron, aluminum, manganese, sulfur, phosphorus and silicon. Most of these "less noble" metals have a much lower commercial value than copper, tin and lead. The method of the present invention easily removes most of these "less noble" metals when they are introduced as part of the portion of the black copper supplied to step o) immediately from the method as part of the third used up snail obtained in step o).
Applicants have found that the present invention therefore further loosens the acceptability criteria for the black copper introduced in step o). This advantage considerably reduces any need for pre-refining before the black copper can be used as starting material for pyrometallurgical copper refining steps, as described in US 3,682,623. This advantage also broadens the acceptability criteria for the raw materials used in the upstream production of the black copper, usually in a smelting furnace step. The upstream step is therefore able to do much
BE2018 / 5874 to include more low-quality raw materials, which are generally more widely available under more economically attractive conditions.
The applicants have found that the addition of a substantial amount of copper in step o), for example as part of the black copper composition being introduced, brings a considerable advantage because the copper can act as an excellent extractant for any other valuable metals remaining in the fifth solder refining slag from step (iii), and that this advantageous extraction step can be carried out without loss of significant amounts of copper in the third spent slag produced in step o).
The applicants have further established that the part of the third part of the black copper composition that can be added in step o) can contain significant amounts of other valuable metals, in particular of zinc, nickel, tin and / or lead. The applicants have found that, especially when sufficient copper is made available in step o), the losses of in particular tin and / or lead used up in the third slag can be kept very low and therefore do not entail any risk for the possible further use or trajectory of this third spent snail.
Applicants have found that in step o) a substantial amount of the black copper provided in step a) can be added in step o) to extract more valuable metals from the fifth solder refining slag obtained from step (iii) without excessive loss of extra valuable metals in the third spent snail produced in step o). Applicants have found that the amounts of such black copper from, for example, an upstream smelting furnace step that are acceptable in step o) are very substantial, even on the order of the amount of black copper that can be fed to the first step of the copper refining sequence. Applicants have found that incorporating step o) into the method of the present invention substantially further increases the capacity to process black copper from
BE2018 / 5874 the smelting furnace type, and therefore to process larger quantities of the lower quality raw materials in which valuable metals are supplied at basic material value and therefore with a high potential for upgrading. Applicants have found that this further extends the additional benefit that a substantial third of the black copper can be re-processed from the upstream smelting furnace step without all of that black copper having to go through the first step of the copper refining (i). Any metals present in the black copper feed to step o) that under the conditions of the process have a higher affinity for oxygen than copper, tin and / or lead are most likely already removed before the copper introduced with this fresh black feed copper to step o) can find its way into the step sequence of the copper refining process (i).
In an embodiment of the method according to the present invention, step o) comprises adding a sixth reducing agent to step o), preferably before reducing the fifth solder refining slag.
Applicants have found that the sixth reducing agent makes it possible to steer the result of reduction step o) towards the desired separation of valuable metals in the third lead-tin-based metal composition and to leave metals to be rejected in the third used up snail. Applicants have found that the sixth reducing agent can be a gas, such as methane or natural gas, but can also be a solid or a liquid, such as carbon, a hydrocarbon, even aluminum or iron.
In an embodiment of the method according to the present invention comprising step o), the sixth reducing agent comprises a metal, and preferably the sixth reducing agent is essentially a metal which has a higher affinity for oxygen under the conditions of the method then tin, lead, copper and nickel, preferably iron metal, more preferably scrap iron. Applicants preferentially use iron, preferably scrap iron, as the reducing agent, due to their high availability in economically attractive
BE2018 / 5874 conditions. Applicants have found that the addition of the solid reducing agent may entail the additional advantage that the furnace requires less additional heating to maintain or reach its desired temperature. The applicants have found that this positive effect can be large enough that additional heating, by burning a fuel with the aid of air and / or oxygen, could remain fairly limited or would even hardly be necessary to reach the desired temperature. The applicants have furthermore determined that step f) may furthermore be positively effected by the addition of silica, as explained elsewhere in this document.
Applicants prefer to add to step o) an amount of a sixth reducing agent that is rich in iron and that may further contain copper, preferably as a multi-metal material, because such multi-metal material is more readily available at more advantageous conditions than tin of higher purity, copper of higher purity or iron of higher purity. Another suitable material could be electric motors, preferably such motors after use, because of their high iron content for the cores and copper for the windings. Applicants have found that the copper and / or tin can easily be kept in the metal phase and prevented from passing into the slag phase, while the iron present in this copper-containing fresh feed easily passes to the slag phase as iron oxide while contributing to the chemical reduction of other metals that have a lower affinity for oxygen than iron under the conditions of the process.
In an embodiment of the method according to the present invention, the second and / or fifth solder refining slag comprises at most 2.0% by weight of copper and nickel together, preferably at most 1.5% by weight, more preferably at most 1, 0% by weight, even more preferably at most 0.5% by weight, preferably at most 0.45% by weight, more preferably at most 0.40% by weight of copper and nickel together. The second solder refining slag is in balance at the end of step e) with the first raw solder metal composition, and the fifth
BE2018 / 5874 solder refining slag is balanced at the end of step n) with the second raw solder metal composition. Less copper and nickel in the second and / or fifth solder refining slag means that there is also less copper and nickel present in the first and / or the second raw solder metal composition, which at the end of the upstream pyrometallurgical steps is in equilibrium with the second and / or or the fifth solder refining slag. The advantages of the presence of less copper and nickel in the second and / or fifth solder refining slag thus include the advantages set out elsewhere in this document with regard to the presence of less copper and / or nickel in the first and / or fourth solder refining slag . Moreover, this feature entails the additional positive effect that less copper and nickel may end up in the second and / or the third lead-tin-based metal composition obtained in step f) and step o), respectively, and should be derived therefrom recovered. Another advantage is that more furnace volume becomes available for step f) and / or step o), which makes it possible to introduce a larger amount of black copper as part of step f) and / or step o).
In an embodiment of the method according to the present invention, the second and / or fifth solder refining slag comprises at most 8.0% by weight and optionally at least 1.0% by weight of tin and lead together, preferably at most 7.0% by weight %, more preferably at most 6.0% by weight, even more preferably at most 5.0% by weight, preferably at most 4.5% by weight, more preferably at most 4.0% by weight even more preferably at most 3.5% by weight of tin and lead together. Applicants have determined that it is advantageous to limit the presence of tin and lead in the second and / or fifth solder refining slag at the end of the respective upstream process step because the majority of these amounts of tin and lead to be recovered in step f) and / or o), end up in the second and / or third lead-tin-based metal composition, and must be further processed for their recovery into high-quality, high-quality metal products. It is also important to recover tin and in particular lead upstream from the production of the second spent snail in step f) and
BE2018 / 5874 the third used up snail in step o). Generally, all tin and / or lead that ends up in an exhausted slag means a loss of valuable metals from the process, and may require further processing before the exhausted slag can be disposed of, or becomes suitable for use in an economically more valuable application.
On the other hand, applicants also prefer the presence of at least 1.5% by weight of tin and lead together in the second and / or fifth solder refining slag, preferably at least 2.0% by weight, more preferably at least 2 5% by weight, even more preferably at least 3.0% by weight, preferably at least 3.5% by weight. This entails the advantage that more tin and lead are also present together in the first and / or the second raw solder metal composition, which at the end of the respective upstream process step is considered to be in equilibrium with the second and / or the fifth solder refining slag, the benefits of which are explained elsewhere in this document.
In an embodiment of the method according to the present invention, the second and / or third metal composition on a lead-tin basis comprises at least 60% by weight and optionally at most 90% by weight of copper and nickel together, preferably at least 65% by weight , more preferably at least 68% by weight, even more preferably at least 70% by weight, even more preferably at least 72% by weight of copper and nickel together. Applicants have found that a large amount of copper and nickel together, in particular a large amount of copper, in the second lead-tin-based metal composition at the end of step f) and / or in the third lead-tin-based metal composition at the end of step o) is advantageous. The copper and also the nickel act in steps f) and o) as extraction agents for other valuable metals, in particular for tin and lead, and the phase balance of copper and nickel makes this achievable under the right conditions without at the same time leading to an unacceptable large loss of copper and / or nickel in the second and / or third spent snail.
On the other hand, applicants prefer that the second and / or the third metal composition on a lead-tin basis
BE2018 / 5874 at most 85% by weight, preferably at most 82% by weight, more preferably at most 80% by weight, even more preferably at most 77.5% by weight, preferably at most 75% by weight copper and nickel together. This leaves more room for the recovery of tin and / or lead and for reducing the loss of tin and / or lead in the spent slag from step f) and / or step o). Applicants have also found that compliance with this upper limit greatly reduces the loss of valuable metals, in particular copper, in the spent slag at the end of step f) and / or o).
In an embodiment of the method according to the present invention, the second and / or the third lead-tin-based metal composition comprises at least 12% by weight of tin and lead together, preferably at least 15% by weight, more preferably at least 17% by weight %, even more preferably at least 18% by weight, preferably at least 19% by weight, more preferably at least 20% by weight, even more preferably at least 21% by weight, preferably at least 22% by weight % tin and lead together. Applicants have found that a minimum presence of metals other than copper, such as a minimum presence of tin and lead together, in the metal phase at the end of step f) and / or o) entails the advantage that less copper is lost in the spent snail, which is in equilibrium with it at the end of step f) and / or o).
In an embodiment of the method according to the present invention, the second and / or the third lead-tin-based metal composition comprises at least 60% by weight and optionally at most 85% by weight of copper, preferably at least 65% by weight, with more preferably at least 67% by weight, even more preferably at least 69% by weight, preferably at least 70% by weight, more preferably at least 71% by weight of copper. Applicants have found that in particular a large amount of copper in the second and / or third metal tin-based metal composition at the end of step f) and / or o) is advantageous. The copper acts in steps f) and / or o) as an extraction agent for other valuable metals, in particular for tin and lead, and the phase balance of copper makes this achievable under the right conditions without at the same time leading to a
BE2018 / 5874 unacceptably large loss of copper in the second and / or third spent snail.
On the other hand, the applicants prefer that the second and / or the third lead-tin-based metal composition is at most 82.5% by weight of copper, preferably at most 80% by weight, more preferably at most 77.5% by weight. %, even more preferably at most 75% by weight, preferably at most 72.5% by weight of copper. This leaves more room for the recovery of tin and / or lead and for reducing the loss of tin and / or lead in the spent slag from step f) and / or o). Applicants have also found that compliance with this upper limit greatly reduces the loss of valuable copper in the spent slag at the end of step f) and / or o).
In an embodiment of the method according to the present invention, the second and / or third consumed slag comprises at most 2.5% by weight of tin and lead together, preferably at most 2.0% by weight, more preferably at most 1 5% by weight, even more preferably at most 1.00% by weight, preferably at most 0.95% by weight of tin and lead together.
In an embodiment of the method according to the present invention, the second and / or third consumed slag comprises at most 2.0% by weight of copper and nickel together, preferably at most
1.5% by weight, more preferably at most 1.0% by weight, even more preferably at most 0.75% by weight, preferably at most 0.60% by weight of copper and nickel together.
In an embodiment of the method according to the present invention, the second and / or third consumed slag comprises at most 2.0% by weight of copper, preferably at most 1.5% by weight, more preferably at most 1.0% by weight %, even more preferably at most 0.70% by weight of copper.
The specified upper limits on the presence of copper, nickel, tin, lead and any combination of these metals together entail for each individual the advantage that the economic value of the quantities of the intended
BE2018 / 5874 metals that leave the process with the second and / or the third spent snail from step f) and / or o) are contained. This reduces the need or desirability of providing additional process steps on the second and / or third spent snail before it can be disposed of, and thus brings with it the advantage that fewer, or possibly no further processing steps are needed before the second and / or third spent snail can be disposed of, or is considered acceptable before the snail in a more economically attractive application or end use.
In the second and / or third spent slag of the method according to the present invention, most of the elements are collected which under the conditions of the method have a higher affinity for oxygen than tin and / or lead and / or copper and / or nickel. This applies in particular to metals such as zinc, chromium, manganese, vanadium, titanium, iron, aluminum, sodium, potassium, calcium and other alkaline earth alkaline metals, but also to other elements such as silicon or phosphorus. All of these elements that end up in the second and / or third consumed slag are removed from the process, and do not take up a useful furnace volume compared to the case that they would be recycled to an upstream process step.
In an embodiment of the method according to the present invention, the black copper composition meets at least one and preferably all of the following conditions:
· Comprising at least 51% by weight of copper, • including at most 96.9% by weight of copper, • covering at least 0.1% by weight of nickel, • covering at most 4.0% by weight % nickel, · comprising at least 1.5% by weight of tin, · comprising at most 15% by weight of tin, · comprising at least 1.5% by weight of lead, · comprising at most 25% by weight of lead, · comprising at most 3.5% by weight of iron, and · including at most 8.0% by weight of zinc.
BE2018 / 5874
Applicants prefer that any black copper that can be used in the method of the present invention, ie also any black copper that is used in a process step other than step f), meets at least one of the above conditions, and preferably all conditions.
In one embodiment of the method of the present invention, the black copper comprises at most 96.9% by weight or more preferably at most 96.5% by weight of copper, preferably at most 96.0% by weight, more preferably at least at most 95.0% by weight, even more preferably at most 90.0% by weight, even more preferably at most 85.0% by weight, preferably at most 83.0% by weight, more preferably at most at most 81.0% by weight, even more preferably at most 80.0% by weight, even more preferably at less than 80.0% by weight and preferably at most 79.0% by weight of copper. This entails the advantage that the upstream process for producing the black copper can incorporate raw materials that comprise much more metals than copper. It is particularly advantageous to accept more tin and / or lead in the production of the black copper, and these larger amounts of tin and / or lead can easily be processed into a larger amount of crude soldering co-product, a product with a relatively high economic value .
In one embodiment of the method of the present invention, the black copper comprises at least 51% by weight of copper, preferably at least 52% by weight, more preferably at least 53% by weight, even more preferably at least 54% by weight. %, even more preferably at least 55% by weight, preferably at least 57% by weight, more preferably at least 59% by weight, even more preferably at least 60% by weight, even more preferably at least at least 62% by weight, preferably at least 64% by weight, more preferably at least 66% by weight, even more preferably at least 68% by weight, even more preferably at least 70% by weight, preferably at least 71% by weight, more preferably at least 72% by weight, even more preferably at least 73% by weight, even more preferably at least 74% by weight, preferably at least 75% by weight, with more preferably at least
BE2018 / 5874
77.5% by weight, even more preferably at least 80% by weight, even more preferably at least 85% by weight of copper.
This entails the advantage that a stock refining step as provided in U.S. Pat. No. 3,682,623 for upgrading a black copper containing 75-80% by weight copper to about 85% by weight copper or higher (85.12% by weight) copper in the Example, Table VI) can be omitted.
The applicants have further established that the process as a whole is more workable and efficient, and generally produces more of the high-quality products, if the concentration of copper in the black copper remains within the prescribed lower limit. With a lower concentration of copper in the black copper, other elements complete the balance. That is quite acceptable and often even desirable if they are valuable metals that complement the balance, such as lead, but even more interesting if they also include tin. These metals use chemicals during every oxidation and / or reduction step, but ultimately a large part of them ends up in a high-quality product stream. On the other hand, if lower value metals or elements inevitably end up in one of the used up slags that form the balance, then the lower copper concentration is rather disadvantageous because these metals and / or elements use chemicals in the oxidation steps as part of the copper refining steps, and / or other chemicals can consume in one of the downstream reduction steps. Moreover, these low value metals or elements take up volume in the furnace, and therefore their presence requires larger furnaces and therefore higher investment costs. Within a given format of available equipment, the presence of these metals or elements reinforces the restrictions on introducing higher value raw materials into any of the process steps, such as those with high concentrations of copper, tin and / or lead. The black copper composition is typically an intermediate produced by another pyrometallurgical process step, i.e., a smelting furnace step. A smelting furnace step yields a molten metal product, the so-called
BE2018 / 5874 "black copper", and a liquid slag of mainly metal oxides, usually in the presence of significant amounts of silicon dioxide. Applicants prefer to obtain in a smelting furnace step a black copper product containing at least the minimum prescribed amount of copper, because the high presence of copper acts as an extractant for other valuable metals, for example tin and lead. Therefore, by keeping the copper concentration in the black copper composition above the stated limit value, a higher recovery is achieved of these other valuable metals present in the black copper composition, rather than losing these valuable metals as part of the smelting furnace slag, where these metals usually have little to no value and can even form a load.
In an embodiment of the method of the present invention, the black copper comprises at least 1.5% by weight of tin, more preferably at least 2.0% by weight, even more preferably at least
2.5% by weight, even more preferably at least 3.0% by weight, preferably at least 3.5% by weight, more preferably at least 3.75% by weight, even more preferably at least 4.0% by weight, even more preferably at least
4.5% by weight, preferably at least 5.0% by weight, more preferably at least
5.5% by weight, even more preferably at least 6.0% by weight, even more preferably at least 6.5% by weight, preferably at least 7.0% by weight, more preferably at least 7.5% by weight, even more preferably at least 8.0% by weight, even more preferably at least 8.5% by weight, preferably at least 9.0% by weight, more preferably at least 9.5% by weight, even more preferably at least 10.0% by weight, even more preferably at least 11.0% by weight of tin. Tin is a very valuable metal that is relatively scarce in the form of a product with a higher purity. Applicants therefore prefer to produce as much tin as their method can handle. In addition, applicants prefer to recover this tin from raw materials of low economic value, in which tin is usually present in low concentrations. Such low value materials often contain large amounts of elements that are difficult to
BE2018 / 5874 are in a pyrometallurgical copper refining process, and are therefore usually first processed in a smelting furnace step. The tin in those low value materials, therefore, ends primarily as part of the black copper composition. Applicants prefer to produce as much tin as possible from such low value materials, and therefore prefer that the black copper composition of the process of the present invention contains as much tin as possible within the other limitations of the process .
In an embodiment of the method of the present invention, the black copper comprises at least 1.5% by weight of lead, more preferably at least 2.0% by weight, even more preferably at least
2.5% by weight, even more preferably at least 3.0% by weight, preferably at least 3.5% by weight, more preferably at least 3.75% by weight, even more preferably at least 4.0% by weight, even more preferably at least
4.5% by weight, preferably at least 5.0% by weight, more preferably at least
5.5% by weight, even more preferably at least 6.0% by weight, even more preferably at least 7.0% by weight, preferably at least 8.0% by weight, more preferably at least 9.0% by weight, even more preferably at least 10.0% by weight, even more preferably at least 11.0% by weight, preferably at least 12.0% by weight, more preferably at least 13.0% by weight, even more preferably at least 14.0% by weight, even more preferably at least 15.0% by weight of lead.
Lead is also a valuable metal. In addition, the presence of lead promotes the recovery of the even more valuable tin metal because it behaves similarly to tin and ends up in the same process streams, forming a mixture called "solder", and the resulting solder streams having a higher density and thereby be easier to separate from lower density liquid streams such as slag, or solid streams such as scratch. Applicants therefore prefer to provide a considerable amount of lead in their process. In addition, applicants prefer to recover this lead from raw materials with low economic value, in which lead is usually in low concentrations
BE2018 / 5874 is present. Such low value materials often contain large amounts of elements that are difficult to process in a pyrometallurgical copper refining process, and are therefore usually first processed in a smelting furnace step. The lead in those low-value raw materials therefore mainly ends as part of the composition of black copper. Applicants prefer to obtain as much lead as possible from such low value materials, and therefore prefer that the black copper composition of the process of the present invention contains as much lead as possible within the other limitations of the process.
A higher presence of tin and / or lead in the black copper brings with it the advantage that the raw materials containing this tin and / or lead can be processed in a smelting furnace step, a step that is very tolerant of other impurities, much more then the typical steps performed as part of a copper refining process, including any steps associated with the co-production of other non-ferrous metals such as tin and / or lead. These acceptable raw materials are therefore generally of a much lower quality and therefore also of a lower economic value. Most of the tin and / or lead in the black copper of the process of the present invention ends up in a coarse soldering co-product, which is a product with relatively high economic value. The economic upgrading of the tin and / or lead in the black copper supplied to the process of the present invention is therefore generally much higher than the same amount that is introduced as part of a much more concentrated raw material that may be directly acceptable in a of the steps in the copper refining process, including the frames.
Applicants therefore prefer to provide larger amounts of tin and / or lead in the black copper, because that entails the advantage that within a limited amount of these metals to be produced, due to equipment limitations, more of these metals are recovered from raw materials
BE2018 / 5874 of low value, and therefore more of these metals can be recovered with a high economic valuation of their low value in the raw material and their high economic value in the end product.
In one embodiment of the process of the present invention, the black copper comprises at most 15.0% by weight of tin, preferably at most 14.0% by weight, more preferably at most 13.0% by weight, with even more preferably at most 12.0% by weight, even more preferably at most 11.0% by weight, preferably at most 10.0% by weight, more preferably at most 9.0% by weight, even more preferably at most 8.0% by weight, even more preferably at most 7.0% by weight, preferably at most 6.0% by weight of tin. Applicants have found that limiting the concentration of tin in the black copper composition to the specified upper limits entails the advantage that the black copper composition leaves sufficient room for other metals and elements. As stated above, a presence of copper is very advantageous in the upstream smelting furnace step, and that also applies to the presence of lead. Applicants therefore prefer to keep the concentration of tin within the specified upper limit.
In one embodiment of the method of the present invention, the black copper comprises at most 25.0% by weight of lead, preferably at most 24.0% by weight, more preferably at most 23.0% by weight, with even more preferably at most 22.0% by weight, even more preferably at most 21.0% by weight, preferably at most 20.0% by weight, more preferably at most 19.0% by weight, even more preferably at most 18.0% by weight, even more preferably at most 17.0% by weight, preferably at most 16.0% by weight, more preferably at most 15.0% by weight, even more more preferably at most 14.0% by weight, even more preferably at most 13.0% by weight, even more preferably at most 12.0% by weight, preferably at most 11.0% by weight, with more preferably at most 10.0% by weight, even more preferably at most 9.0% by weight, even more preferably at most 8.0% by weight, preferably at most 7.0% by weight of lead. Applicants have determined that limiting the
BE2018 / 5874 concentration of lead in the composition of black copper to the specified upper limits entails the advantage that sufficient composition is left in the composition of black copper for other metals and elements. As stated above, a presence of copper is very advantageous in the upstream smelting furnace step, and also the presence of significant amounts of tin is highly desirable. Applicants therefore prefer to keep the lead concentration within the specified upper limit.
The applicants have established that the presence of excessive amounts of tin and / or lead in the black copper has an influence on any possible separation step between copper (and nickel) on the one hand, and tin and lead on the other. The separation is less clear and, as a rule, more tin and / or lead remains with the copper. Even if the copper stream is at least partially recycled, this leads to larger amounts of tin and / or lead being in circulation in the process and taking up furnace volume. However, even if the copper stream from that separation, or a part thereof, is removed from the process, the larger amounts of tin and / or lead in that stream represent an additional burden for its downstream processing.
In an embodiment of the method according to the present invention, the black copper comprises at least 0.1% by weight and optionally at most 4.0% by weight of nickel (Ni). Preferably, the feed of black copper to step b), introduced later in this document, comprises at least 0.2% by weight of nickel, more preferably at least 0.3% by weight, even more preferably at least 0 4% by weight, even more preferably at least 0.5% by weight, preferably at least 0.75% by weight, more preferably at least 1.00% by weight of nickel.
Nickel is a metal that is present in many raw materials that contain copper, tin and / or lead, and it is also present in many alloys that contain or are even based on iron. Nickel shows an affinity for oxygen lower than that of tin and / or lead under the conditions in the furnace, and which is close to and slightly higher than that of copper. It is therefore a metal that is difficult to separate from copper
BE2018 / 5874 by pyrometallurgy. In US 3,682,623, most of the nickel contained in the pre-refined black copper (Table VI, 541.8 kg) disappears from the process as an impurity in the refined copper product (Table XII, 300 kg), which was cast into anodes ( Col. 19, quantity of the nickel finds lines 61-62). his way The method
A small to it includes one of with
Applicants have found that nickel in the disturbing element
Below the is in the downstream conditions of the lead / tin metal product (Table XV, 110 kg). significant black copper recycling stream, in which the presence of nickel appears to increase with each cycle (Table XIV, 630 kg, compared to Table VI, 500 kg). copper anodes an electrical refining step.
Electrefining process dissolves the nickel in the electrolyte but does not deposit on the cathode. As a result, it may accumulate in the electrolyte and may lead to the precipitation of nickel salts when their solubility limit is exceeded. But even at lower levels, the nickel can already lead to anode passivation due to a possible build-up of a nickel concentration gradient on the anode surface. The method according to US 3,682,623 is thus limited in its ability to process nickel. The melting step in US 3,682,623 can therefore only take up a fairly limited amount of raw materials that contain significant amounts of nickel.
Applicants have now determined that the method of the present invention is capable of incorporating much larger amounts of nickel, for example, as part of the black copper from an upstream smelting furnace step. This higher tolerance for nickel provides for the process of the present invention, and for any process steps carried out upstream, a wider acceptance window with respect to raw materials. The method of the present invention, and according to any of its upstream process steps, can thus incorporate raw materials that may not accept alternative methods known in the art, or accept only in very limited quantities, and thus may be more readily available to more economically attractive conditions.
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In spite of the higher nickel tolerance, the applicants have also found that the method of the present invention may be able to produce a high-quality anode copper product that is richer in copper and comprises less nickel as compared to the anode copper produced in US 3,682,623.
In an embodiment of the method according to the present invention, the black copper comprises at most 3.5% by weight of iron, preferably at most 3.0% by weight, more preferably at most
2.5% by weight, even more preferably at most 2.0% by weight, even more preferably at most 1.80% by weight, preferably at most 1.60% by weight of iron.
Optionally, the black copper comprises at least 0.1% by weight of iron, preferably at least 0.2% by weight, more preferably at least 0.5% by weight of iron. Applicants have found that this iron promotes the reactions in step f) and / or o) because it reacts quickly in step f) and / or step o) to form an iron oxide by removing at least one oxygen atom from an oxide of a metal with a lower affinity for oxygen than iron under the conditions of the process step, such as tin and / or lead.
In an embodiment of the method of the present invention, the black copper comprises at most 8.0% by weight of zinc, preferably at most 7.5% by weight, more preferably at most 7.0% by weight, with even more preferably at most 6.5% by weight, even more preferably at most 6.0% by weight, preferably at most 5.5% by weight, more preferably at most 5.0% by weight, even more preferably at most 4.7% by weight of zinc.
Optionally, the black copper comprises at least 0.1% by weight of zinc, preferably at least 0.2% by weight, more preferably at least 0.5% by weight of zinc. Applicants have found that this zinc promotes the reactions in step f) and / or o) because it reacts quickly in step f) and / or step o) to form a zinc oxide by removing at least one oxygen atom from an oxide of a metal with a lower affinity for
BE2018 / 5874 oxygen than zinc under the conditions of the process step, such as tin and / or lead.
Applicants have determined that it is advisable to keep the iron and / or zinc concentrations within the specified limits. These metals are usually oxidized in the copper refining steps, where they use consumables. Zinc is quickly reduced in each of the reduction steps of the process, and therefore consumes additives there as well. In addition, these metal take up oven volume. For these reasons, applicants wish to limit these metals to the respective concentrations indicated.
In an embodiment of the method according to the present invention, the first and / or the second raw solder metal composition comprises at least 65% by weight of tin and lead together, preferably at least 67% by weight, more preferably at least 69% by weight, even more preferably at least 70% by weight, preferably at least 72% by weight, more preferably at least 74% by weight, preferably at least 75% by weight, more preferably at least 76% by weight, with even more preferably at least 77% by weight of tin and lead together. Applicants have found that the presence of a larger amount of tin and lead in the first and / or the second raw solder metal composition makes it possible to recover a larger volume of tin of high purity and high purity lead, products with a high economic value.
In an embodiment of the method according to the present invention, the first and / or the second raw solder metal composition comprises at least 5.0% by weight of tin, preferably at least
7.5% by weight, more preferably at least 10.0% by weight, even more preferably at least 15.0% by weight, preferably at least 17% by weight, more preferably at least 19% by weight even more preferably at least 20% by weight, preferably at least 21% by weight, more preferably at least 22% by weight of tin. Applicants have found that the more tin is present in the first and / or the second raw solder metal composition, the higher the volume of high purity tin that can be recovered therefrom.
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In an embodiment of the method according to the present invention, the first and / or the second raw solder metal composition comprises at least 45% by weight of lead, preferably at least
47.5% by weight, more preferably at least 50% by weight, even more preferably at least 52% by weight, preferably at least 53% by weight, more preferably at least 54% by weight, even more preferably at least 55% by weight of lead. Applicants have found that the more lead is present in the first and / or the second raw solder metal composition, the higher the volume of high purity lead that can be recovered therefrom, i.e. commercial products with significant economic added value. The lead further has the advantage that, in any phase separations that take place downstream during the further processing of the first and / or the second raw solder metal composition, the liquid metal streams comprising the lead have a higher density and are therefore more easily gravitated separated from a supernatant snail or scratch phase. An additional advantage is that the basic materials of the global process may contain more lead, so that a wider diversity of basic materials become acceptable, which entails the positive effect of a wider selection of possible basic materials, possibly including basic materials that are wider and more attractive conditions are available.
In an embodiment of the method according to the present invention, the first and / or the second raw solder metal composition comprises at most 26.5% by weight of copper and nickel together, preferably at most 25.0% by weight, more preferably at most
22.5% by weight, even more preferably at most 20.0% by weight, preferably at most 17.5% by weight, more preferably at most 16.0% by weight, even more preferably at most 15 5% by weight of copper and nickel together, and optionally at least 1% by weight of copper and nickel together, preferably at least 2% by weight, more preferably at least 3, 4 or 5% by weight of copper and nickel together. Applicants have found that the presence of less copper and nickel in the first and / or the second raw solder metal composition is advantageous. The first and / or the second raw solder metal composition
BE2018 / 5874 should generally be subjected to further purification steps to reduce the presence of metals other than tin, lead and antimony in the raw solder metal composition, for example before this raw solder metal composition becomes suitable for the recovery of high purity tin and / or lead products . This includes the removal of copper and nickel. Such a treatment can be, for example, silicon metal, as described in the patent DE 102012005401 A1. Silicon metal is a fairly expensive process substance, and the treatment leads to silicon compounds of the contaminating metals as a by-product that needs to be reworked or disposed of. The copper and nickel entrained in the first and / or the second raw solder metal thus cause an increase in the consumption of silicon metal in such a purification step. Thus, it is advantageous to limit the copper and nickel in the first and / or the second raw solder metal composition in accordance with the prescribed upper limit or limits.
In an embodiment of the method according to the present invention, the first and / or the second raw solder metal composition comprises at most 17.5% by weight of copper, preferably at most 15% by weight, more preferably at most 14% by weight, with even more preferably at most 13% by weight, preferably at most 12% by weight, more preferably at most 11% by weight of copper, and optionally at least 1% by weight of copper, preferably at least 2% by weight, with more preferably at least 3, 4 or 5% by weight copper. For the reasons stated above for copper and nickel together, applicants prefer to limit the copper in the first and / or the second raw solder metal composition in accordance with the prescribed upper limit.
In an embodiment of the method according to the present invention, the first and / or the second raw solder metal composition comprises at most 9.0% by weight of nickel, preferably at most 7.0% by weight, more preferably at most 5.0% by weight %, even more preferably at most 4.0% by weight, preferably at most 3.0% by weight, more preferably at most 2.0% by weight of nickel, and optionally at least 1% by weight of nickel, preferably at least 2% by weight, more preferably at least
BE2018 / 5874 at least 3, 4 or 5% by weight of nickel. For the reasons stated above for copper and nickel together, applicants prefer to limit the nickel in the first and / or the second raw solder metal composition in accordance with the prescribed upper limit.
In an embodiment of the method according to the present invention, the first and / or the second raw solder metal composition comprises at most 8% by weight of iron, preferably at most 8.0% by weight, more preferably at most 7.5% by weight , even more preferably at most 7.0% by weight, preferably at most 6.5% by weight, more preferably at most 6.0% by weight, even more preferably at most
5.5% by weight, preferably at most 5.0% by weight, more preferably at most 4.5% by weight, even more preferably at most 4.0% by weight, preferably at most 3.5 % by weight of iron, and optionally at least 0.2% by weight of iron, preferably at least 0.4% by weight, more preferably at least 0.5, 0.6 or 0.7% by weight of iron. Applicants have found that the presence of less iron in the first and / or the second raw solder metal composition is advantageous. The first and / or the second raw solder metal composition should generally be subjected to at least one further purification step to reduce the presence of metals other than tin, lead and antimony in the raw solder metal composition, e.g., before this raw solder metal composition becomes suitable for the recovery of high purity tin and / or lead products. This also includes the removal of iron. Such a treatment can be, for example, silicon metal, as described in the patent DE 102012005401 A1. Silicon metal is a fairly expensive process substance, and the treatment results in a silicon compound of the contaminating metal as a by-product to be reworked or disposed of. The iron entrained in the first and / or the second raw solder metal thus leads to an increased consumption of silicon metal in such a purification step. Thus, it is advantageous to limit the iron in the first and / or the second raw solder metal composition in accordance with the prescribed upper limit or limits.
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In an embodiment of the method of the present invention, step (i) comprises the step of b) partially oxidizing the first portion of the black copper composition, thereby forming a first enriched copper metal phase and a first copper refining slag, followed by separation of the first copper refining slag from the first enriched copper metal phase.
The applicants have found that the partial oxidation of a black copper base material is extremely effective for producing a slag phase, ie the first solder refining slag, which is particularly suitable for deriving a raw solder current, such as the first and / or the second raw solder metal composition, wherein this raw solder current can then act as an intermediate for the recovery of high purity tin and / or lead products.
In one embodiment of the method according to the present invention, the recovery of tin in step b) as part of the first copper refining slag, relative to the total amount of tin present in step b), is at least 20%, preferably at least 30%, more preferably at least 40.00%, even more preferably at least 45%, even more preferably at least 50%, preferably at least 55%, more preferably at least 57%. No units need to be specified for the% recovery of a given element, because whether one looks at atoms or by weight, the% recovery remains the same.
In one embodiment of the method according to the present invention, the recovery of lead in step b) as part of the first copper refining slag, relative to the total amount of lead present in step b), is at least 20%, preferably at least 30.00%, more preferably at least 40%, even more preferably at least 45%, even more preferably at least 50%, preferably at least 55%, more preferably at least 60%.
The specified lower limit on the recovery of tin and / or lead in step b) as part of the first copper refining slag
BE2018 / 5874 has the advantage that already in the first oxidation step carried out on the black copper, a considerable amount of the tin and / or lead present is removed, together with significant amounts of other elements other than copper. This entails the advantage that fewer impurities are supplied to the steps performed downstream on the first enriched copper metal phase. This means that the downstream process steps on the first enriched copper metal phase must process a smaller number of impurities, and also face less volume intake by the first enriched copper metal phase. This generally means that more expensive furnace volume is released in the following process steps that are performed on the first enriched copper metal phase, which creates space for introducing additional material into these process steps, and thus creates the opportunity for increased production of final copper product within the same limitations concerning oven volume. The listed benefits are linked to the lower limit on the recovery of tin in step b), and also to the lower limit on the recovery of lead in step b), and to a combination of a lower limit on the recovery of tin with a lower limit on the recovery of lead in step b). The effects are cumulative with respect to the two metal tin and lead, and together they even produce an enhanced effect in proportion to the sum of the two individual effects.
Applicants have found that the desired recuperations in step b) can be achieved by checking the presence of oxygen and / or oxygen donors in step b) within appropriate limits, if necessary combined with a controlled addition of scavengers for oxygen, and by addition of flux material.
In an embodiment of the method according to the present invention, additional raw materials are added as fresh feed to step b). Applicants prefer to add raw material containing solid metal because the melting of this solid metal is capable of absorbing some of the reaction heat and helps to keep the temperature of the furnace within the preferred range.
BE2018 / 5874. Applicants prefer to use raw materials rich in copper for this purpose and which may contain at least small amounts of Sn and / or Pb. The preferred temperature range is defined by a lower limit below which the viscosity of at least one of the liquid phases becomes too high for the operation of the oven. The preferred temperature range is defined by an upper limit above which the volatility of valuable metals, in particular tin and / or lead, becomes too high and the recovery of these metals as part of the furnace dust becomes too difficult, complicated and expensive. .
In an embodiment of the method according to the present invention, step (i) further comprises the step of
c) partially reducing the first copper refiner slag, forming a first lead-tin-based metal composition and a first spent slag, followed by separating the first spent slag from the first lead-tin-based metal composition, the latter forming the basis for a first liquid bath.
Applicants have found that a slag obtained from copper refining is an extremely suitable base material for obtaining, by means of a partial reduction, such as in step c), a metal composition containing copper, together with at least one soldering metal selected from tin and lead, this metal composition being extremely suitable to form the basis for the first liquid bath as the base material for partial oxidation step d), which is introduced later in this document. The reason for this is that a slag obtained from the metallurgical refining of copper contains copper together with at least one of the soldering metals tin and lead, usually with both tin and lead. The applicants have determined that most of the copper supplied with the first copper refining slag will become part of the first lead-tin-based metal composition forming in step c) in step c). The copper that ends up in the first lead-tin-based metal composition helps as a solvent for it
BE2018 / 5874 present tin and / or lead in process step c). The copper present in step c) thus helps to keep the tin and / or lead in the metal phase of step c), ie the first lead-tin-based metal composition, and reduces the amounts of tin and / or lead that may end up in the first spent slag from step c), and which could thus be lost from the process.
The applicants have further established that the inclusion of step c) in the method of the present invention entails several additional positive effects. Step c) of the method according to the present invention is a reduction step. Its purpose is to selectively reduce those metals in the furnace that have a lower affinity for oxygen to their respective metals under the conditions of the process. These reduced metals can then be separated as a liquid metal phase, leaving behind a liquid slag phase that has a lower concentration of those metals, but still contains metals and elements that have a higher affinity for oxygen. In the context of the present invention, the purpose of step c) is preferably to selectively recover most of the copper from the first copper refining slag as copper metal, together with as much of the tin and / or lead present as possible. The reduction in step c) is thus preferably carried out in such a way that the first spent slag comprises a total of at most 20% by weight of copper, tin and lead together. Preferably, the first spent slag comprises in total less than 20% by weight of copper, tin and lead together, more preferably much less. Strongly the amounts of copper, tin and / or lead in this slag are sufficiently low that they would no longer represent an economically significant value. Most preferably, the concentrations of copper, tin and / or lead are sufficiently low that the first spent slag would no longer cause environmental problems if it was disposed of as such, or would be acceptable to be disposed of after only limited further processing.
In the first spent slag of step c), most of the elements are preferably recovered which have a higher affinity for oxygen than tin and / or lead under the conditions of the process. This applies in particular to metals such as iron,
BE2018 / 5874 aluminum, sodium, potassium, calcium and other alkali and alkaline earth metals, but also for other elements such as silicon or phosphorus.
Applicants have found that the method of the present invention comprising step c) preferably produces a first lead-tin-based metal composition that is highly suitable for further processing, in particular for producing the first and / or the second raw solder metal composition which may itself have commercial value and / or may be suitable for recovery of tin and / or lead products of higher and commercially acceptable purity.
The applicants have surprisingly determined that in step c) of the method according to the present invention it is possible to obtain a fairly clear separation between the valuable metals copper, nickel, tin and lead in the metal phase, and metals of lower value such as iron and aluminum, and other elements such as silicon in the slag phase. This allows a very high recovery of the valuable metals while producing a slag phase that exhibits a very low content of these metals, and can therefore be disposed of, either directly or with relatively limited further processing. Applicants believe that this clear separation is possible because the presence of copper in step c) as part of the combined furnace content is within a certain concentration window. On the one hand, the copper acts as an extraction agent for tin and lead from the slag phase. On the other hand, the presence of copper is sufficiently low for the loss of copper in the slag phase to remain very limited.
Another important advantage is that the process of the present invention comprising step c) has become much more tolerant to elements other than copper, most of which are elements that have a higher affinity for oxygen under the conditions of the process than copper, tin and lead, and therefore become part of the first spent snail. This considerably broadens the eligibility criteria for any raw materials that may additionally be added to step b), i.e. in addition to the black copper. Moreover
BE2018 / 5874 also considerably eases the acceptability criteria for the black copper itself. This characteristic thus considerably broadens the acceptability criteria for the raw materials used in the production of the black copper, usually in a smelting furnace step. As a result, the smelting furnace step may accept many more low-quality raw materials that are more widely available at more economically attractive conditions.
Yet another advantage stems from the fact that in step b) the volume of slag is high in relation to the total furnace content. The removal of the slag from the furnace thus releases a substantial part of the volume of the furnace, such that in the further processing of the first enriched copper metal phase obtained from step b), which is usually carried out in the same furnace, additional space is created for the introduction of additional additional raw materials.
The applicants have found that the further processing of the first lead-tin-based metal composition from step c) can be carried out much more efficiently and also much more efficiently thanks to the upstream removal from the process, as part of the first spent slag, of at least a substantial part of the metals and elements that have a high affinity for oxygen under the conditions of the process. Applicants have found that this feature of the process brings considerable benefits downstream of step b) in processing the first lead-tin-based metal composition.
A major advantage is that the volume of material to be processed downstream is considerably reduced by the removal in step c of a considerable amount of material as the first spent slag, ie before the recovery of the soldering metals (Sn and / or Pb ). In further downstream steps, this material would be dead weight, and would entail disadvantages rather than advantages. In the method according to the present invention comprising step c), the further processing of the first lead-based metal composition can be performed much more efficiently in terms of volume, i.e. either smaller equipment can be used or the method
BE2018 / 5874 according to the present invention that includes step c) creates opportunities for processing additional streams for which the known methods would have no or less space. In addition, energy consumption can also be reduced in these downstream process steps, due to the smaller volume of hot material to be processed.
The applicants have furthermore surprisingly determined that, by removing the first spent slag from the method of the present invention comprising step c), the separations in the pyrometallurgical process steps downstream,
i.e., for processing the first lead-tin-based metal composition, can also be greatly improved. Clearer separations between the respective metal phases and their corresponding slag phases enable downstream recovery of valuable metals to be carried out more efficiently and efficiently, ie with higher yields of high-quality product, lower rejection of valuable metals, and lower required energy input, for example due to lower volumes to recycling flows.
An additional advantage of the method according to the present invention comprising step c) is that in the further processing of the first lead-tin-based metal composition, additional materials can be introduced thanks to the additional furnace space made available by removing the large volume of the first spent snail from the method of the present invention. Such additional materials can for example be rich in tin and / or lead. Such additional materials may, for example, be process slag and / or scratch generated as by-products of downstream refining steps as part of the further purification of tin and / or lead streams into commercially valuable high-quality products.
Another important advantage of the method according to the present invention comprising step c) is that it allows a much larger amount of crude soldering co-product for the same amount of copper being processed. Applicants have found that co-production of raw solder, in proportion to the amount of copper that
BE2018 / 5874 is processed in the first copper refining step, about 29% can be increased compared to the amounts obtained in the method described in the patent US 3,682,623. The economic value of raw solder, in particular as a possible intermediate for the production of a high purity tin product, is considerable in relation to the value of the high-quality anode copper product that can be obtained from the black copper. The increase in the relative amount of crude soldering co-product in relation to the amount of copper that is processed in the first copper refining step, therefore, entails a considerable economic advantage for the person carrying out the process according to the present invention.
Applicants have also found that it is advantageous that step c) only takes up the first copper refining slag, and that any subsequent copper refining slags are better processed separately, and preferably each in a different way. Applicants have found that the first copper refining slag is the copper refining slag containing the largest total amount of elements other than copper, and in particular those elements which have a higher affinity for oxygen under copper conditions than copper, more particularly an affinity for oxygen which also higher than that of tin and lead. The applicants have therefore surprisingly determined that it is most effective to perform step c) on the first copper refining slag, i.e. before mixing in one of the other copper refining slags produced in process steps downstream of step b). Applicants have found that subsequent copper refining slags generally comprise higher concentrations of copper, and therefore applicants prefer to process these downstream copper refining slags differently than the first copper refining slag.
In an embodiment of the method of the present invention comprising step c), the total feed to step c) comprises at least 29.0% by weight of copper, preferably at least 30.0% by weight, more preferably at least 31.0% by weight, even more preferably at least 32.0% by weight, even more preferably at least 33.0% by weight, preferably
BE2018 / 5874 at least 34.0% by weight, more preferably at least 35.0% by weight, even more preferably at least 36.0% by weight, preferably at least 37.0% by weight, more preferably at least 38.0% copper by weight.
In an embodiment of the method according to the present invention comprising step c), the total feed to step c) comprises an amount of copper at least 1.5 times as high as the total amount of solder metals present, ie the sum of Sn plus Pb, preferably at least 1.6 times, more preferably at least 1.7 times, even more preferably at least 1.8 times, even more preferably at least 1.9 times, preferably at least 2, 0 times, more preferably at least 2.1 times as high as the total amount of solder metals present.
Applicants have found that the prescribed amount of copper entails the advantage that sufficient copper is present to act as a solvent for extracting solder metals from the slag phase to the first lead-tin-based metal composition, and therefore improves the recovery of valuable tin and / or lead from the slag in step c).
Applicants have found that the lower limit specified for the presence of copper, relative to the presence of the sum of Sn plus Pb present, in the total feed to step c) brings the advantage that a better extraction of Sn and P Pb is obtained from the slag phase, and that without adding significant amounts of copper in the slag phase. The applicants have found that the high presence of copper in the feed to step c) influences the balance for tin and lead between the slag and the metal phase at the end of step c), the transition of these solder metals from the slag phase to the metal phase is promoted. Applicants have found that this effect can be achieved without increasing the concentration of copper in the spent slag obtained from step c) to economically significant and possibly unacceptable levels. Applicants have found that the large amount of copper in the feed to step c) makes it possible to obtain a spent slag from step c) that only low concentrations of tin
BE2018 / 5874 and / or lead, as well as copper. This entails the advantage that the spent slag from step c) requires less, or even no further processing, for its responsible disposal or for its use in a suitable downstream application.
In an embodiment of the method according to the present invention comprising step c), step c) comprises adding a first reducing agent to step c) preferably by adding the agent to the first copper refining slag before reducing the first copper refining slag . Applicants have determined that the addition of the reducing agent contributes to achieving the desired chemical reduction. Applicants have found that the first reducing agent may be a gas, such as methane or natural gas, but may also be a solid or a liquid, such as carbon, a hydrocarbon, even aluminum or iron.
In an embodiment of the method of the present invention comprising step c), the first reducing agent comprises a metal, and the first reducing agent is preferably a metal which has a higher affinity for oxygen than tin under the conditions of the method , lead, copper and nickel, preferably iron metal, more preferably scrap iron. Applicants preferably use iron, preferably scrap iron, as the reducing agent, due to their high availability at economically attractive conditions. Applicants have found that the addition of the solid reducing agent may entail the additional advantage that the furnace requires less additional heating to maintain or reach its desired temperature. The applicants have found that this positive effect can be so great that additional heating, by burning a fuel with the aid of air and / or oxygen, can hardly be necessary to reach the desired temperature. The applicants have furthermore determined that step c) may further be positively impacted by the addition of silica, as explained elsewhere in this document.
In an embodiment of the present invention, the method further comprises the step of
BE2018 / 5874
g) recycling at least a portion of the second lead-tin-based metal composition to step c), preferably the majority, if not all, of the second lead-tin-based metal composition being added to step c), and preferably prior to reducing the first copper refining slag, and / or recycling at least a portion of the second lead-tin-based metal composition to step b) and / or recycling at least a portion of the second lead-tin-based metal composition to step d), introduced later in this document.
Applicants have found that the valuable metals in the second lead-tin-based metal composition from step f) can be easily recovered by adding this composition to step c) and / or step b) and / or step d). The metals in the second lead-tin-based metal composition with a higher affinity for oxygen under the conditions of the process oxidize easily and lead to a reduction of those metals fed to step c) which have a lower affinity for oxygen under the same conditions . The presence in step c) of the additional metals from step f) leads to a partial reduction of the metals present in the first copper refining slag as oxides. Consequently, more valuable metals, such as Cu, Ni, Sn, Pb, Sb, As, pass into the metal phase of step c), and more metals to be rejected, such as Fe, Si, and Al, pass into the first spent slag which is produced in step c). The addition of this second lead-tin-based metal composition in step c) thereby improves the desired separation of the other base materials to step c), in combination with obtaining a desired separation of the metals recovered from step f).
In an embodiment of the method according to the present invention, step (i) further comprises the step of
d) partially oxidizing the first liquid bath, thereby forming a first diluted copper metal composition and a first solder refining slag, followed by separating the first solder refining slag from the first diluted
BE2018 / 5874 copper metal composition.
Applicants have found that step d) is highly suitable for concentrating a large amount of the solder metals, ie tin and / or lead, present in the first liquid bath, to the first solder refining slag without having to carry a significant portion of the copper, and optionally also the nickel, present in the first liquid bath, at the same time recovering a metal stream containing most of the copper and nickel present in the first liquid bath without having to carry significant amounts of metals that have a higher affinity for oxygen than tin and / or lead under the conditions of step d). In particular, in step d) the majority is removed from the copper and nickel, if any, as part of the first diluted copper metal composition, and thereby a slag phase is formed which comprises only small amounts of copper and / or nickel but relatively large amounts of tin and / or lead, together with most of the metals that have an even higher affinity for oxygen than lead and / or tin under the conditions of the process. On the other hand, step d) produces a metal stream that is extremely suitable for recovering its metal content because it is rich in valuable metals with very little dilution with metals with little or no value.
The applicants have found that the formation of the first diluted copper metal composition in step d) offers a great advantage for obtaining a relatively clear separation between copper on the one hand in a copper current with high purity, possibly even up to anode quality, and on the other hand a raw solder current such as the first raw solder metal composition obtained in step e), which is introduced later in this document. Any elemental copper present in step d) acts in step d) as an extraction agent for the tin and / or the lead, but also upstream. The copper therefore acts as a support for the tin and / or the lead. The entrainment of a portion of the copper to the respective slag phases in steps b) and / or h), wherein step h) is introduced later in this document, helps to remove more tin and / or lead from the main copper process stream that acts as a metal stream by the
BE2018 / 5874 copper refining process steps b) and / or h) sets out to become a high-quality copper product stream that is sufficiently rich for further processing into a high purity copper product. The copper also helps as a solvent for the tin and / or lead in process step c). The copper in step c) thus helps to keep the tin and / or lead in the metal phase of step c), ie the first lead-tin-based metal composition, and reduces the amounts of tin and / or lead that may end up in the first used up snail from step c).
The applicants have further established that, thanks to the production of the first diluted copper metal composition as the metal phase, the oxidation step d) is able to produce a first solder refining slag richer in tin and / or lead, in particular tin and lead combined in proportion to the amount of copper entrained with that first solder refining slag. Because the first solder refining slag is enriched in tin and / or lead, this facilitates downstream recovery of the solder metals (i.e. tin and / or lead) from this first solder refining slag.
Applicants have also found that the formation of the first diluted copper metal composition in step d) offers the additional advantage that more tin and / or lead can be introduced with the raw materials. This considerably broadens the acceptability criteria for any raw materials that may additionally be added to step b), ie in addition to the black copper, but also in the steps downstream thereof, such as in steps h), c) and d), and in step j ), which is introduced later in this document. Moreover, this also considerably eases the acceptability criteria for the black copper itself. This feature thus considerably broadens the acceptability criteria for the raw materials used in the production of the black copper, usually obtained as the main product from a smelting furnace step. As a result, the smelting furnace step may accept many more low-quality raw materials that are more widely available at more economically attractive conditions.
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The applicants have further established that the formation of the first diluted copper metal composition entails the additional advantage that in step d) a better separation can be obtained between the copper and the nickel intended to enter the first diluted copper metal composition, and the tin and lead intended for entering the first solder refining slag.
Applicants have found that performing step c) upstream of, or before, step d) makes it possible to achieve in step d) an advantageously high recovery from the copper and / or nickel in step d) to the metal product, and allowing only a relatively small amount of copper and / or nickel, if any, to enter the first solder refining slag.
The amounts of copper and / or nickel that end up in the raw solder as impurities represent, together with the iron present, a burden on the refining process of raw solder, in particular when this is done using silicon metal, and are therefore undesirable. Applicants have found that downstream of step d), a crude solder metal can be produced that contains considerably less than the 18.11% by weight of copper, nickel and iron combined in US 3,682,623.
The applicants have further established that the first diluted copper metal phase recovered from the slag re-treatment furnace can contain much less non-valuable metals. In US 3,682,623, the black copper for recycling (Table XIV) contains only 97.52% by weight of the total of Cu, Sn, Pb and Ni, leaving 2.48% by weight as a balance. This difference brings with it the advantage that the first diluted copper metal phase becomes much easier to process further, especially for the recovery of the valuable metals contained in the stream.
The applicants have further established that the first diluted copper metal phase recovered from step d) may contain relatively important amounts of tin and / or lead. This entails the advantage that the corresponding slag phase that is obtained from
BE2018 / 5874 step d), i.e. the first solder refining slag which, with sufficient time and mixing, must be in equilibrium with the first diluted copper metal phase, is also richer in tin and / or lead. As a result, more tin and / or lead becomes available for recovery downstream through the further processing of the first solder refining slag for the recovery therefrom of the solder metals, i.e. the tin and / or the lead. The overall result is that more crude solder can be produced in proportion to the amount of copper produced by the method of the present invention. This positive effect entails the associated additional advantage that a considerably higher amount of high purity tin product can be produced relative to the copper production rate of the process of the present invention. Because the co-production of tin generates an additional income on top of the income from copper production, this advantage can mean a significant economic added value for the person carrying out the process.
The applicants have further established that the more significant presence of tin and / or lead in the first diluted copper metal phase that is recovered from step d) makes it technically easier, and also more economically interesting, to recover the tin and / or lead from this stream by processing this stream separately, instead of simply recycling this stream as such to the first copper refining step b), as is done in US 3,682,623. Applicants have found that the first diluted copper metal phase or composition obtainable from step d) is now highly suitable for further separation into a stream with a higher concentration of tin and / or lead on the one hand and a stream with a higher concentration of copper and / or nickel on the other. The formation of another stream with a higher concentration of tin and / or lead entails the possibility of generating a tin by-product with an even greater purity in relation to copper production, which adds to the advantages set out above on that subject. Even if, following that additional separation, at least a portion of the stream with a higher concentration of copper and / or nickel would be recycled to the first copper refining step b),
BE2018 / 5874 similar to what happened in US 3,682,623, there would then be less tin and / or lead present in that recycling stream in relation to the copper content, and therefore more furnace volume becomes available for processing extra fresh feeds in the steps through which this recycling stream would pass.
Applicants have also found that the method with step d) is very effective for producing a slag phase,
i.e. the first solder refining slag, which is particularly suitable for producing a derived raw solder current, which can serve as an intermediate for the recovery of high purity tin and / or lead products. Applicants have found that this effectiveness is due in part to obtaining, in step d), the first diluted copper metal composition, but also to the sequence of oxidation and reduction steps as prescribed in the method of the present invention.
In one embodiment, the method of the present invention comprises the addition of a fresh feed to the furnace charge of step d). Applicants have determined that step d) is highly suitable for recovering valuable metals from their oxides. The copper, tin and / or lead added as part of fresh feed to step d) in the form of an oxide can be easily recovered as elemental metal in the metal phases formed in step d), e) or f) under the conditions of the process. Step e) is introduced later in this document. Applicants have determined that step d) is therefore suitable for, for example, recycling volumes of a final slag containing higher levels of certain metals than desired, and therefore less economically or ecologically suitable for disposal, or volumes of slag layers that have occurred collected as a crust that can grow on the inside of containers used to transport molten slag from one process step to another. Applicants have found that adding such materials as fresh feed to step d) allows improved recovery of the valuable metals therein.
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In an embodiment of the method according to the present invention, the temperature of the slag in step b) and / or in step c) is at least 1000 ° C, preferably at least 1020 ° C, more preferably at least 1040 ° C, even more preferably at least 1060 ° C, preferably at least 1080 ° C, more preferably at least 1100 ° C, even more preferably at least 1110 ° C, preferably at least 1120 ° C, more preferably at least 1130 ° C, even more preferably at least 1140 ° C, preferably at least 1150 ° C. Applicants have found that the separation between the metal phase and the slag phase is better when the temperature of the slag corresponds to the prescribed limit value, and is preferably above the prescribed limit value. Without wishing to be bound by this theory, the applicants believe that the higher temperature produces a better separation, at least because the viscosity of the slag is lower at higher temperatures. A lower viscosity of the slag enables the bubbles of heavier metals to combine more rapidly into larger bubbles and to sink faster through the slag phase until they reach the underlying metal phase and can be combined with it. A higher temperature also entails the advantage of faster reaction kinetics, such that a desired equilibrium state can be achieved more quickly.
However, the applicants also believe that the balance between the metal and slag phase is influenced by the temperature. Typically, a higher temperature decreases the differences between different metals in their affinity for oxygen under the conditions of the process. Applicants therefore prefer to limit the oven temperature in step b) and / or c) to at most 1300 ° C, preferably at most 1250 ° C, more preferably at most 1200 ° C. Applicants prefer to apply this limit to most, if not all, steps in the method of the present invention in which a phase separation is performed between at least two liquid phases, usually a supernatant slag phase and an underlying metal phase.
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At the high temperatures in a non-ferrous metal smelting or refining step, the metals and metal oxides both occur in the liquid, molten state. The metal oxides generally have a lower density than the metals and form a separate so-called "slag" phase that comes to surface as the supernatant liquid phase on the molten metal phase. The metal oxides can thus be separated from the molten metal phase by gravity as a separate liquid slag phase. Silicon dioxide, usually in the form of normal sand, can be added as a so-called "flux material", i.e. as a slag diluent and / or to improve the fluidity of the slag such that it separates more easily from the metal phase and is easier to handle. The silicon dioxide is also able to bind certain elements, and thereby also influences the urge of that element to become part of the slag phase instead of the metal phase. Applicants have found that the addition of silica is a highly desirable element of the process for many of the steps that form part of the process of the present invention in which a slag phase and a metal phase are to be separated from each other because the silica is in many conditions contributes to altering the balance between the metal phase and the slag phase in favor of the desired separation with regard to the metals which are desired in the metal phase and the metals which preferably remain in the slag phase. The applicants have further established that when the slag contains iron and is removed from the furnace and pelletized by contacting the hot liquid slag with water, the addition of silica may eliminate the risk of the iron being in a form that acts as a catalyst for the splitting of water and thereby the formation of hydrogen gas, which poses an explosion hazard. Silicon dioxide also increases the activity of any tin present in the slag, whereby a portion of the SnO 2 is reduced to Sn metal, whereby this Sn will pass to the metal phase. This latter mechanism lowers the amount of Sn remaining in the slag for the same underlying metal composition.
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Under the pyrometallurgy operating conditions, various chemical reactions take place between the various metals and oxides in the furnace. The metals with a higher affinity for oxygen are more easily oxidized, and those oxides tend to pass to the slag phase, while the metals with a lower affinity for oxygen, if present as oxides, rapidly reduce to return to their metal state, and these metals tend to transition to the liquid metal phase. If sufficient contact area and time are provided, a state of equilibrium is established between the metal phase in which the metals with a lower affinity for oxygen collect under the conditions of the process, and the slag phase, in which the metals with a higher affinity for oxygen under the conditions of the process collect in the form of their oxides.
Metals such as sodium (Na), potassium (K), calcium (Ca) and silicon (Si) have an extremely high affinity for oxygen and will be collected almost exclusively in the slag phase. Metals such as silver (Ag), gold (Au) and other precious metals have an extremely low affinity for oxygen, and are collected almost exclusively in the metal phase. Most other metals usually exhibit "between" these two extremes, and their tendencies can moreover be influenced by the presence of other elements or substances, or possibly their relative absence.
The metals of interest for this invention exhibit, under the typical furnace conditions of non-ferrous metal refining, affinities for oxygen, and will tend to divide between the metal and the slag phase. From lower to higher affinity for oxygen, and consequently from a relatively high affinity to a lower affinity for the metal phase, the arrangement of these metals can be roughly presented as follows: Au> Ag >> Bi / Cu> Ni> As> Sb> Pb> Sn >> Fe> Zn> Si> Al> Mg> Ca. For the sake of convenience, this can be called a ranking of the metals from the more noble to the less noble, but this qualification must be linked to the specific
BE2018 / 5874 conditions and conditions of pyrometallurgical non-ferrous metal processes, and can fail when exported to other fields. The relative position of specific metals in this list can be influenced inter alia by the presence or absence of other elements in the furnace, such as silicon.
The equilibrium distribution of a metal between the metal and slag phase can also be influenced by the addition of oxygen and / or oxygen scavenging materials (or reducing agents) to the liquid bath in the furnace.
Due to the addition of oxygen, some of the metals in the metal phase will be converted to their oxidized form, after which this oxide will then transfer to the slag phase. The metals in the metal phase that have a high affinity for oxygen will show a stronger tendency to undergo this conversion and change phase. Their distribution in equilibrium between the metal and slag phase may therefore be more subject to change.
The opposite can be accomplished by the addition of oxygen scavenging materials. Suitable oxygen consumers can be, for example, carbon and / or hydrogen, in whatever form, such as in organic materials, for example wood, or other combustible substances, such as natural gas. Carbon and hydrogen will easily oxidize ("burn") and be converted to H2O and / or CO / CO2, components that easily leave the liquid bath and carry its oxygen content from the bath. But metals such as Si, Fe, Al, Zn and / or Ca are also suitable reducing agents. Iron (Fe) and / or aluminum (Al) are of particular importance because of their easy availability. By oxidizing, these components will reduce some of the metals in the slag phase from their oxidized state to their metal state, and these metals will then transfer to the metal phase. Now it is the metals in the slag phase with a lower affinity for oxygen that will be more inclined to undergo this reduction reaction and to carry out the transition in the reverse direction.
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In a smelting furnace step, one of the goals is to reduce oxides of valuable non-ferrous metals that are introduced with the feed to their corresponding reduced metals. The direction and speed of the reactions that take place in the smelting furnace step can also be controlled by checking the nature of the atmosphere in the furnace. Alternatively, or additionally, oxygen donating material or oxygen scavenging material may be added to the smelting furnace.
An extremely suitable oxygen scavenging material for such activities is iron metal, with scrap iron being generally preferred. Under the typical operating conditions, the iron will react with hot oxides, silicates and the other compounds of metals with a lower affinity for oxygen than iron, to form a melt containing the latter metals in elemental form. Typical responses include:
MeO + Fe FeO + Me + heat (MeO) _x SiO ₂ + x Fe (FeO) _x SiO ₂ + x Me + heat
The temperature of the bath remains high due to the exothermic heat of reaction and the heat of combustion. The temperature can easily be kept within a range in which the slag remains liquid and the volatilization of lead and / or tin remains limited.
Each of the reduction reactions that take place in the melting furnace forms a balance. Therefore, the conversion induced by each reaction is limited by the equilibrium states defined in equations such as the following:
[FeO] [Me]
K1 = ------------------------ [MeO] [Fe] [(FeO) xSiO2] [Me] ^x
K2 = ------------------------------------ [(MeO) xSiO2] [Fe] ^x
The parameters in these formulas represent the activities of the chemical components listed below
BE2018 / 5874 operating conditions, often involving the multiplication of the concentration of the component times the activity coefficient of the component under the operating conditions, the latter not always being 1.0 or equal for different components. Applicants have found that the activity coefficients can be influenced by the presence of other chemical compounds, such as so-called flux compounds, which are sometimes referred to as slag formers, in particular by the addition of silicon dioxide.
In the case that Me is copper, K1 and K2 are high at normal reaction temperatures and thus the reduction of copper compounds takes place until it is nearly complete. In the case of lead and tin, K1 and K2 are both relatively low, but the copper in the metal phase extracts lead and tin in metal form from the slag reaction zone, thereby reducing the activities of these metals in the slag and the reduction of combined lead and tin is driven to completion.
The vapor pressure of zinc is relatively high at the typical reaction temperature and a large proportion of zinc, unlike lead and tin, can be easily evaporated from the furnace. Zinc vapors leaving the oven are oxidized by air, which can be blown in, for example, between the oven access and the hood and / or the exhaust pipe. The resulting zinc oxide dust is condensed and collected by conventional dust collection systems.
Preferably, the copper content, the tin content and the lead content of the slag in the smelting furnace are each reduced to 0.5% by weight or less. To this end, the metal phase must contain sufficient copper to act as the solvent to extract the lead and tin present from the slag. For the same reason, applicants also prefer that the concentration of copper in the black copper supplied to the process of the present invention is above the lower limit specified elsewhere in this document.
In an embodiment step (ii) of, the method of the present invention further comprises the following step:
BE2018 / 5874
e) partially reducing the first solder refining slag, thereby forming the first raw solder metal composition and the second solder refining slag, followed by separating the second solder refining slag from the first raw solder metal composition.
This step e) produces a crude solder current that is rich in tin and / or lead, and which also comprises the majority of the relatively small amounts of copper and / or nickel entrained in the first solder refining slag. The first raw solder current is suitable for further processing for further enrichment in tin and / or lead, for example by treatment with silicon metal as described in patent DE 102012005401 A1. Alternatively, or additionally, this crude solder current, optionally after an enrichment step for increasing the tin and / or lead content, may be further updated as described in WO 2018/060202 A1 or the like, and then subjected to a distillation and recovery of the tin and / or lead as high purity metal products, as described in the same document.
Applicants have found that in step e) the recovery of the solder metals in the first raw solder metal composition can be advantageously high, and the entrainment of tin and / or lead, but also of copper and / or nickel, advantageously low in the second solder refining slag can be had.
In an embodiment of the method according to the present invention, step e) comprises adding a second reducing agent to step e), preferably to the first solder refining slag prior to reducing the first solder refining slag. The applicants have further determined that to perform the reduction in step e), in addition to the metal stream that can be added in step e) or alternatively, a reducing agent can be added to step e). Applicants have determined that the addition of the reducing agent contributes to achieving the desired chemical reduction. Applicants have determined that the second reducing agent can be a gas, such as methane or natural gas, but
BE2018 / 5874 can also be a solid or a liquid, such as carbon, a hydrocarbon, even aluminum or iron.
Applicants have determined that the reduction in step e) can be carried out at least in part by adding a suitable metal stream (second reducing agent),
i.e. by the addition of a metal composition containing metals that have a higher affinity for oxygen under the conditions of the process than tin and / or lead such as zinc, silicon, magnesium, iron, calcium or aluminum. This metal stream preferably also additionally contains tin and / or lead, and may optionally also contain an amount of antimony and / or arsenic. This additional antimony, tin and / or lead quickly ends up in the first raw solder metal composition from step e) and can easily be recovered downstream as part of a high-quality purified metal product. The added metal stream preferably contains only small amounts of nickel and / or copper, ie metals that are likely to become part of the first raw solder metal composition from step e) but that may entail additional process loads and operating costs, such as additional consumption of silicon when a step of silicon treatment is provided downstream in the refining of the first raw solder metal composition. Iron is also preferably present in only limited quantities, because not all of the added iron can end up in the slag phase, but can also leave step e) together with the first raw solder metal composition, and increase the process loads downstream.
In an embodiment of the method according to the present invention, the second reducing agent comprises a metal, and the second reducing agent is preferably a metal which, under the conditions of the method, has a higher affinity for oxygen than tin, lead, copper and nickel wherein the second reducing agent preferably comprises iron metal, more preferably scrap iron. Applicants preferentially use iron, preferably scrap iron, as the reducing agent, due to its high availability in economic terms
BE2018 / 5874 attractive conditions. Applicants have found that the addition of the solid reducing agent may entail the additional advantage that the furnace requires less additional heating to maintain or reach its desired temperature. The applicants have found that this positive effect may be large enough for additional heating by burning a fuel with the aid of air and / or oxygen to remain limited, or even hardly necessary to reach the desired temperature. The applicants have furthermore determined that step e) may furthermore be positively effected by the addition of silica, as explained elsewhere in this document.
In an embodiment of the method according to the present invention, a first Pb and / or Sn-containing fresh feed is added to step e), wherein the first Pb and / or Sn-containing fresh feed preferably comprises scratch, and preferably is scratch obtained from downstream processing of concentrated streams of Pb and / or Sn.
Applicants have found that step e) is also a very suitable location in the process for adding materials that are rich in tin and / or lead, but low in copper and nickel, but that may contain metals which under the conditions of the process have a higher affinity for oxygen than tin and lead. Adding it to step e) entails the advantage that the tin and / or lead are easily recovered as part of the first raw solder metal composition, and removed from the process, while the so-called "less noble" metals have a short and direct process route to the second spent snail that is produced in the downstream step f).
The applicants have determined that step e) is very suitable for the recovery of tin and / or lead, and possibly antimony and / or arsenic, in raw materials or process by-products that are rich in such metals but relatively low in copper and / or nickel. Applicants have determined that the first Pb and / or Sn-containing fresh feed
BE2018 / 5874 may also contain metals which, under the conditions of the process, have a higher affinity for oxygen than tin and / or lead, such as sodium, potassium, calcium. Such metals can be added, for example, as part of process chemicals used in downstream steps to refine a stream rich in tin and / or lead, such as the first crude solder metal composition or a downstream derivative. Applicants have determined that step e) is very suitable for recovering valuable metals from a scratch by-product formed in one of the refining steps that are carried out as part of the processes disclosed in patent WO 2018/060202 A1 or the like. Such scratch by-product streams usually carry significant amounts of tin and / or lead, but also contain the other metals that may have been added as part of process chemicals.
In an embodiment of the method according to the present invention, step (i) further comprises the step of
h) partially oxidizing the first enriched copper metal phase, thereby forming a second enriched copper metal phase and a second copper refining slag, followed by separating the second copper refining slag from the second enriched copper metal phase.
Applicants have found that the first enriched copper metal phase formed in step b) can be further enriched in copper by subjecting the stream to a subsequent oxidation step. The following oxidation step leads to the formation of a second copper refining slag which may contain economically significant amounts of valuable metals other than copper, but in which also an economically significant amount of copper is entrained.
In an embodiment of the method of the present invention comprising step h), at least 37.0% by weight of the total amount of the tin and lead processed through process steps b) and / or h) is recovered in the first copper refining slag and the second copper refining slag together.
BE2018 / 5874
In an embodiment of the method of the present invention comprising step h), at least 37.5% by weight, and more preferably at least 38% by weight, of the total amount of the tin and lead processed through process steps b) and / or h) recovered in the first copper refining slag and the second copper refining slag together, preferably at least 40% by weight, more preferably at least 45% by weight, even more preferably at least 50% by weight, preferably at least 60% by weight, more preferably at least 70% by weight, even more preferably at least 80% by weight, even more preferably at least 85% by weight, preferably at least 90% by weight, with more preferably at least 92% by weight, even more preferably at least 94% by weight, even more preferably at least 95% by weight of the total amount of the tin and the lead processed through process steps b) and / or h). Applicants have found that a high recovery of the tin and / or lead in the early slag of the copper refining step sequence is advantageous for obtaining a better separation between the copper on the one hand, and the solder metal tin and / or lead on the other hand.
In one embodiment of the method of the present invention, at least 8.5% by weight of the total amount of the tin and lead processed through process step b) is recovered in the first copper refining slag, preferably at least 10% by weight , more preferably at least 15% by weight, even more preferably at least 20% by weight, preferably at least 30% by weight, more preferably at least 40% by weight, even more preferably at least 45% by weight. %, even more preferably at least 50% by weight, preferably at least 55% by weight, more preferably at least 60% by weight, even more preferably at least 64% by weight, even more preferably at least at least 68% by weight of the total amount of the tin and lead processed through process step b). Applicants have found that the earlier in the sequence of the copper refining steps b) and h) more of the tin and / or lead is oxidized and transferred to the copper refining slag phase, the clearer the overall separation between the copper on the one hand and the soldering metals on the other hand can become performed.
BE2018 / 5874
In an embodiment of the method of the present invention comprising step h), at least 41.0% by weight of the total amount of the tin processed through process steps b) and / or h) is recovered in the first copper refining slag and the second copper refining slag together, preferably at least 45% by weight, more preferably at least 50% by weight, even more preferably at least 55% by weight, preferably at least 60% by weight, more preferably at least 65 % by weight, even more preferably at least 70% by weight, preferably at least 75% by weight, more preferably at least 80% by weight, even more preferably at least 85% by weight, preferably at least 90% by weight, more preferably at least 92% by weight of the total amount of the tin processed through process steps b) and / or h).
In an embodiment of the method of the present invention comprising step h), at least 34.5% by weight of the total amount of lead processed through process steps b) and / or h) is recovered in the first copper refining slag and the second copper refining slag together, preferably at least 35% by weight, more preferably at least 40% by weight, even more preferably at least 45% by weight, even more preferably at least 50% by weight, more preferably at least at least 55% by weight, preferably at least 60% by weight, even more preferably at least 65% by weight, more preferably at least 70% by weight, more preferably at least 75% by weight, even more preferably at least 80% by weight, even more preferably at least 85% by weight, preferably at least 90% by weight, more preferably at least 91% by weight of the total amount of the lead processed through process steps b) and / or h).
In one embodiment, the method of the present invention further comprises the step of
i) adding at least a portion of the second copper refining slag to the first liquid bath and / or adding at least a portion of the second copper refining slag to step d).
BE2018 / 5874
Applicants have found that the composition of the second copper refining slag is extremely suitable for being added to the first liquid bath. Applicants therefore prefer to add the complete second copper refining slag into the first liquid bath. The stream is suitable in the first place because the second copper refining slag is already relatively rich in the intended valuable metal tin and lead, but also contains significant amounts of copper, which can function downstream as an extractant for non-copper metals such as tin and lead. Secondly, the second copper refining slag contains only small amounts of metals that have a higher affinity for oxygen under the conditions of the process than tin and / or lead, more particularly metals that are less desirable in the final purified metal products copper, tin and / or lead, which will have to be removed from the process as part of a spent snail. Because the second copper refining slag is relatively poor in such metals, the addition of this slag in the first liquid bath does not lead to the ingestion of a large useless amount of furnace volume in one of the downstream steps in the process sequence d), e) and f), ie the process path that is preferred for such "less noble" metals to end up in a spent snail, in this case the second spent snail.
Applicants have found that the method according to the present invention comprising steps b), h), c), i) and d) is very effective for the production of a slag phase, ie the first solder refining slag, a slag which is particularly suitable for producing a derived solder current, ie the first raw solder metal composition, which can serve as an intermediate for the recovery of high purity tin and / or lead products. Applicants have found that this effectiveness is due in part to obtaining, in step d), the first diluted copper metal composition, but also to the sequence of oxidation and reduction steps as indicated.
Applicants have further determined that the method of the present invention comprising steps i) and d), too
BE2018 / 5874 is extremely energy efficient. In step d), the second copper refiner slag that can be added in step i) acts as an oxidizing agent for impurities in the first liquid bath. The copper oxides in the second copper refining slag smoothly reduce to elemental copper in that bath, thereby releasing the oxygen and making oxygen available to convert those metals which, under the conditions of the process, have a higher affinity for oxygen than copper, of their elemental metal form to oxides. The elemental copper formed in step d) thereby passes to the metal phase and leaves step d) with the first diluted copper metal composition. The metals that are converted to their oxides in step d) will pass to the slag phase and are recovered in the first solder refining slag. Applicants have found that in step d) a substantial amount of Sn and / or Pb can be transferred from the metal phase introduced into the furnace to the first solder refining slag present at the end of step d). Applicants have also found that these chemical conversions in step d), from copper oxides to elemental copper and from tin, lead or other metals to their oxides, can be accomplished with relatively little additional energy input, external oxidizing agents and / or reducing agents , and therefore with a relatively limited consumption of energy or process chemicals.
In one embodiment, the method of the present invention further comprises the steps of
j) partially oxidizing the second enriched copper metal phase, thereby forming a third enriched copper metal phase and a third copper refining slag, followed by separating the third copper refining slag from the third enriched copper metal phase, wherein the third enriched copper metal phase preferably forms the refined copper product which is obtained in step (i),
k) adding at least a portion of the third copper refining slag to the first diluted copper metal composition, thereby forming a second liquid bath, and / or adding at least a portion of the third copper refining slag to step 1),
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l) partially oxidizing the second liquid bath, thereby forming a first copper metal composition with a high copper metal content and a third solder refining slag, followed by separating the third solder refining slag from the first copper metal composition with a high copper metal content.
Applicants have found that the second enriched copper metal phase formed in step h) can be further enriched in copper by subjecting the stream to the next oxidation step j). The following oxidation step leads to the formation of the third copper refining slag, which may still contain economically significant amounts of valuable metals other than copper, but in which also an economically significant amount of copper is entrained. The advantage is that these valuable non-copper metals become recoverable from the third copper refining slag in a much simpler way compared to the amounts of non-copper metals that would remain in the third enriched copper metal phase if this stream were subjected to a copper electrofining step for the recovery of copper with high purity, in which the non-copper metals often represent a burden on the process. Some non-copper metals remain in the so-called anode mucus during electro refining, and some other non-copper metals dissolve in the electrolyte.
The applicants have further established that the three consecutive oxidation steps, as part of the series b), h) and j), are capable of extracting from a starting material of black copper which can be freely diluted in copper, but rich in tin and / or lead, to produce a third enriched copper metal phase that has a concentration of copper that is highly suitable for further purification by electro-refining, and can therefore be labeled as “of anode quality”. Applicants have found that the sequence of oxidation steps as indicated is capable of producing, from a black copper with hardly more than 75% by weight copper, a third enriched copper metal phase containing up to 99.0% by weight copper. The applicants have further established that, together with the processing of the black copper supplied to step b), additional
BE2018 / 5874 copper-containing raw materials can be processed through the indicated sequence of oxidation steps.
Applicants have found that the composition of the third copper refining slag is extremely suitable for being added to the second liquid bath. Applicants therefore prefer to add the complete third copper refining slag into the second liquid bath.
The stream is first of all suitable because the third copper refining slag still contains economically significant amounts of the intended valuable metals tin and / or lead, but is also relatively rich in copper, which can be used as a useful extractant for non-copper metals such as tin and / or lead.
Secondly, the third copper refining slag contains very small amounts of metals that have a higher affinity for oxygen than tin and / or lead under the conditions of the process, more particularly metals that are less desirable in the final purified metal products copper, tin and / or lead, and which are preferably removed from the method of the present invention as part of a spent snail. Because the third copper refining slag is very poor in such metals, the addition of this slag in the second liquid bath leads to only very little unnecessary use of useless furnace volume in any of the downstream steps in the process, including step 1) , but also in any of the downstream steps in the process that such "less noble" metals must follow before they eventually end up in a spent snail.
The applicants have furthermore found that any further recovery of valuable metals from the second liquid bath, as in step 1), can take place extremely energy-efficient due to the addition of at least a part of the third copper refining slag in step k). In step k), the third copper refining slag added in the second liquid bath upstream of any additional metal recovery steps acts as an oxidizing agent for impurities in the
BE2018 / 5874 second liquid bath. The copper oxides in the third copper refining slag smoothly reduce to elemental copper in step 1), thereby releasing the oxygen to convert metals that have a higher affinity for oxygen than copper from their elemental metal form to oxides. The elemental copper formed during the processing of the second liquid bath in step l) thereby passes to the metal phase, which in step l) is the first copper metal composition with a high copper metal content. The metals that are converted to their oxides in step 1) pass to the slag phase, i.e. the third solder refining slag. Applicants have found that in step 1) a substantial amount of Sn and / or Pb can be transferred from the metal phase that is supplied to the slag phase. Applicants have also found that these chemical conversions in step 1), from copper oxides to elemental copper and from tin, lead and / or other metals to their oxides, can be triggered with relatively little additional supply of energy, external oxidizing agents and / or reducing agents , and therefore with a relatively limited consumption of energy or process chemicals.
Applicants have determined that in step 1) most of the copper and nickel present in the first copper metal composition diluted and in the third copper refining slag can be recovered in the first copper metal composition with a high copper metal content, together with an amount of the bismuth and the antimony that may be present, while most of the tin and / or lead in those streams can be recovered in the third solder refining slag. Applicants have found that the third solder refining slag can advantageously become rich in tin and / or lead and also relatively poor in copper, such that this slag can be fairly easily further processed for recovery of the majority of its solder metals in a current flowing on a appears to be raw solder current and is suitable for processing as a raw solder current.
In an embodiment of the method of the present invention comprising steps b), h), c), d), j) and 1), the first copper metal composition with high copper metal content becomes at least
BE2018 / 5874 partially recycled to a suitable location upstream in the process. Preferably, that location is step b), but a portion of the recycled stream can be recycled to step h) and / or step j) and / or step c) and / or step d).
Applicants have found that on the one hand the step 1) is also extremely suitable for providing a path for the removal of at least a part of the nickel from the metal casting process as a whole, because there is a high chance that nickel will which upstream location is introduced into the method becomes part of the first copper metal composition with a high copper metal content. On the other hand, the applicants have found that if no nickel, or only a small amount of nickel, is introduced into the process as a whole with the feeds, the first copper metal composition with a high copper metal content has a composition very similar to that of the black copper feed which was provided in step a), and that this first copper metal composition stream with high copper metal content can therefore be easily recycled to step b), or alternatively and / or additionally, partially to any of the following copper oxidation steps h) and j) for the recovery of the copper from it as part of the third enriched copper metal phase. The method described in U.S. Pat. No. 3,682,623 includes such a recycling of a copper-rich stream to the first oxidation step performed on the black copper. However, any recycling of the first copper metal composition with high copper metal content to step b), or to one of the following steps h) or j), is, in comparison with the prior art, benefited by the upstream removal of impurities in one of the depleted snails, such as the first depleted snail produced in step c) and / or the second depleted snail produced in step f).
Applicants have found that if nickel is present in the feeds to the process, a partial recycling of the first copper metal composition with high copper metal content to an upstream location in the process, such as
BE2018 / 5874 step b), h) or j), has the advantage that nickel is concentrated to a higher content in the first copper metal composition with a high copper metal content, compared to a process without such partial recycling. This concentration effect entails the advantage that withdrawing a certain amount of nickel from the process, for example to keep the levels of nickel in certain steps of the process below certain levels, withdrawing a smaller amount of copper together with the amount of nickel required. This entails the advantages that the removal of nickel from the process is more efficient, that the further processing of the extracted copper / nickel mixture can be carried out more efficiently and in smaller equipment, and can also be carried out more efficiently, ie with a lower consumption of energy and / or process chemicals.
Applicants have found that the first copper metal composition with high copper metal content that is withdrawn from the process can be further processed for the recovery of copper and nickel present therein, by means known in the art, or preferably by the means described in the related patent application EP-A-18172598.7, filed May 16, 2018 with the title Improvement in Copper Electrorefining.
In an embodiment of the method according to the present invention comprising step l), at the end of step l) the first copper metal composition with high copper metal content is only partially removed from the oven, and a portion of this metal composition is kept in the oven together with the third soldering refiner. This portion may represent at least 3 wt%, 4 wt% or 5 wt% of the total first copper metal composition with high copper metal content present in the furnace at the end of step 1), preferably at least 10 wt% , more preferably at least 20 wt%, even more preferably at least 30 wt%, even more preferably at least 40 wt% of the total first copper metal composition with high copper metal content present in the furnace. Applicants have determined that this amount of metal is useful
BE2018 / 5874 oven improves during the current and at least one of the following process steps.
In one embodiment, the method of the present invention further comprises the step of
m) partially reducing the third solder refining slag, thereby forming a second diluted copper metal composition and a fourth solder refining slag, followed by separating the fourth solder refining slag from the second diluted copper metal composition.
Applicants have found that the third solder refining slag may contain amounts of copper and / or nickel that are still on the high side for deriving a current of the crude solder type from this slag. Applicants therefore prefer to include the additional partial reduction step m) as part of the method of the present invention. Applicants have found that a significant amount of the copper and / or nickel present in the third solder refining slag can be easily removed as part of the second diluted copper metal composition formed in step m), while most of the tin and / or lead are used as part of the fourth solder refining slag can be retained before further processing is carried out on the fourth solder refining slag. Preferably, step m) is carried out in such a way that at least 50% by weight of the copper present in step m) is removed as part of the second diluted copper metal composition, more preferably at least 70% by weight, even more preferably at least at least 80% by weight, even more preferably at least 90% by weight. Alternatively, or additionally, step m) is preferably carried out in such a way that at least 50% by weight of the tin present in step m) is recovered in the fourth solder refining slag, more preferably at least 70% by weight, even more preferably at least 80% by weight, even more preferably at least 90% by weight.
In an embodiment of the method of the present invention comprising step m), at the end of step m), the second diluted copper metal composition is only partially removed
BE2018 / 5874 from the oven, and a portion of this metal composition is held in the oven together with the fourth solder refining slag. This portion may represent at least 1 wt%, 2 wt%, 3 wt%, 4 wt% or 5 wt% of the total second diluted copper metal composition present in the furnace at the end of step m), preferably at least 10% by weight, more preferably at least 20% by weight, even more preferably at least 30% by weight, even more preferably at least 40% by weight of the total second diluted copper metal composition present in the oven. Applicants have found that this amount of metal improves the usability of the furnace during at least one of the following process steps.
In an embodiment of the method according to the present invention, step (iii) further comprises the step of
n) partially reducing the fourth solder refining slag, forming the second raw solder metal composition and the fifth solder refining slag, followed by separating the second raw solder metal composition from the fifth solder refining slag.
Applicants have found that the fourth solder refining slag is a highly suitable base material for recovering a raw solder type material, with high acceptability for further processing into high quality purity tin and / or lead products. Applicants have found that in the partial reduction step n) a large portion of the tin and / or lead present in the furnace can be recovered in the second raw solder metal composition, together with virtually all of the copper and / or nickel present, while most of the metals which have a higher affinity for oxygen, such as iron, under the process conditions can be retained as part of the fifth solder refining slag. Applicants have determined that the second raw solder metal composition is suitable for further processing, for example, by subjecting the stream to a silicon metal treatment as described in patent DE 102012005401 A1. Alternatively, or additionally, it may be crude
BE2018 / 5874 soldering current, optionally after an enrichment step for increasing the tin and / or lead content, are further updated as described in WO 2018/060202 A1 or the like, and then subjected to a distillation and recovery of the tin and / or lead as high purity metal products, as described in the same document.
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at most 10.0% by weight of copper, preferably at most 9.0% by weight, more preferably at most 8.0% by weight %, even more preferably not more than 7.0% by weight, even more preferably not more than 6.0% by weight of copper, preferably not more than 5.5% by weight, more preferably not more than 5.0 % by weight, even more preferably at most 4.5% by weight, preferably at most 4.0% by weight, more preferably at most 3.5% by weight, even more preferably at most 3.0% by weight %, preferably at most
2.5% by weight, more preferably at most 2.0% by weight, even more preferably at most 1.5% by weight of copper, and optionally at least 0.1% by weight, preferably at least 0, 5% by weight, more preferably at least 1.0% by weight of copper. Applicants have found that compliance with the upper limit entails the advantage of a more economical and possibly even simpler further refining of the raw solder current that can be recovered downstream from the first solder refining slag and / or the fourth solder refining slag.
Applicants have found that the presence of less copper in the first solder refining slag and / or the fourth solder refining slag also lowers the copper content of the first and / or the second raw solder metal composition obtained in step e) and / or step n) since the copper is usually also reduced in step e) and / or step n) and the majority of the copper becomes part of the resulting first and / or second raw solder metal composition. The first and / or the second raw solder metal composition should generally be subjected to further purification steps to reduce the presence of metals other than tin, lead and antimony in the raw solder metal composition, e.g. before this raw
BE2018 / 5874 solder metal composition becomes suitable for the recovery of high purity tin and / or lead products. This includes the removal of copper. Such a treatment can be, for example, silicon metal, as described in the patent DE 102012005401 A1. Silicon metal is a fairly expensive process substance, and the treatment results in a silicon compound of the contaminating metal as a by-product to be reworked or disposed of. The copper entrained in the first and / or the second raw solder metal thus leads to an increased consumption of silicon metal in such a purification step. It is therefore advantageous to limit the copper in the first solder refining slag and / or the fourth solder refining slag.
Preferably, the first solder refining slag and / or the fourth solder refining slag comprises at least 1.0% by weight of copper, more preferably at least 1.5% by weight, even more preferably at least 2.0% by weight, preferably at least at least 2.5% by weight, more preferably at least 3.0% by weight, even more preferably at least 3.5% by weight of copper.
Applicants have also found that it is advantageous to tolerate an amount of copper in the first solder refining slag and / or the fourth solder refining slag and to remain above the specified lower limit. Applicants have found that this has a positive effect on the upstream process steps, also with regard to the base materials that can incorporate these upstream process steps. At these levels, a higher presence of copper generally also means a higher presence of tin and / or lead, which can be very beneficial. Both positive technical effects are advantages that compensate for the load resulting from the presence of copper in the first solder refining slag and / or the fourth solder refining slag, and as a result, the presence of copper in the first and / or the second raw solder metal composition.
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at least 2.0% by weight of tin and optionally at most
BE2018 / 5874% by weight of tin. Preferably, the first solder refining slag and / or the fourth solder refining slag comprises at least 3.0% by weight of tin, more preferably at least 3.5% by weight, even more preferably at least 4.0% by weight, preferably at least at least 4.5% by weight, more preferably at least 5.0% by weight, even more preferably at least 5.5% by weight, preferably at least 6.0% by weight, more preferably at least 6 5% by weight, even more preferably at least 7.0% by weight, preferably at least 7.5% by weight, more preferably at least 8.0% by weight, even more preferably at least 8, 5 wt%, preferably at least 9.0 wt%, more preferably at least 9.5 wt%, even more preferably at least 10.0 wt%, preferably at least 10.5 wt. %, more preferably at least 11.0% by weight of tin. Applicants have found that the more tin is present in the first solder refining slag and / or the fourth solder refining slag, the more tin can end up in the first and / or the second raw solder metal composition obtained downstream. Since high-purity tin is a commercial product with considerable economic added value, a larger amount of tin in the first and / or the second raw solder metal composition makes it possible to recover a larger volume of high-purity tin from it.
Preferably, the first solder refining slag and / or the fourth solder refining slag in the method according to the present invention comprises at most 19% by weight of tin, more preferably at most 18% by weight, even more preferably at most 17% by weight, preferably at most 16% by weight, more preferably at most 15% by weight, even more preferably at most 14% by weight, preferably at most 13% by weight, more preferably at most 12% by weight, with even more preferably at most 11% by weight of tin. Applicants have found that satisfying the tin content at the specified upper limit entails the advantage of leaving room for other metals that may have benefits. In particular, the presence of significant amounts of lead in the first solder refining slag and / or the fourth solder refining slag, a large proportion of which ends up in the first and / or the second raw solder metal composition, has the advantage that the raw solder metal composition has a higher density, which
BE2018 / 5874 is extremely useful in separating the solder from other phases such as a slag phase or a scratch by gravity, for example during further downstream refining of the raw solder metal composition.
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at least 9% by weight of lead and optionally at most 30% by weight of lead. Preferably, the first solder refining slag and / or the fourth solder refining slag comprises at least 10% by weight of lead, more preferably at least 11% by weight, even more preferably at least 12% by weight, preferably at least 13% by weight, more preferably at least 14% by weight, even more preferably at least 15% by weight, preferably at least 16% by weight, more preferably at least 17% by weight, even more preferably at least 18% by weight lead. Applicants have found that more lead in the first solder refining slag and / or the fourth solder refining slag leads to more lead in the first and / or the second raw solder metal composition. More lead in this first and / or second raw solder metal product produces downstream positive effects for the process when the first and / or the second raw solder metal product is subjected to refining steps, as required when the first and / or the second raw solder metal product is the raw material for the extraction of high-quality tin and / or lead products of higher purity, for example by vacuum distillation. Applicants have also found that a greater presence of lead can have positive effects for processing, such as smoother phase separations, in various steps that can be performed as part of the conversion of the first and / or the second raw solder metal product to high-quality tin and / or lead products of higher purity.
Preferably, the first solder refining slag and / or the fourth solder refining slag in the method according to the present invention comprises at most 28% by weight of lead, more preferably at most 26% by weight, even more preferably at most 24% by weight, preferably at most 23% by weight, more preferably at most 22% by weight, even more preferably at most 21% by weight, preferably at most 20% by weight, more preferably at most 19% by weight, with even more
BE2018 / 5874 preferably at most 18% by weight, preferably at most 17% by weight, more preferably at most 16% by weight and even more preferably at most 15% by weight of lead. Applicants have found that it is advantageous to limit the presence of lead in the first solder refining slag and / or the fourth solder refining slag in the method according to the present invention to below the prescribed limits, since this leaves room for the presence of tin. The presence of more tin entails the advantage that more tin can end up in the first and / or the second raw solder metal composition and consequently more tin of high purity can be obtained as end product. Due to the high commercial value of tin of high purity, this technical advantage also means a great economic advantage.
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at least 12% by weight of tin and lead together and optionally at most 50% by weight of tin and lead together. Preferably, the first solder refining slag and / or the fourth solder refining slag comprises at least 13% by weight of tin and lead together, more preferably at least 14% by weight, even more preferably at least 15% by weight, preferably at least 16% by weight %, more preferably at least 17% by weight, even more preferably at least 18% by weight, preferably at least 19% by weight, more preferably at least 20% by weight, even more preferably at least 21% % by weight, preferably at least 22% by weight, more preferably at least 23% by weight, even more preferably at least 24% by weight, preferably at least 25% by weight, more preferably at least 26% by weight %, even more preferably at least 27% by weight, preferably at least 28% by weight, more preferably at least 29% by weight, even more preferably at least 30% by weight of tin and lead together. Applicants have found that the more tin and lead are present in the first solder refining slag and / or the fourth solder refining slag, the more tin and lead can end up in the first and / or the second raw solder metal composition. Because tin and lead of high purity are commercial products with considerable economic added value, a larger amount of tin and lead together in the first and / or the
BE2018 / 5874 second raw solder metal composition, it is possible to recover from it a larger volume of high-purity tin and high-purity lead. This also entails the advantage that the process of the present invention can produce more crude solder for the same amount of copper production. The crude solder product can lead to the production of higher purity tin products and / or higher purity lead products, ie products that can undergo significant economic upgrading, especially if the tin and / or lead are derived from mixed metal base materials, which often have a relatively high have a lower economic value.
Preferably, the first solder refining slag and / or the fourth solder refining slag in the method according to the present invention comprise at most 45% by weight of tin and lead together, more preferably at most 40% by weight, even more preferably at most 39% by weight , preferably at most 38% by weight, more preferably at most 36% by weight, even more preferably at most 34% by weight, preferably at most 33% by weight, more preferably at most 32% by weight, even more preferably at most 31% by weight, preferably at most 30% by weight, more preferably at most 29% by weight, even more preferably at most 28% by weight, preferably at most 27% by weight, more preferably at most 26% by weight, even more preferably at most 24% by weight of tin and lead together. Applicants have found that it is advantageous to limit the presence of tin and lead together in the first solder refining slag and / or the fourth solder refining slag in the method according to the present invention to below the prescribed limits, since this leaves room for the presence of oxygen and of other metals which have a higher affinity for oxygen under the conditions of the process than copper, nickel, tin and lead. This applies in particular to metals such as iron, aluminum, sodium, potassium, calcium and other alkali and alkaline earth metals, but also to other elements such as silicon or phosphorus. These elements with a higher affinity for oxygen usually become part of the second and / or the third spent slag obtained from step f) and / or step o), i.e. they are removed from the method with
BE2018 / 5874 a drain flow. As a result, these elements do not end up as impurities in one of the high-quality metal products of the process, that is to say that these streams have a greater purity with regard to the desired metals. The higher tolerance for these elements with a higher affinity for oxygen than copper, nickel, tin and lead also broadens the acceptability criteria for the base materials for the process of the present invention. These upstream steps may therefore absorb many more low-quality raw materials that are more widely available at more economically attractive conditions.
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at most 4.0% by weight and optionally at least 0.2% by weight nickel, preferably at most 3.5% by weight , more preferably at most 3.0% by weight, even more preferably at most 2.5% by weight, preferably at most 2.0% by weight, more preferably at most 1.5% by weight, with even more preferably at most 1.0 wt% nickel. The applicants have established that the behavior of nickel is very similar to that of copper in step e) and / or step n). The advantages of keeping the nickel content of the first solder refining slag and / or the fourth solder refining slag within the prescribed limits therefore also correspond to the advantages described elsewhere in this document for copper, or for copper and nickel together. Preferably, the first solder refining slag and / or the fourth solder refining slag comprises at least 0.20% by weight of nickel, more preferably at least 0.25% by weight, even more preferably at least 0.30% by weight, preferably at least at least 0.35% by weight, more preferably at least 0.40% by weight, even more preferably at least 0.45% by weight of nickel. This entails the advantage that the upstream process steps from which the first solder refining slag and / or the fourth solder refining slag are obtained are capable of incorporating base materials containing nickel. These base materials are less acceptable in other processes because of the nickel present therein, and can therefore be available more widely and at more economically attractive conditions.
BE2018 / 5874
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at most 10.0% by weight of copper and nickel together, preferably at most 9.0% by weight, more preferably at most 8 , 0 wt%, even more preferably at most 7.0 wt%, even more preferably at most 6.0 wt%, preferably at most 5.5 wt%, more preferably at most 5 0% by weight, even more preferably at most 4.5% by weight, preferably at most 4.0% by weight, more preferably at most 3.5% by weight, even more preferably at most 3, 0% by weight copper and nickel together. Applicants have found that smaller amounts of copper and / or nickel in the first solder refining slag and / or the fourth solder refining slag leave more room for more easily oxidizing metals, such as iron, which tend to lower the viscosity of the slag phase, which is advantageous for good quality and rapid separation of the metal phase and the slag phase in the furnace, in particular as part of step e) and / or step n).
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at least 10% by weight and optionally at most 30% by weight of iron. Preferably, the first solder refining slag and / or the fourth solder refining slag comprises at least 11% by weight of iron, more preferably at least 12% by weight, even more preferably at least 13% by weight, preferably at least 14% by weight, more preferably at least 15% by weight, even more preferably at least 16% by weight, preferably at least 17% by weight, more preferably at least 18% by weight, even more preferably at least 19% by weight , preferably at least 20% by weight, more preferably at least 21% by weight, even more preferably at least 22% by weight of iron. Preferably, the first solder refining slag and / or the fourth solder refining slag comprises at most 29% by weight of iron, more preferably at most 28% by weight, even more preferably at most 27% by weight, preferably at most 26% by weight, more preferably at most 25% by weight, even more preferably at most 24% by weight, preferably at most 23% by weight, more preferably at most 22% by weight, even more preferably at most 21% by weight , preferably at
BE2018 / 5874 maximum 20 wt% iron. Applicants have found that iron is an advantageous reducing agent for metals that have a lower affinity for oxygen under the process conditions than iron, such as copper, nickel, tin and lead. Applicants therefore prefer to have a presence of iron in the first solder refining slag and / or the fourth solder refining slag that meets the indicated limits because this allows an upstream process step to use significant amounts of iron as a reducing agent, for example, it has the advantage that it makes many of the upstream process steps more energy efficient. Another advantage is that the acceptability criteria for base materials of these upstream process steps are also relaxed, which makes it possible to accept base materials that may be more widely available and at more economically attractive conditions.
In an embodiment of the method according to the present invention, the first solder refining slag and / or the fourth solder refining slag comprises at least 0.003% antimony by weight, preferably at least 0.004% by weight, more preferably at least 0.005% by weight, even more preferably at least 0.010 wt%, preferably at least 0.015 wt%, more preferably at least 0.020 wt%, even more preferably at least 0.025 wt%, preferably at least 0.030 wt%, and optionally at least at most 0.200% by weight, preferably at most 0.180% by weight, more preferably at most 0.150% by weight, even more preferably at most 0.100% by weight of antimony, preferably at most 0.090% by weight, more preferably at least at most 0.080% by weight, even more preferably at most 0.070% by weight, preferably at most 0.060% by weight, more preferably at most 0.050% by weight, even more preferably at most 0.040% by weight, with even more more preferably, at most 0.030% antimony by weight. Applicants have also found that most of the antimony as part of the first solder refining slag and / or the fourth solder refining slag is generally reduced as part of step e) and / or step n) and most of it becomes part of the first and / or step or the second raw solder metal composition. The applicants have furthermore established that
BE2018 / 5874 an amount of antimony may be acceptable in the process steps carried out on the first and / or the second raw solder metal composition, even when they aim at the recovery of high quality high purity tin and / or lead products. Applicants have found that an amount of antimony may be acceptable, and even desirable, in some of these high quality purity metal products. However, applicants have found that the ability to incorporate antimony in these downstream processes is limited with respect to the amount of lead present. Applicants therefore also prefer to respect the specified upper limits for antimony as part of the first solder refining slag and / or the fourth solder refining slag.
In an embodiment of the method according to the present invention comprising step n), step n) further comprises adding a fifth reducing agent to step n), preferably before reducing the fourth solder refining slag.
Applicants have found that the fifth reducing agent makes it possible to steer the result of reduction step n) in the direction of the desired separation of valuable metals in the second raw solder metal composition and to leave metals to be rejected in the fifth solder refining slag. Applicants have found that the sixth reducing agent can be a gas, such as methane or natural gas, but can also be a solid or a liquid, such as carbon, a hydrocarbon, even aluminum or iron.
In an embodiment of the method according to the present invention, the fifth reducing agent comprises a metal, and the fifth reducing agent is preferably a metal which, under the conditions of the method, has a higher affinity for oxygen than tin, lead, copper and nickel wherein the fifth reducing agent preferably comprises iron metal, more preferably scrap iron. Applicants preferably use iron, preferably scrap iron, as the reducing agent, due to their high availability at economically attractive conditions. The applicants have established that the
BE2018 / 5874 addition of the solid reducing agent may entail the additional advantage that the oven requires less additional heating to maintain or reach its desired temperature. Applicants have found that this positive effect may be large enough for additional heating, by burning a fuel with the aid of air and / or oxygen, to remain limited or hardly necessary to reach the desired temperature. The applicants have further determined that the step n) may further be positively impacted by the addition of silica, as explained above.
Preferably, the fifth reducing agent contains little copper and / or nickel, more preferably less than 1% by weight of copper and nickel together. This entails the advantage that little or no additional copper and / or nickel ends up in the second raw solder metal composition, such that any consumption of process chemicals in a downstream step for refining this raw solder composition is not significantly increased.
In an embodiment of the method according to the present invention, a second Pb and / or Sn-containing fresh feed is added to step n), preferably before reducing the fourth solder refining slag, the second Pb and / or Sn-containing fresh feed preferably comprises scratch, and is preferably substantially scratch, obtained from downstream processing of concentrated streams of Pb and / or Sn.
Applicants have found that step n) is also a very suitable location in the process for adding materials rich in tin and / or lead, and poor in copper and nickel, but which may contain metals which under the conditions of the process have a higher affinity for oxygen than tin and lead. Adding it to step n) entails the advantage that the tin and / or lead are easily recovered as part of the second raw solder metal composition, and removed from the process, while the so-called "less noble" metals have a short and direct process route
BE2018 / 5874 to the third spent snail that is produced in the downstream step o).
Applicants have found that step n) is very suitable for the recovery of tin and / or lead, and possibly antimony and / or arsenic, in raw materials or process by-products that are rich in such metals but relatively low in copper and / or nickel. Applicants have found that the second Pb and / or Sn-containing fresh feed may further contain metals which have a higher affinity for oxygen under the conditions of the process than tin and / or lead, such as sodium, potassium, calcium. Such metals can be added, for example, as part of process chemicals used in downstream steps to refine a stream rich in tin and / or lead, such as the first crude solder metal composition or a downstream derivative. Applicants have determined that step n) is very suitable for recovering valuable metals from a scratch by-product formed in one of the refining steps that are carried out as part of the processes disclosed in patent WO 2018/060202 A1 or the like. Such scratch by-product streams usually carry significant amounts of tin and / or lead, but also contain the other metals that may have been added as part of process chemicals.
In one embodiment, the method of the present invention further comprises the step of
p) partially oxidizing the third lead-tin-based metal composition, forming a fourth lead-tin-based metal composition and a sixth solder refining slag, followed by separating the sixth lead-tin-based metal refining slag.
Applicants have found that step p) has the advantage that the third lead-based metal composition recovered from step o) is split into, on the one hand, a metal stream in which the copper from step p) concentrates, along with most of the nickel present and, on the other hand, a snail phase in which very
BE2018 / 5874 little copper, but a substantial part of the tin and / or lead present in step p) concentrates, together with most of the iron, and if present also zinc. Applicants have found that this division entails the advantage that the two streams resulting from step p) can be processed differently and / or separately, using steps that are better suited to their compositions.
In one embodiment, the method of the present invention further comprises the step of
q) recycling at least a portion of the sixth solder refining slag to step d), preferably before oxidizing the first liquid bath, and / or adding at least a portion of the sixth solder refining slag to the first liquid bath, and / or recycling at least a portion of the sixth solder refining slag to step e), preferably prior to reducing the first solder refining slag.
Applicants prefer to recycle the sixth solder refining slag to step d) and / or to step e) because this allows a recovery of the tin and / or lead in this slag stream to the first raw solder metal composition from step e) or the second raw solder metal composition from step n), while the iron present in the sixth solder refining slag finds its way fairly easily to the second spent slag from step f) without creating the risk that the iron would accumulate in a cycle forming part of the method according to the present invention.
In one embodiment, the method of the present invention further comprises the step of
r) recycling at least a portion of the fourth lead-tin-based metal composition to step 1) and / or adding at least a portion of the fourth lead-tin-based metal composition to the second liquid bath, preferably before oxidizing the second liquid bath as part of step 1).
Applicants prefer to recycle the fourth lead-tin-based metal composition to step 1) because
BE2018 / 5874 this metal stream is highly suitable to be brought into contact, together with the first diluted copper metal composition from step d), with the third copper refining slag from step j) which is added to the second liquid bath, the third copper refining slag being partially reduced and the two added metal compositions are partially oxidized and a state of equilibrium can arise in which most of the copper present in the furnace, together with the nickel and a part of the tin and / or the lead, become part of the first copper metal composition with a high copper metal content , while any metals to be rejected (iron, silicon, aluminum), together with a significant portion of the tin and / or lead present, become part of the third solder refining slag produced by step 1).
In one embodiment, the method of the present invention further comprises the step of
s) recycling at least a portion of the second diluted copper metal composition formed in step m) to step c), preferably before reducing the first copper refining slag, and / or recycling at least a portion of the second diluted copper metal composition to step d), preferably before the first lead-tin metal composition is oxidized, and / or recycling at least a portion of the second diluted copper metal composition to the first liquid bath.
Applicants have found that, regardless of which recycling option is chosen to recycle the second diluted copper metal composition, the copper recovered in the second diluted copper metal composition, in addition to any nickel present, is easily recovered in the first diluted copper metal composition formed in step d), and further downstream easily finds its way to the first copper metal composition with high copper metal content formed in step 1), whereby the copper can be withdrawn from the process, while at the same time any tin and / or lead present in the second diluted copper metal composition can easily finds its way to the first
BE2018 / 5874 solder refining slag which is formed in step d) and can then be recovered further downstream as part of the first raw solder metal composition formed in step e), with which it can then be withdrawn from the process.
In an embodiment of the method according to the present invention, step m) further comprises adding a fourth reducing agent to step m), preferably before reducing the third solder refining slag.
Applicants have found that the fourth reducing agent makes it possible to steer the result of reduction step m) in the direction of the desired separation of valuable metals in the second diluted copper metal composition and to leave metals to be discarded in the fourth solder refining slag. Applicants have found that the fourth reducing agent can be a gas, such as methane or natural gas, but can also be a solid or a liquid, such as carbon, a hydrocarbon, even aluminum or iron.
In an embodiment of the method according to the present invention, the fourth reducing agent comprises a metal, and the fourth reducing agent is preferably a metal which, under the conditions of the method, has a higher affinity for oxygen than tin, lead, copper and nickel , preferably iron metal, more preferably iron scrap.
Applicants preferably use iron, preferably scrap iron, as the reducing agent, due to their high availability at economically attractive conditions. Applicants have found that the addition of the solid reducing agent may entail the additional advantage that the furnace requires less additional heating to maintain or reach its desired temperature. Applicants have found that this positive effect can be large enough for additional heating by burning a fuel with the aid of air and / or oxygen to remain limited, or even hardly necessary to achieve the desired temperature. The applicants have furthermore determined that step m) is furthermore a positive one
BE2018 / 5874 may be affected by the addition of silica, as explained above.
Applicants prefer to add to step m) an amount of a fourth reducing agent rich in copper and iron, preferably as a multi-metal material, because such multi-metal material is more readily available at more advantageous conditions than tin of higher purity, copper of higher purity or iron of higher purity. Another suitable material could be electric motors, preferably such motors after use, because of their high iron content for the cores and copper for the windings. Applicants have found that the copper can easily be kept in the metal phase and prevented from passing into the slag phase, while any tin, lead and iron present in this copper-containing fresh feed easily passes to the slag phase in the form of their respective oxides while contributing to the chemical reduction of other metals which have a lower affinity for oxygen under the conditions of the process than tin, lead and iron.
In an embodiment of the method according to the present invention, at least one of the process steps involving separation of a metal phase from a slag phase is added an amount of silicon dioxide, preferably in the form of sand.
Applicants have found that the silica promotes the formation of the slag phase, improves the fluidity of the slag and improves the gravitational separation of the metal phase from the slag phase. Without wishing to be bound by this theory, the applicants believe that the reduction of the viscosity of the slag in itself brings about a considerable improvement of the phase separation, because the metal bubbles formed in the slag phase as a result of a chemical reduction are easier to pass through move the slag phase and thus reach the intermediate phase region between the two phases, where they are able to be combined with the underlying continuous metal phase. The addition of silicon dioxide also has a positive effect on the balance of certain metals between the metal phase and the slag phase,
BE2018 / 5874 in particular for lead. The silica also increases the acidity of the slag, which exerts an additional influence on the equilibrium in the oven between the different phases. When the slag contains iron and is removed from the furnace and pelleted by contacting the hot liquid slag with water, the addition of silica may eliminate the risk that the iron is in a form that acts as a catalyst for the splitting of water and therefore the formation of hydrogen gas, which entails an explosion hazard. Silicon dioxide also increases the activity of any tin present in the slag, whereby a portion of the SnO 2 is reduced to Sn metal, whereby this Sn will pass to the metal phase. This latter mechanism lowers the amount of Sn remaining in the slag for the same underlying metal composition.
In an embodiment of the method of the present invention, the black copper is produced by a step in a smelting furnace.
Applicants have found that a smelting furnace step is extremely suitable, and even preferred, to produce any, and preferably all, of the black copper compositions used as possible feeds and fresh feeds to process process steps. the present invention, in particular steps b), h), f) and / or o). A smelting furnace step offers the advantage that it is simple in terms of operation and equipment, and therefore economically advantageous. A smelting furnace step brings the additional advantage that it is tolerant in terms of the quality of raw materials. A smelting furnace step is capable of incorporating raw materials that are highly diluted and / or contaminated with a wide variety of components, as described above in this document. Because these mixed and / or contaminated raw materials hardly have any other end use, they can be supplied at very attractive economic conditions. The ability to process these raw materials and to upgrade the valuable metals contained therein is therefore of interest to the person carrying out the process of the present invention.
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In a smelting furnace, the metals are melted, and organic substances and other combustible materials are removed by incineration. Metals with a relatively high affinity for oxygen are converted to their oxides and collect in the supernatant slag phase with lower density. The metals with a lower affinity for oxygen remain as elemental metal and remain in the bottom of the smelting furnace in the liquid metal phase with higher density. In a copper production step, the smelting step can be carried out in such a way that most of the iron ends up in the slag, while copper, tin and lead end up in the metal product, a stream commonly referred to as "black copper". Most of the nickel, antimony, arsenic and bismuth will also become part of the black copper product.
Applicants have found that the metal product from a smelting furnace step can be introduced into the process of the present invention as a molten liquid, but that it can alternatively be allowed to cure and cool, such as by processing into pellets, which is a possible transport between different industrial sites, and they can subsequently be introduced into the process before or after they have been melted again.
In an embodiment of the method of the present invention, at least one of the first raw solder metal composition and the second raw solder metal composition is pre-refined using silicon metal to produce a pre-refined solder metal composition.
A suitable pre-refining treatment for such a crude solder metal composition is described in the patent
DE 102012005401 A1.
In one embodiment, the method of the present invention further comprises the step of cooling the first raw solder metal composition and / or the second raw solder metal composition and / or the pre-refined solder metal composition to a temperature of at most 825 ° C to form a bath having a first surfacing scratch, passing through the
BE2018 / 5874 gravity comes to the surface on a first liquid molten updated soldering phase. Applicants have found that this additional downstream process step is capable of removing a significant amount of copper and other unwanted metals from the raw solder. Further details about this step can be found in WO 2018/060202 A1. The applicants have further established that this cooling step, in combination with some of the additional downstream process steps performed on this lead / tin stream, may at least in part be an alternative to the pretreatment with silicon metal mentioned elsewhere in this document. This is advantageous because silicon metal is a fairly scarce process substance, and if its use can be reduced and / or eliminated, that is beneficial.
In one embodiment, the method of the present invention further comprises the step of adding an alkali metal and / or an alkaline earth metal, or a chemical compound comprising an alkali metal and / or an alkaline earth metal, to the first raw solder metal composition and / or to the second raw solder metal composition and / or to the pre-refined solder metal composition and / or to the first liquid molten updated solder phase to form a bath containing a second supernatant scratch, which gravitates to a second liquid molten updated solder phase.
In one embodiment, the method of the present invention further comprises the step of removing the second supernatant scratch from the second liquid molten updated solder phase, thereby forming a second updated solder.
In one embodiment, the method of the present invention further comprises the step of removing the first superficial scratch from the first liquid molten updated solder phase, thereby forming a first updated solder.
In one embodiment, the method of the present invention further comprises the step of distilling the first updated solder and / or the second updated solder, wherein
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100 lead (Pb) is removed from the solder by evaporation and a distillation top product and a distillation bottom product are obtained, preferably by vacuum distillation.
In an embodiment of the method of the present invention comprising the step of distilling at least one of the solder streams for removing lead (Pb) from the solder by evaporation, thereby obtaining a distillation top product and a distillation bottoms product, the distillation bottoms product comprises at least 0.6% by weight of lead. The positive effects thereof are discussed in patent WO 2018/060202 A1.
In an embodiment of the method according to the present invention, at least a part of the method is electronically monitored and / or controlled, preferably by a computer program. Applicants have found that electronically controlling steps of the method of the present invention, preferably through a computer program, entails the advantage of much better processing, with results that are much more predictable and that are closer to the objectives of the method. method. For example, the driver can be based on temperature measurements, and if desired also based on measurements of pressures and / or levels, and / or in combination with the results of chemical analyzes of samples taken from process flows and / or analytical results obtained online , control the equipment with regard to the supply or consumption of electrical energy, the supply of heat or a cooling medium, or a flow and / or pressure control. Applicants have determined that such monitoring or control is particularly advantageous in steps performed in continuous mode, but that it can also be advantageous in steps performed in batch or semi-batch mode. In addition and preferably, the results of monitoring obtained during or after performing steps in the method are also useful for monitoring and / or controlling other steps forming part of the method of the present invention, and / or of methods that are upstream or downstream of the method of the present invention
BE2018 / 5874
The invention can be applied as part of a global process of which the method according to the present invention is only a part. Preferably the entire global process is electronically monitored, more preferably by at least one computer program. The global process is preferably controlled electronically as much as possible.
Applicants prefer that the computer control also means that data and instructions are passed from one computer or computer program to at least one other computer or other computer program or other module of the same computer program, for monitoring and / or controlling other methods, including but not limited to the methods described in this document.
Applicants prefer to perform certain steps of the method according to the present invention in a top blown rotary converter or top blown rotary converter (TBRC), optionally an oven as disclosed in U.S. Pat. No. 3,682,623, Figs. 3 5 and the associated description, or an oven of the type generally known as a Kaldo oven or Kaldo converter. Applicants particularly use this type of furnace in the steps in which a chemical reaction takes place and / or in which a balance is desired between a molten slag phase and an underlying molten metal phase.
Applicants have found that this type of furnace allows the processing of complex materials, materials that produce a large amount of slag phase, and material with large variations in physical appearance and chemical composition. This type of furnace is capable of receiving as slag feed from other process steps and / or large pieces of solid material, i.e. base materials that are much more difficult to introduce into other furnace types.
Such ovens have the advantage that the oven can be rotated, such that more intensive contact between solids and liquids, and between different liquid phases
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102 can be obtained, which makes it possible to approach and / or achieve the desired balance between the phases more quickly.
Preferably, the rotational speed of the furnace is variable, such that the rotational speed of the furnace can be adapted to the process step performed in the furnace. In process steps where a reaction is required and the furnace content is to be brought to an equilibrium state, a high rotational speed is preferred, while in other process steps, such as when solid fresh feed is to be melted, a low rotational speed may be preferred or possibly not even rotation.
The angle of inclination of the furnace is preferably variable, which allows a better control over the mixing, and therefore also over the reaction kinetics. A variable angle of inclination also allows a better start-up with solid feeds, preferably at a low angle of inclination, until sufficient liquid that is sufficiently hot, and thus more liquid liquid, has been formed to keep the remaining solids floating.
Applicants prefer under certain circumstances not to use the oven at least periodically in the conventional rotary mode, but in a so-called "rocking mode", ie to rotate the oven alternately in opposite directions over only a part of a full 360 ° rotation. Applicants have found that in this mode of operation any extreme forces on the oven drive equipment can be avoided that would occur if the oven with the same content were to rotate completely. Applicants prefer to use this mode of operation when there is still a relatively large amount of solids present in the furnace charge, and too little liquid to keep these solids floating, or when the liquid is still little liquid, for example because she is still quite cold.
Applicants prefer that the TBRC is provided with a refractory coating, and more preferably that that coating comprises two layers. Preferably the inner layer of the
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103 coating, ie the layer that comes into contact with the oven contents, made of a material that visually becomes lighter at the high temperatures of the oven contents during full operation, while the underlying layer of material remains dark when exposed to the internal temperatures of the oven contents. barrel. This configuration makes it possible to quickly detect defects in the coating by simple visual inspection during the operation of the oven.
The outer layer of the covering thus acts as a kind of safety layer. Applicants prefer that this protective layer has a lower thermal conductivity than the inner coating layer.
When installing the TBRC liner, where the liner is preferably constructed by applying individual, conical refractory blocks, applicants prefer to provide a sacrificial layer between individual liner elements or blocks, such as a cardboard layer or roofing material. This entails the advantage that when the furnace temperature is raised during its first campaign, the sacrificial layer burns up and disappears, and creates space for the thermal expansion of the blocks.
In various steps in the method of the present invention, the underlying molten metal phase is preferably drained from the furnace while the supernatant liquid slag phase is still in the furnace. Applicants prefer to drain this liquid metal through a drain or drain hole in the refractory furnace lining. Applicants prefer to close this hole by means of a sacrificial metal rod during the movements of the oven during operation. To prepare metal tapping, applicants prefer to burn out the rod while keeping it above the liquid level of the furnace, and to temporarily close the burned-out tapping hole with a flammable stopper made, for example, of cardboard , after which the oven is turned to the metal drain position. The applicants have established that the
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104 time required to burn the combustible plug, the time provided to turn the furnace to the metal drain position and allow the drain hole to pass the slag phase.
To heat the furnace with an external heat source, applicants preferably use a burner that burns a mixture of fuel and an oxygen source, rather than adding the fuel and the oxygen source separately into the furnace. The applicants have found that such a mixing burner may or may be more difficult to use, but the advantage is that the flame can be directed more precisely to the desired location in the oven.
Applicants have found that the ratio of fuel to the oxygen source can be easily used to control furnace oxidation / reduction operation, and thus assist in setting and / or controlling the direction of the chemical reactions that serve to take place in the oven.
Applicants have found that in the steps of the process of the present invention in which cold base materials are introduced, dioxins and / or volatile organic compounds (VOC) can be formed. Applicants prefer to carry out these process steps in furnaces equipped with suitable equipment for collecting dioxins and / or VOCs from the exhaust vapors. The applicants have determined that the method can be carried out in such a way that only a part of the ovens must be equipped with such exhaust treatment equipment, while for the other ovens dust collection and / or filtering is sufficient to meet the legally imposed emission standards.
The method of the present invention provides several occasions to transfer a liquid molten metal / or slag phase from one furnace to another. Applicants have determined that this transfer is the most convenient to carry out using transfer crucibles. To protect the materials from which the transfer crucibles are made, the applicants give
BE2018 / 5874
It is preferable to provide the cast crucibles with an internal coating layer of solid slag.
EXAMPLE
The following example demonstrates a preferred embodiment of the present invention. The example is further illustrated by Figure 1, showing a flow chart of the core portion of the method of the present invention. In this part of the process, the following streams are recovered from various different base materials and with a composition of black copper 1 as starting material: a refined copper product of anode quality 9, a copper metal composition with a high copper metal content as a by-product 22, two raw solder metal composition products 18 and 26 , and three spent snails 12, 20 and 28.
Figure 1 shows the figures for the following conclusion elements:
1. Composition of black copper as the basic material for step b) (100)
2. Fresh supply to step b) (100)
3. First copper refining slag
4. First enriched copper metal phase
5. Fresh supply to step h) (200)
6. Second copper refining slag
7. Second enriched copper metal phase
8. Third copper refining slag
9. Third enriched copper metal phase - Anode quality
10. Second metal composition on a lead-tin basis
11. Second diluted copper metal composition
12. First used up snail
13. First metal composition on a lead-tin basis
14. Sixth solder refining slag to the first liquid bath (450) before step d) (500)
15. First diluted copper metal composition
16. First solder refining slag
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106
17. First Pb and / or Sn containing fresh feed to step e) (600)
18. First raw solder metal composition
19. Second solder refining slag
20. Second spent snail
21. Fourth metal composition on a lead-tin basis
22. First copper metal composition with high copper metal content removed from the process
23. Third solder refining slag
24. Fourth solder refining slag
25. Second Pb and / or Sn containing fresh feed to step n) (1000)
26. Second raw solder metal composition
27. Fifth solder refining slag
28. Third spent snail
29. Third metal composition on a lead-tin basis
30. First copper metal composition with high copper metal content recycled to step b) and / or step d)
31. Fresh supply to step j) (300)
50. First copper-containing fresh feed to step f) (700)
51. Fresh supply to step p) (1200)
52. Fresh supply to the second liquid bath (550) before step 1) (800)
53. Sixth solder refining slag recycled to step e) (600)
55. Second fresh copper-containing feed to step o) (1100)
56. Fresh supply to step c) (400)
57. Fresh supply to the first liquid bath (450) before step d) (500)
58. Fresh supply to step m) (900)
450 First liquid bath
550 Second liquid bath
100 Process step b)
200 Process step h)
300 Process step j)
400 Process step c)
500 Process step d)
600 Process step e)
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700 Process step f)
701 Process step g)
800 Process step l)
801 Recycling of stream 30 from step l) to process step b) and / or d)
900 Process step m)
901 Process step s), i.e. the recycling of stream 11 from step m) to process step c)
1000 Process step n) 1100 Process step o) 1200 Process step p)
1201 Process step q) - Recycling part of the sixth solder refining slag (14) from step p) to the first liquid bath (450) and / or (53) to process step e) (600)
1202 Process step r) - Recycling the fourth lead-tin-based metal composition (21) from step p) to the second liquid bath (550).
Step b) (100): A top blown rotary converter or top blown rotary converter (TBRC), which is used here as refining furnace for step b) (100), was loaded with 21,345 kg of black copper 1 from an upstream melting furnace, 30,524 kg of a first copper metal composition with high copper metal content 30 recycled from the downstream process step l) (800) as part of a previous process cycle, and 86,060 kg of fresh feed 2. The fresh feed 2 consisted mainly of bronze, red brass and some basic materials rich in copper but poor in other valuable metals. The compositions and amounts of all feeds to the furnace charge of step b) (100) are shown in Table I. To the feeds charged in this way, an amount of silica flux in the form of sand flux was added that was large enough to produce the desired effects. in the field of phase separation and / or slag fluidity. The feed was melted and / or heated under oxidizing conditions, and partially with oxygen being blown in while the furnace was being rotated.
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Table I.
Step b) (100) Black copper1 First Cu-rich metal30 Fresh supply2 tons / load 21,345 30,524 86,060tons % by weight tons % by weight tons % by weight Cu 16,153 75.68% 28,143 92.20% 68,410 79.49% Sn 1,114 5.22% 0.522 1.71% 1,380 1.60% Pb 2,218 10.39% 0.531 1.74% 3,116 3.62% Zn 0.989 4.63% 0.005 0.02% 2,470 2.87% Fe 0.336 1.57% 0.002 0.01% 1,747 2.03% Ni 0.428 2.00% 1,105 3.62% 0.888 1.01% Sb 0.043 0.20% 0.171 0.56% 0.085 0.10% Bi 0.005 0.03% 0.012 0.04% 0.013 0.02% Ash 0.013 0.06% 0.017 0.06% 0.014 0.02%
A substantial amount of the zinc present in the feed was smoked out of the oven. At the end of the first oxidation step b) (100), the first copper refining slag 3 was poured off and transferred to a slag reprocessing furnace to be subjected to process step c) (400). This first copper refining slag 3 was rich in lead, tin, zinc and iron. The detailed composition of this slag 3, as well as the first enriched copper metal phase 4 and dust produced during step b) (100), together with their amounts are shown in Table II. The first enriched copper metal phase 4 was transferred to another TBRC to be subjected to process step h) (200).
Table II
Step b) (100) First Curaffin Slag - 3 First enriched copper metal phase - 4 Dust tons / load 27,061116,3711.47 tons % by weight tons % by weight tons % by weight Cu 3,231 11.94% 111,367 95.70% 0.221 15.00% Sn 1,810 6.69% 1,059 0.91% 0.147 10.00% Pb 3,875 14.32% 1,760 1.51% 0.221 15.00% Zn 3,023 11.17% 0.000 0.00% 0.441 30.00% Fe 2,076 7.67% 0.005 0.00% 0.000 0.00% Ni 1.012 3.74% 1,396 1.20% 0.000 0.00% Sb 0.052 0.19% 0.249 0.21% 0.000 0.00% Bi 0.001 0.00% 0.031 0.03% 0.000 0.00% Ash 0.006 0.02% 0.038 0.03% 0.000 0.00%
Step h) (200): To the first enriched copper metal phase 4, 27,091 kg of fresh feed rich in copper 5 was added,
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109 and also an amount of sand flux that was large enough to produce the desired effects in terms of phase separation and / or slag fluidity. This fresh feed 5 consisted of an amount of additional black copper from the upstream smelting furnace, in addition to solid copper-rich material for cooling the furnace temperature. The composition and amounts of the feed to the furnace charge of step h) (200) are shown in Table III.
Table III
Step h) (200) First enriched copper metal phase - 4 Fresh supply5 tons / load 116,371 27,091tons % by weight tons % by weight Cu 111,367 95.70% 23,794 92.48% Sn 1,059 0.91% 0.277 1.08% Pb 1,760 1.51% 0.579 2.25% Zn 0.000 0.00% 0.513 1.99% Fe 0.005 0.00% 0,209 0.81% Ni 1,396 1.20% 0.111 0.51% Sb 0.249 0.21% 0.015 0.06% Bi 0.031 0.03% 0.004 0.01% Ash 0.038 0.03% 0.002 0.01%
Oxidation of the furnace contents was carried out by blowing oxygen into the furnace contents. At the end of the second oxidation step, the second copper refining slag 6 was decanted and transferred to another slag re-treatment furnace to be subjected to step d) (500). The remaining second enriched copper metal phase 7 was transferred to another TBRC to be subjected to step j) (300). The composition and amounts of the second copper refining slag 6 and the second enriched copper metal phase 7 are shown in Table IV. As is apparent from Table IV, the metal phase 7 was considerably enriched in copper, compared to the furnace feed streams 4 and 5 in Table III.
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Table IV
Step h) (200) Second Cu refining slag6 Second enriched copper metal phase - 7 tons / load 17,230 128.573tons % by weight tons % by weight Cu 7,161 41.56% 126.573 98.45% Sn 1,237 7.18% 0.083 0.06% Pb 2.004 11.63% 0.316 0.25% Zn 0.515 2.99% 0.000 0.00% Fe 0.214 1.24% 0.000 0.00% Ni 0.639 3.71% 0.874 0.68% Sb 0.109 0.63% 0.154 0.12% Bi 0.009 0.05% 0.026 0.02% Ash 0.007 0.04% 0.033 0.03%
Step j) (300): To the second enriched copper metal phase 7, a further 22,096 kg of fresh feed rich in copper 31 was added. The composition and amounts of the feeds to the furnace charge of step j) (300) are shown in Table V.
Table V
Step j) (300) Second enriched copper metal phase - 7 Fresh supply31 tons / load 128.573 22,096tons % by weight tons % by weight Cu 126.573 98.45% 20,647 93.44% Sn 0.083 0.06% 0.077 0.35% Pb 0.316 0.25% 0.177 0.80% Zn 0.000 0.00% 0.122 0.87% Fe 0.000 0.00% 0.109 0.49% Ni 0.874 0.68% 0.029 0.13% Sb 0.154 0.12% 0.003 0.02% Bi 0.026 0.02% 0.001 0.00% Ash 0.033 0.03% 0.000 0.00%
Oxygen blowing was carried out on the furnace contents, and at the end of the blowing period an amount of sand flux was added that was sufficiently large to produce the desired effects on the plane of phase separation and / or slag fluidity, before the third copper refining slag 8 was poured off. The remaining copper metal phase of anode grade 9 was removed from the furnace for further processing, e.g. purification by electro refining. The composition and the
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111 quantities of the third copper refining slag 8 and of the copper of anode quality 9 are indicated in Table VI. As shown in Table VI, the metal phase 9 was further enriched in copper, compared to the furnace feed streams 7 and / or 31 in Table V.
Table VI
Step j)(300) Third Cu refining slag8 Third enriched copper metal phase - 9 Anode quality tons / load 17,024 134,781tons % by weight tons % by weight Cu 12.535 73.63% 133,546 99.08% Sn 0.148 0.81% 0.022 0.02% Pb 0.465 2.73% 0.025 0.02% Zn 0.122 1.13% 0.000 0.00% Fe 0.109 0.64% 0.000 0.00% Ni 0.375 2.20% 0.542 0.40% Sb 0.099 0.58% 0.057 0.04% Bi 0.006 0.04% 0.020 0.02% Ash 0.006 0.03% 0.028 0.02% Step c) (400) : 26,710 kg from the first
copper refining slag 3 (with the composition indicated in Table VII) was introduced into another TBRC used as a slag re-treatment furnace, together with 6,099 kg of fresh feed 56 and 11,229 kg of a second diluted copper metal phase 11 obtained from a process step m) (900) from a previous process cycle, and together with 23,000 kg of a second lead-tin-based metal phase or composition obtained from a process step f) (700) of a previous process cycle. 10,127 kg of scrap iron was added to this furnace content as a reducing agent. Furthermore, an amount of sand flux was added that was large enough to produce the desired effects in terms of safety, phase separation and / or slag fluidity. Once the filling was complete, the oven was rotated at a speed in the range of 18-20 rpm. The composition and amounts of the feed to the furnace charge of step c) (400) are shown in Table VII.
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Table VII
Step c)(400) First Curaffin Slag -3 Fresh supply56 Second dilutedCu metal phase - 11 Second Metal Phase on PbSn basis - 10 tons / load 26,710 6,099 11,229 23,000tons % by weight tons % by weight tons % by weight tons % by weight Cu 3,189 11.94% 0.987 16.18% 6,960 61.98% 16,665 72.50% Sn 1,787 6.69% 0.325 5.32% 2,095 18.66% 1,685 7.33% Pb 3,825 14.32% 0.419 6.87% 0.775 6.90% 2,521 10.97% Zn 2,983 11.17% 0.178 2.92% 0.006 0.05% 0.381 1.66% Fe 2,049 7.67% 1,440 23.61% 0.020 0.18% 1,233 5.36% Ni 0.999 3.74% 0.135 2.21% 1,291 11.50% 0.429 1.87% Sb 0.052 0.19% 0.017 0.28% 0.073 0.65% 0.044 0.19% Bi 0.001 0.00% 0.000 0.00% 0.002 0.02% 0.006 0.02% Ash 0.006 0.02% 0.000 0.00% 0.003 0.03% 0.011 0.05% When the reduction made of copper and tin and lead
Sufficiently advanced, a first lead-based metal composition 13, dust and a first spent slag 12 were produced. The compositions and quantities of these products are indicated in Table VIII. The first spent snail 12 was decanted and removed from the process. The first lead-tin-based metal composition 13 was transferred to another TBRC to become part of the first liquid bath 450.
Table VIII
Step c)(400) First used up snail12 First metal phase onPb-Sn basis - 13 Dust tons / load 31,287 46.718 1,346tons % by weight tons % by weight tons % by weight Cu 0.111 0.35% 28,105 60.32% 0.031 2.27% Sn 0.074 0.24% 5,645 12.11% 0.170 12.64% Pb 0.166 0.50% 7,176 15.40% 0.296 20.52% Zn 2,372 7.58% 0.568 1.22% 0.612 45.50% Fe 12,049 38.51% 2,047 4.39% 0.010 0.71% Ni 0.012 0.04% 2,834 6.08% 0.002 0.12% Sb 0.000 0.00% 0.164 0.39% 0.002 0.18% Bi 0.000 0.00% 0.008 0.02% 0.000 0.00% Ash 0.000 0.00% 0.016 0.03% 0.004 0.31%
Step d) (500): To form the first liquid bath 450, the first metal composition on lead113 was added to the 46.718 kg
BE2018 / 5874 tin base 13 17,164 kg of the second copper refining slag 6 (with the composition indicated in Table IV) added, together with 9,541 kg of fresh feed 57, and 474 kg of the sixth solder refining slag 14 (recycled from the downstream process step p) (1200) as part from a previous process cycle). Furthermore, an amount of sand flux was added that was large enough to produce the desired effects in terms of phase separation and / or slag fluidity. The compositions and amounts of the components of the first liquid bath 450 that formed the furnace charge for step d) (500) are shown in Table IX.
Table IX
Step d)(500) First metal phase on a Pb-Sn basis 13 Fresh supply57 Sixth solderrefining slag - 14 Second Curaffin Slag - 6 tons / load 46.718 9,541 0.474 17,164tons % by weight tons % by weight tons % by weight tons % by weight Cu 28,105 60.32% 1,749 22.09% 0.015 3.08% 7.133 41.56% Sn 5,645 12.11% 0.484 6.11% 0.021 4.51% 1,232 7.18% Pb 7,176 15.40% 0.677 8.54% 0.060 12.69% 1,996 11.63% Zn 0.568 1.22% 0.308 3.89% 0.025 5.30% 0.513 2.99% Fe 2,047 4.39% 2,675 33.77% 0.134 28.21% 0.213 1.24% Ni 2,834 6.08% 0,209 2.63% 0.002 0.33% 0.637 3.71% Sb 0.164 0.39% 0.028 0.35% 0.000 0.01% 0.08 0.63% Bi 0.008 0.02% 0.000 0.00% 0.000 0.00% 0.009 0.05% Ash 0.016 0.03% 0.000 0.00% 0.000 0.00% 0.007 0.04%
The mixture of slag and metal phase was reacted until the concentrations of copper and / or nickel were sufficiently reduced in the slag phase. The reaction caused more tin and lead to enter the slag phase. At that point, the oven was drained at the bottom, whereby a first diluted copper metal composition was removed from the oven. The first solder refining slag 16, along with about 1 ton remaining from the first diluted copper metal phase 15, was taken to another TBRC to be subjected to the next step e) (600). The compositions and amounts of both product streams obtained from step 500, with the exception of the 1 tonne metal phase remaining with the slag phase, are shown in Table X.
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Table X.
Step d) (500) First Solder Refining Snail - 16 First diluted Cumetal phase - 15 tons / load 28,200 49,792tons % by weight tons % by weight Cu 1.047 3.71% 35,387 71.07% Sn 1,375 4.87% 5.925 11.90% Pb 5,268 18.68% 4,541 9.12% Zn 1,393 4.94% 0.023 0.05% Fe 5,059 17.94% 0.013 0.03% Ni 0.282 1.00% 3,331 6.69% Sb 0.010 0.04% 0.304 0.61% Bi 0.000 0.00% 0.017 0.03% Ash 0.000 0.00% 0.022 0.05%
The first diluted Cu metal phase from step d) contained about 0.08% by weight of silver (Ag) and 0.03% by weight of sulfur.
Step e) (600): 14,987 kg of the first lead and tin-containing fresh feed 17 was fed to the first solder refining slag 16 before this mixture was reduced in step e) (600). The reduction was carried out by adding 8,017 kg of scrap iron as a reducing agent. Further, as part of step e) (600), 8,650 kg of the sixth solder refining slag 53 obtained from the downstream process step p) (1200) was added to the furnace as part of a previous process cycle, as well as an amount of sand flux sufficient to to produce the desired effects in terms of phase separation and / or slag fluidity. The compositions and amounts of the feeds that formed the furnace charge for step e) (600) are shown in Table XI.
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Table XI
115
Step e)(600) First solder refining slag -16 1st Pb and / or Sn containing fresh feed - 17 Sixth solder refining slag - 53 First diluted Cu metal phase 15 tons / load 28,200 14.987 8,650 1,000tons % by weight tons % by weight tons % by weight tons % by weight Cu 1.047 3.71% 1,361 9.08% 0.266 3.08% 0.711 71.07% Sn 1,375 4.87% 4,184 27.92% 0.390 4.51% 0.119 11.90% Pb 5,268 18.68% 7,738 51.63% 1.098 12.69% 0.091 9.12% Zn 1,393 4.94% 0.043 0.29% 0.458 5.30% 0.000 0.05% Fe 5,059 17.94% 0.106 0.71% 2,440 28.21% 0.000 0.03% Ni 0.282 1.00% 0.011 0.07% 0.029 0.33% 0.067 6.69% Sb 0.010 0.04% 0.298 1.99% 0.001 0.01% 0.006 0.61% Bi 0.000 0.00% 0.002 0.01% 0.000 0.00% 0.000 0.03% Ash 0.000 0.00% 0.000 0.00% 0.000 0.00% 0.000 0.05%
A significant amount of zinc was smoked from the furnace contents during this partial reduction step. The reduction was stopped when the concentration of Sn in the slag phase had reached approximately the target level. At that point, the furnace was again drained at the bottom to remove the first raw solder metal composition 18 from the process. The first raw solder metal composition 18 was further processed into high-quality lead and tin products. The second solder refining slag 19 was fed to another TBRC for further processing as part of step f) (700). The compositions and amounts of the first raw solder metal 18, the second solder refining slag 19 and the dust obtained from step e) (600) are shown in Table XII.
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Table XII
116
Step e)(600) First raw solder metal composition - 18 Second Solder Refining Snail - 19 Dust tons / load 23,132 36,667 1,551tons % by weight tons % by weight tons % by weight Cu 3,256 13.53% 0.166 0.39% 0.016 1.06% Sn 5,389 22.40% 0.778 2.60% 0.150 9.64% Pb 13.224 54.97% 0.652 2.18% 0.318 20.52% Zn 0.087 0.36% 1,106 3.70% 0.706 45.50% Fe 0.282 1.17% 15.003 50.20% 0.011 0.71% Ni 0.354 1.47% 0.032 0.11% 0.002 0.12% Sb 0.311 1.29% 0.002 0.01% 0.003 0.18% Bi 0.002 0.01% 0.000 0.00% 0.000 0.00% Ash 0.000 0.00% 0.000 0.00% 0.000 0.03%
Step f) (700): A further reduction step was performed on the second solder refining slag 19 by adding 1,207 kg of scrap iron as a reducing agent. Furthermore, as part 5 of step f) (700), 22,234 kg was added of a first fresh feed rich in copper 50, and an amount of sand flux sufficient to produce the desired effects in terms of safety, phase separation and / or snail fluidity. This fresh feed 50 consisted of an amount of additional black copper from the upstream smelting furnace, as well as an amount of slag materials that were collected as a remnant of other process steps. The compositions and amounts of the feeds to the furnace charge of step f) (700) are indicated in Table XIII.
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Table XIII
117
Step f) (700) Second Solder Refining Snail - 19 Cu-containing fresh feed - 50 tons / load 36,667 22,234tons % by weight tons % by weight Cu 0.166 0.39% 16,630 75.95% Sn 0.778 2.60% 1.003 4.58% Pb 0.652 2.18% 2,052 9.37% Zn 1,106 3.70% 1.010 4.61% Fe 15.003 50.20% 0.509 2.32% Ni 0.032 0.11% 0.405 1.85% Sb 0.002 0.01% 0.042 0.19% Bi 0.000 0.00% 0.005 0.03% Ash 0.000 0.00% 0.011 0.05%
When Cu, Sn, and Pb in the slag were reduced to a maximum of 0.50% each, a second lead-tin-based metal phase 10 and a second spent slag were produced. The compositions and amounts thereof are indicated in Table XIV. The second spent slag was decanted and removed from the process. The second lead-tin-based metal composition 10 was passed to step c) (400) of the following process cycle, before the first copper refining slag (3) was reduced.
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Table XIV
118
Step f) (700) Second Metal Phase on Pb-Sn basis - 10 Second spent snail 20 tons / load 23,000 37.523tons % by weight tons % by weight Cu 16,665 72.50% 0.115 0.31% Sn 1,685 7.33% 0.090 0.24% Pb 2,521 10.97% 0.188 0.50% Zn 0.381 1.66% 1,726 4.60% Fe 1,233 5.36% 15,384 41.00% Ni 0.429 1.87% 0.010 0.03% Sb 0.044 0.19% 0.000 0.00% Bi 0.006 0.02% 0.000 0.00% Ash 0.011 0.05% 0.000 0.00%
Step 1) (800): 17,024 kg of the third copper refining slag 8 (with the composition shown in Table VI) was fed to a TBRC which was used as a slag re-treatment furnace, together with 14,920 kg of fresh feed rich in copper 52 and 49,792 kg of the first diluted copper metal phase 15 obtained from step d) (500). Furthermore, an amount of sand flux was added that was sufficiently large to produce the desired effects in terms of phase separation and / or slag fluidity. These materials were melted together with the fourth metal-phase lead-tin based 21 (20,665 kg) obtained from the downstream process step p) (1200) as part of a previous process cycle. Together, these feeds formed the second liquid bath 550. Once the filling and melting was completed, the oven was rotated at a speed of 20 rpm. The compositions and amounts of the feeds to the slag re-treatment furnace charge for step 1) (800) are shown in Table XV.
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Table XV
119
Step l)(800) FourthMetal phase onPb-Sn basis - 21 Fresh supply52 First dilutedCu metal phase - 15 Third Curefining slag - 8 tons / load 20,665 14.920 49,792 17,024tons % by weight tons % by weight tons % by weight tons % by weight Cu 16,483 79.76% 3,985 30.10% 35,387 71.07% 12.535 73.63% Sn 1,882 9.11% 0.610 4.61% 5.925 11.90% 0.148 0.81% Pb 1,643 7.95% 3,104 23.45% 4,541 9.12% 0.465 2.73% Zn 0.019 0.09% 0.792 5.98% 0.023 0.05% 0.122 1.13% Fe 0.012 0.06% 1,363 10.29% 0.013 0.03% 0.109 0.64% Ni 0.533 2.58% 0.316 2.39% 3,331 6.69% 0.375 2.20% Sb 0.063 0.31% 0.043 0.33% 0.304 0.61% 0.099 0.58% Bi 0.006 0.03% 0.000 0.00% 0.017 0.03% 0.006 0.04% Ash 0.011 0.05% 0.000 0.00% 0.022 0.05% 0.006 0.03%
The mixture was reacted, if necessary also partially oxidized by blowing oxygen, until the concentrations of copper and nickel in the slag reached approximately their target values. At that point, the furnace was drained at the bottom to remove 64,500 kg of the first copper metal composition with high copper metal content (streams 22 and 30 together) from the third solder refining slag 23. The third solder refining slag 23, together with about 6 tons of the first copper metal phase with a high copper metal content that had remained with the slag, was transferred to another TBRC for further processing as part of step m) (900). The compositions and amounts of the product streams at the end of step 1) (800) are shown in Table XVI, and this time including the 6 ton metal phase remaining with the slag phase on the way to the next treatment step.
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Table XVI
120
Step l)(800) First Cu metal phase with high content of Cumetal 22 + 30 Third solder refining slag23 tons / load 70,500 39.276tons % by weight tons % by weight Cu 59,469 92.20% 3,182 8.10% Sn 1,103 1.71% 7,317 18.63% Pb 1,122 1.74% 8,515 21.68% Zn 0.011 0.02% 1.013 2.58% Fe 0.004 0.01% 1,496 3.81% Ni 2,335 3.62% 1,980 5.04% Sb 0.362 0.56% 0.114 0.29% Bi 0.026 0.04% 0.000 0.00% Ash 0.036 0.06% 0.000 0.00%
30,524 kg of the first copper metal composition with high copper metal content in the furnace was fed into the copper refining furnace as stream 30, before a new step b) (100) of a following cycle was started. A further 33,976 kg was removed from the process as stream 22, for further processing.
Step m) (900): After removing the (30,524 kg + 33,976 kg =) 64,500 kg of the first copper metal phase with high copper metal content (22 + 30) from the furnace, the furnace content was passed to another TBRC for further processing as part of step m) (900). The mixture of the 39,276 kg of third solder refining slag 23 and the 6 tons of metal with the composition of the first copper metal composition with high copper metal content was partially reduced as part of step m) (900). Scrap iron was added as a reducing agent. Furthermore, an amount of sand flux was added to step m) that was sufficiently large to produce the desired effects in terms of phase separation and / or slag fluidity, and a small amount (37 kg) of fresh feed 58. The compositions and amounts of the feed which constituted the furnace charge for step m) (900) are indicated in Table XVII.
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Table XVII
121
Step m) (900) Third solder refining slag - 23 Fresh supply58 Metal phase that remained with the slag (23) tons / load 39.276 0.037 6,000 0tons % by weight tons % by weight tons % by weight Cu 3,182 8.10% 0.001 2.38% 5,532 92.20% Sn 7,317 18.63% 0.001 3.31% 0.103 1.71% Pb 8,515 21.68% 0.004 10.88% 0.104 1.74% Zn 1.013 2.58% 0.002 5.94% 0.001 0.02% Fe 1,496 3.81% 0.010 27.53% 0.000 0.01% Ni 1,980 5.04% 0.000 0.22% 0.217 3.62% Sb 0.114 0.29% 0.000 0.00% 0.034 0.56% Bi 0.000 0.00% 0.000 0.00% 0.002 0.04% Ash 0.000 0.00% 0.000 0.00% 0.003 0.06%
The reduction step m) (900) was stopped when the copper and nickel concentrations in the slag phase were sufficiently reduced. At that point, the furnace was drained at the bottom to remove an amount of 11,229 kg of second diluted copper metal composition 11 for further processing in step c) (400) of a subsequent process cycle. A fourth solder refining slag 24, together with approximately 1,400 kg of metal with the composition of the second diluted copper metal phase 11, was fed to another TBRC to be subjected to step n) (1000). The compositions and total amounts of the second diluted copper metal phase or composition 11 and of the fourth solder refining slag 24 are shown in Table XVIII, wherein the 1,400 kg of metal phase remaining with the slag phase is included in the total stated amount for the second diluted copper metal phase 11.
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Table XVIII
122
Step m) (900) Second diluted Cumetal phase - 11 Fourth solder refining slag - 24 tons / load 12.629 41,342tons % by weight tons % by weight Cu 6,960 61.98% 1,389 3.36% Sn 2,095 18.66% 5,069 12.26% Pb 0.775 6.90% 7,743 18.73% Zn 0.006 0.05% 1.009 2.44% Fe 0.020 0.18% 9,037 21.86% Ni 1,291 11.50% 0.752 1.82% Sb 0.073 0.65% 0.066 0.16% Bi 0.002 0.02% 0.000 0.00% Ash 0.003 0.03% 0.000 0.00%
The second diluted Cu metal phase 11 from step m) contained about 0.11% by weight of silver (Ag) and 0.01% by weight of sulfur.
Step n) (1000): After the 11,229 kg of the second diluted copper metal phase 11 was drained from the furnace, the remaining furnace content was transferred to another TBRC to perform step n) (1000). 11,789 kg of second lead and tin-containing fresh feed 25 was added as part of step n) (1000) and the furnace content was further reduced. The reduction was carried out by adding 9,692 kg of scrap iron as a reducing agent, together with an amount of sand flux that was large enough to produce the desired effects in terms of phase separation and / or slag fluidity. The compositions and amounts of the various furnace feeds for step n) (1000) are shown in Table XIX.
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Table XIX
123
Step n) (1000) Fourth solder refining slag - 24 Fresh supply25 Second diluted Cu metal phase - 11 tons / load 41,342 11,789 1,400tons % by weight tons % by weight tons % by weight Cu 1,389 3.36% 0.728 6.18% 0.888 61.98% Sn 5,069 12.26% 1,864 15.81% 0.261 18.66% Pb 7,743 18.73% 8,790 74.56% 0.097 6.90% Zn 1.009 2.44% 0.019 0.16% 0.001 0.05% Fe 9,037 21.86% 0.070 0.59% 0.003 0.18% Ni 0.752 1.82% 0.003 0.02% 0.161 11.50% Sb 0.066 0.16% 0.074 0.63% 0.009 0.65% Bi 0.000 0.00% 0.037 0.32% 0.000 0.02% Ash 0.000 0.00% 0.000 0.00% 0.000 0.03%
The partial reduction step was stopped when the concentration of tin in the slag phase had reached approximately the target level. At that point, the furnace was again drained from the bottom to remove the second raw solder metal composition 26 from the furnace, leaving only the fifth solder refining slag 27 in the furnace. The second raw solder metal composition 26 was further processed into high-quality lead and tin products. The fifth solder refining slag 27 was transferred to another TBRC to perform step o) (1100). The compositions and amounts of the second raw solder metal 26 and of the fifth solder refining slag 27 are shown in Table XX.
Table XX
Step n) (1000) Second Raw Solder 26 Fifth solder refining slag27 tons / load 23,080 41,956tons % by weight tons % by weight Cu 2,934 10.57% 0.054 0.13% Sn 6.245 22.49% 0.975 2.32% Pb 16,080 57.90% 0.550 1.31% Zn 0.000 0.00% 1.032 2.46% Fe 1,363 4.91% 17,373 41.41% Ni 0.895 3.22% 0.021 0.05% Sb 0.149 0.54% 0.000 0.00% Bi 0.038 0.14% 0.000 0.00% Ash 0.000 0.00% 0.000 0.00%
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Step o) (1100): A further reduction step was performed on the fifth solder refining slag 27 by adding 922 kg of scrap iron as a reducing agent, together with 23,735 kg of fresh feed rich in copper 55 and an amount of sand flux that was large enough to 5 to produce desired effects in terms of safety, phase separation and / or slag fluidity. The second copper-containing fresh feed 55 essentially consisted of additional black copper from the upstream smelting furnace. The compositions and amounts of the feeds to step o) (1100) are indicated in Table XXI.
Table XXI
Step o) (1100) Fifth solder refining slag27 Cu-containing fresh feed 55 tons / load 41,956 23,735tons % by weight tons % by weight Cu 0.054 0.13% 15,456 67.27% Sn 0.975 2.32% 0.997 4.34% Pb 0.550 1.31% 2,022 8.80% Zn 1.032 2.46% 1,097 4.77% Fe 17,373 41.41% 1,603 6.98% Ni 0.021 0.05% 0.391 1.70% Sb 0.000 0.00% 0.040 0.17% Bi 0.000 0.00% 0.005 0.02% Ash 0.000 0.00% 0.011 0.05%
The reduction was continued until an acceptable quality of spent snail was obtained. When this goal was achieved, a third metal-phase based on lead-tin 29 and a third spent slag were produced, the compositions and amounts of which are given in Table XXII. The third spent snail 28 was decanted and removed from the process. The third metal composition on lead-tin base 29 was transferred to the TBRC intended for performing step p) (1200).
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Table XXII
125
Step o) (1100) Third Metal Phase on Pb-Snbase - 29 Third used up snail28 tons / load 22,300 45,542tons % by weight tons % by weight Cu 15,446 69.56% 0.155 0.34% Sn 1,923 8.66% 0.069 0.15% Pb 2,417 10.88% 0.205 0.45% Zn 0.347 1.56% 1,812 3.98% Fe 1,598 7.20% 18,522 40.67% Ni 0.406 1.83% 0.015 0.03% Sb 0.041 0.18% 0.000 0.00% Bi 0.005 0.02% 0.000 0.00% Ash 0.011 0.05% 0.000 0.00%
Step p) (1200): To the third metal composition on lead-tin base 29 was added 5,204 kg of fresh feed 51, together with an amount of sand flux sufficient to produce the desired effects in terms of phase separation and / or slag fluidity. Subsequently, by partial oxidation, the majority of the iron and zinc were oxidized from the metal phase and to the slag phase. The compositions and amounts of the products from this oxidation step p) (1200) are shown in Table XXIII.
Table XXIII
Step p) (1200) Third Metal Phase on Pb-Snbase - 29 Fresh supply51 tons / load 22,300 5,204tons % by weight tons % by weight Cu 15,446 69.56% 1,402 32.04% Sn 1,923 8.66% 0.368 8.42% Pb 2,417 10.88% 0.386 8.83% Zn 0.347 1.56% 0.166 3.56% Fe 1,598 7.20% 0.989 22.61% Ni 0.406 1.83% 0.158 3.61% Sb 0.041 0.18% 0.023 0.54% Bi 0.005 0.02% 0.000 0.01% Ash 0.011 0.05% 0.000 0.00%
When the oxidation of iron and zinc was sufficiently advanced, a fourth lead-tin-based metal composition 21 and a sixth solder refining slag 14 were produced, the
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126 compositions and amounts are indicated in Table XXIV. The sixth solder refining slag 14 was decanted and was added at least partially as stream 14 to the first liquid bath (450), and / or at least partially as stream 53 added to step e) (600) of the following process cycle. The fourth lead-tin-based metal composition 21 was transferred to another TBRC to become part of the second liquid bath 550 and to perform step 1) (800) as part of the following process cycle.
Table XXIV
Step p) (1200) Fourth Metal phase on Pb-Sn basis - 21 Sixth solder refining slag14 tons / load 20,665 9.124tons % by weight tons % by weight Cu 16,483 79.76% 0.281 3.08% Sn 1,882 9.11% 0.411 4.51% Pb 1,643 7.95% 1,158 12.69% Zn 0.019 0.09% 0.483 5.30% Fe 0.012 0.06% 2,573 28.21% Ni 0.533 2.58% 0.030 0.33% Sb 0.063 0.31% 0.001 0.01% Bi 0.006 0.03% 0.000 0.00% Ash 0.011 0.05% 0.000 0.00%
The process steps 100-1200 involving molten metal and / or slag phases are all carried out at a temperature in the range of 1100 to 1250 ° C. Depending on the purpose of the step, its operating temperature may preferably be close to the upper or lower end of this temperature range.
Applicants have determined that the embodiment of the method described in this Example can be performed in a limited number of TBRCs. Applicants have succeeded in carrying out this method in only 8 ovens, several of which are preferably of the TBRC type. Applicants prefer to perform this method in only 6 ovens, more preferably in only 5 ovens, even more preferably in only 4 ovens, even more preferably in only 3 ovens.
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Now that this invention has been fully described, it will be clear to those skilled in the art that the invention can be implemented with a wide range of parameters within what is claimed, without thereby falling outside the scope of the invention as defined by the claims.

权利要求:
Claims (61)
[1]
CONCLUSIONS
A method for the production of a crude solder product and a copper product comprising the step of
a) providing a black copper composition comprising at least 50% copper by weight together with at least 1.0% tin and at least 1.0% lead by weight, the method further comprising the steps of:
(i) refining a first portion (1) of the black copper composition obtained from step a) to obtain a refined copper product (9) together with at least one copper refining slag (3, 6, 8), ( ii) recovering a first raw solder metal composition (18, 26), as a first raw solder product, from the at least one copper refining slag (3, 6, 8), thereby forming a second solder refining slag (19, 27) in equilibrium with the first raw solder metal composition (18, 26), characterized in that the method further comprises the step of
f) contacting (700) a second portion (50) of the black copper composition from step a), different from the first portion (1), with the second solder refining slag (19) whereby a second spent slag ( 20) and a second lead-tin-based metal composition (10) is formed, followed by separation of the second spent slag from the second lead-tin-based metal composition.
[2]
The method of claim 1 wherein step f) (700) comprises adding a third reducing agent (R3) to step f) (700).
[3]
The method of claim 2 wherein the third reducing agent (R3) comprises a metal that has a higher affinity for oxygen under the conditions of the method than tin and lead, copper and nickel, preferably iron metal, more preferably scrap iron.
[4]
4.
The method according to any
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129 of the preceding claims, further comprising the steps of:
(iii) recovering a second raw solder metal composition (26), different from the first raw solder metal composition (18), as a second raw solder product, from the at least one copper refining slag (3, 6, 8), whereby a fifth solder refining slag ( 27) is formed in equilibrium with the second raw solder metal composition (26), and
o) contacting (1100) a third portion (55) of the black copper composition obtained from step a), which differs from the first portion (1) and the second (50) portion, with the fifth solder refining slag (27), thereby forming a third spent slag (28) and a third lead-based metal composition (29), followed by separating the third spent slag (28) from the third lead-tin based metal composition (29).
[5]
The method of claim 4 wherein step o) (1100) comprises adding a sixth reducing agent (R6) to step o) (1100).
[6]
The method of claim 5 wherein the sixth reducing agent (R6) comprises a metal that has a higher affinity for oxygen under the conditions of the process than tin, lead, copper, and nickel, preferably iron metal, more preferably scrap iron.
[7]
The method according to any of the preceding claims, wherein the second and / or fifth solder refining slag (19, 27) comprises at most 2.0 wt% copper and nickel together.
[8]
The method according to any of the preceding claims, wherein the second and / or fifth solder refining slag (19, 27) is at most 8.0% by weight and optionally at least 1.0% by weight of tin and lead together includes.
[9]
The method according to any of the preceding claims, wherein the second and / or third
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130 lead-tin-based metal composition (10, 29) comprises at least 60% by weight and optionally at most 90% by weight of copper and nickel together.
[10]
The method according to any of the preceding claims, wherein the second and / or third metal composition on a lead-tin basis (10, 29) comprises at least 12% by weight of tin and lead together.
[11]
The method according to any of the preceding claims, wherein the second and / or third metal composition based on lead-tin (10, 29) comprises at least 60% by weight and optionally at most 85% by weight of copper.
[12]
The method according to any of the preceding claims, wherein the second and / or the third spent slag (20, 28) comprises at most 2.5% by weight of tin and lead together.
[13]
The method according to any of the preceding claims, wherein the second and / or the third spent slag (20, 28) comprises at most 2.0% by weight of copper and nickel together.
[14]
The method according to any of the preceding claims, wherein the second and / or the third spent slag (20, 28) comprises at most 2.0 wt% copper.
[15]
The method according to any of the preceding claims, wherein the black copper composition meets at least one and optionally all of the following conditions:
· Comprising at least 51% by weight of copper, • including at most 96.9% by weight of copper, • covering at least 0.1% by weight of nickel, • covering at most 4.0% by weight % nickel, · comprising at least 1.5% by weight of tin, · comprising at most 15% by weight of tin, · comprising at least 1.5% by weight of lead, · comprising at most 25% by weight of lead, · comprising at most 3.5% by weight of iron, and · including at most 8.0% by weight of zinc.
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[16]
The method according to any of the preceding claims, wherein the first and / or the second raw solder metal composition (18, 26) comprises at least 65% by weight of tin and lead together.
[17]
The method according to any of the preceding claims, wherein the first and / or the second raw solder metal composition (18, 26) comprises at least 5.0% by weight of tin.
[18]
The method of any one of the preceding claims, wherein the first and / or the second raw solder metal composition (18, 26) comprises at least 45 weight percent lead.
[19]
The method according to any of the preceding claims, wherein the first and / or the second raw solder metal composition (18, 26) comprises at most 26.5% by weight copper and nickel together.
[20]
The method according to any of the preceding claims, wherein the first and / or the second raw solder metal composition (18, 26) comprises at most 17.5% by weight copper.
[21]
The method according to any of the preceding claims, wherein the first and / or the second raw solder metal composition (18, 26) comprises at most 9.0 wt% nickel.
[22]
The method according to any of the preceding claims, wherein the first and / or the second raw solder metal composition (18, 26) comprises at most 8% by weight of iron.
[23]
The method of any one of the preceding claims, wherein step (i) comprises the step of
b) partially oxidizing (100) the first portion of the black copper composition (1), thereby forming a first enriched copper metal phase (4) and a first copper refining slag (3), followed by separating the first copper refining slag (3) ) of the first enriched copper metal phase (4).
[24]
The method according to the preceding claim, wherein the recovery of tin in step b) (100) as part of the first copper refining slag (3), relative to the total amount of tin that is
BE2018 / 5874
132 is present in step b) (100), is at least 20%.
[25]
The method of claim 23 or 24 wherein the recovery of lead in step b) (100) as part of the first copper refining slag (3), relative to the total amount of lead present in step b) (100), at least 20%.
[26]
The method of any one of claims 23-25, wherein step (i) further comprises the step of
c) partially reducing (400) the first copper refining slag (3), thereby forming a first lead-tin metal composition (13) and a first spent slag (12), followed by separating the first spent slag (12) from the first lead-tin-based metal composition (13), the latter forming the basis for a first liquid bath (450).
[27]
The method of the preceding claim, wherein the total feed to step c) (400) comprises at least 29.0 wt% copper.
[28]
The method of any one of claims 26-27 wherein the total feed to step c) (400) comprises an amount of copper that is at least 1.5 times as high as the total amount of solder metals present.
[29]
The method of any one of claims 26-28 wherein step c) (400) comprises adding a first reducing agent (R1) to step c) (400).
[30]
The method of claim 29, wherein the first reducing agent (R1) comprises a metal that has a higher affinity for oxygen than tin, lead, copper, and nickel, preferably iron metal, more preferably scrap iron, under the conditions of the method.
[31]
The method of any one of claims 26-30, further comprising the step of
g) recycling (701) at least a portion of the second lead-tin-based metal composition (10) to step c) (400) and / or recycling at least a portion of the second metal composition
BE2018 / 5874
133 on lead-tin basis (10) to step b) (100) and / or recycling at least a portion of the second lead-base-based metal composition (10) to step d) (500).
[32]
The method of any one of claims 26 to 31, wherein step (i) further comprises the step of
d) partially oxidizing (500) the first liquid bath (450), thereby forming a first diluted copper metal composition (15) and a first solder refining slag (16), followed by separating the first solder refining slag (16) from the first diluted copper metal composition (15).
[33]
The method of any one of claims 23 to 32 wherein the temperature of the slag in step b) (100) and / or in step c) (400) is at least 1000 ° C.
[34]
The method of claim 32 or 33, wherein step (ii) further comprises the step of
e) partially reducing (600) the first solder refining slag (16), thereby forming the first rough solder metal composition (18) and the second solder refining slag (19), followed by separating the second solder refining slag (19) from the first raw solder metal composition (19) (18).
[35]
The method of claim 34 wherein step e) (600) comprises adding a second reducing agent (R2) to step e) (600).
[36]
The method of claim 35, wherein the second reducing agent (R2) comprises a metal that has a higher affinity for oxygen under the conditions of the method than tin, lead, copper, and nickel, wherein the second reducing agent (R2) at preferably iron metal, more preferably scrap iron.
[37]
The method according to any of claims 34-36, wherein a first Pb and / or Sn-containing fresh feed (17) is added to step e) (600), wherein the first Pb and / or Sn-containing fresh feed (17) preferably comprises scratch, and is preferably scratch, obtained from downstream processing of concentrated
BE2018 / 5874
134 streams of Pb and / or Sn.
[38]
The method of any one of claims 23-37, wherein step (i) further comprises the step of
h) partially oxidizing (200) the first enriched copper metal phase (4), thereby forming a second enriched copper metal phase (7) and a second copper refining slag (6), followed by separating the second copper refining slag (6) from the second enriched copper copper metal phase (7).
[39]
The method of claim 38, further comprising the following step:
i) adding at least a portion of the second copper refining slag (6) to the first liquid bath (450) and / or adding at least a portion of the second copper refining slag (6) to step d) (500).
[40]
The method of claim 38 or 39 further comprising the following steps:
j) partially oxidizing (300) the second enriched copper metal phase (7), thereby forming a third enriched copper metal phase (9) and a third copper refining slag (8), followed by separating the third copper refining slag (8) from the third enriched copper copper metal phase (9),
k) adding at least a portion of the third copper refining slag (8) to the first diluted copper metal composition (15), thereby forming a second liquid bath (550), and / or adding at least a portion of the third copper refining slag (8) at step 1) (800);
l) partially oxidizing (800) the second liquid bath (550), thereby forming a first copper metal composition with high copper metal content (22) and a third solder refining slag (23), followed by separating the third solder refining slag (23) from the first copper metal composition with high copper metal content (22).
[41]
The method of claim 40 which
BE2018 / 5874
135 further comprises the following step:
m) partially reducing (900) the third solder refining slag (23), thereby forming a second diluted copper metal composition (11) and a fourth solder refining slag (24), followed by separating the fourth solder refining slag (24) from the second diluted copper metal composition (11).
[42]
The method of claim 41, further comprising the following step:
n) partially reducing (1000) the fourth solder refining slag (24), thereby forming the second raw solder metal composition (26) and the fifth solder refining slag (27), followed by separating the second raw solder metal composition (26) from the fifth solder refining slag (27).
[43]
The method of claim 42 wherein step n) (1000) comprises adding a fifth reducing agent (R5) to step n) (1000).
[44]
The method of claim 43, wherein the fifth reducing agent (R5) comprises a metal that has a higher affinity for oxygen under the conditions of the method than tin, lead, copper, and nickel, preferably iron metal, more preferably scrap iron.
[45]
The method of any one of claims 42 to 44, wherein a second Pb and / or Sn containing fresh feed (25) is added to step n) (1000), wherein the second Pb and / or Sn-containing fresh feed (25) preferably comprises scratch, and is preferably substantially scratch, obtained from downstream processing of concentrated streams of Pb and / or Sn.
[46]
The method according to any of claims 4 to 45, further comprising the following step:
p) partially oxidizing (1200) the third lead-tin-based metal composition (29), thereby forming a fourth lead-tin-based metal composition (21) and a sixth solder refining slag (14), followed by separating the sixth solder refining slag (14) from
BE2018 / 5874
136 the fourth metal composition on a lead-tin basis (21).
[47]
The method of claim 46, further comprising the following step:
q) recycling (1201) at least a portion of the sixth solder refining slag (14) to step d) (500), and / or adding at least a portion of the sixth solder refining slag (14) to the first liquid bath ( 450), and / or recycling (1201) at least a portion of the sixth solder refining slag (53) to step e) (600).
[48]
The method of claim 46 or 47 further comprising the following step:
r) recycling (1202) at least a portion of the fourth lead-tin-based metal composition (21) to step 1) (800) and / or adding at least a portion of the fourth lead-tin-based metal composition (21) ) to the second liquid bath (550).
[49]
The method of any one of claims 41 to 48, further comprising the following step:
s) recycling (901) at least a portion of the second diluted copper metal composition (11) formed in step m) (900) to step c) (400), and / or recycling at least a portion of the second diluted copper metal composition (11) to step d) (500), and / or recycling at least a portion of the second diluted copper metal composition (11) to the first liquid bath (450).
[50]
The method of any one of claims 41 to 49, wherein step m) (900) comprises adding a fourth reducing agent (R4) to step m) before reducing (900) the third solder refining slag (23).
[51]
The method of claim 50, wherein the fourth reducing agent (R4) comprises a metal that has a higher affinity for oxygen under the conditions of the process than tin, lead, copper, and nickel, preferably iron metal, more preferably iron scrap.
[52]
The method of any one of the preceding claims, wherein at least one of the
BE2018 / 5874
137 process steps involving a separation of a metal phase from a slag phase, an amount of silicon dioxide is added, preferably in the form of sand.
[53]
The method of any one of the preceding claims, wherein the black copper is produced by a step in a smelting furnace.
[54]
The method of any one of the preceding claims, wherein at least one of the first raw solder metal composition (18) and the second raw solder metal composition (26) is pre-refined using silicon metal to produce a pre-refined solder metal composition.
[55]
The method according to any of the preceding claims, further comprising the step of cooling the first raw solder metal composition (18) and / or the second raw solder metal composition (26) and / or the pre-refined solder metal composition to a temperature of not more than 825 ° C to form a bath containing a first surfacing scratch, which comes to float by gravity on a first liquid molten updated soldering phase.
[56]
The method according to any of the preceding claims, further comprising the step of adding an alkali metal and / or an alkaline earth metal, or a chemical compound comprising an alkali metal and / or an alkaline earth metal to the first raw solder metal composition (18) and / or at the second raw solder metal composition (26) and / or at the pre-refined solder metal composition and / or at the first liquid molten updated solder phase to form a bath containing a second supernatant scratch that floats to the surface a second liquid molten updated soldering phase.
[57]
The method of the preceding claim, further comprising the step of removing the second supernatant scratch from the second liquid molten updated
BE2018 / 5874
138 soldering phase, whereby a second updated solder is formed.
[58]
The method according to any of claims 55 to 57, further comprising the step of removing the first superficial scratch from the first liquid molten updated solder phase, thereby forming a first updated solder.
[59]
59. The method according to claim 57 or 58, further comprising the step of distilling the first updated solder and / or the second updated solder, wherein lead (Pb) is removed from the solder by evaporation and a distillation top product and a distillation bottom product be obtained, preferably by vacuum distillation.
[60]
60. The method of the preceding claim, wherein the distillation bottoms product comprises at least 0.6% by weight of lead.
[61]
The method according to any of the preceding claims, wherein at least a portion of the method is electronically monitored and / or controlled.

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US20210172039A1|2021-06-10|

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BR112019005833A2|2016-09-27|2019-06-18|Metallo Belgium|improved welding and method to produce high purity lead|BE1027795B1|2019-11-22|2021-06-23|Metallo Belgium|Improved copper smelting process|

法律状态:
2019-08-19| FG| Patent granted|Effective date: 20190708 |

优先权:

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申请号 | 申请日 | 专利标题

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EP17207372.8|2017-12-14|

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EP17207372|2017-12-14|

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