Improved combined production of lead and tin products

专利摘要:
A method is disclosed which produces soft lead (27), hard lead (28) and tin (20), and which comprises a) a first distillation (200) of solder (6) comprising Pb + Sn + Sb, wherein a first peak lead current (7) and a first tin bottoms stream (8) are produced, b) optionally a crystallization (300) of the first bottoms stream (8), producing a silver draw-off stream (9) and a first tin rich product (10), c) a second distillation (400) of the first tin rich product (10) and / or the first tin bottoms stream (8), producing a second bottoms stream (13) and a second top lead stream (12), d) a third distillation (600) of the second top lead stream (12) to vaporize Pb + Sb, producing a third top stream (22) and a third top lead stream (21). Also disclosed is an intermediate composition of the process containing 0.08-6.90 wt.% Pb, 0.50-3.80 wt.% Sb, 92.00-98.90 wt.% Sn, ≥96.00 wt. -% Sn + Pb + Sb, 1-500 ppm by weight of Cu, ≤0.0500% by weight Ag, ≤0.40% by weight As, each time ≤0.1% by weight of Al, Ni, Fe, Zn and ≤0.1 weight% of the total of Cr + Mn + V + Ti + W.
公开号:BE1027016B1
申请号:E20205057
申请日:2020-01-30
公开日:2020-09-01
发明作者:Koen Govaerts；Pelle Lemmens；Jan Dirk A Goris；Visscher Yves De；Charles Geenen；Kris Mannaerts；Bert Coletti
申请人:Metallo Belgium；
IPC主号:

专利说明:

4; BE2020 / 5057 Improved combined production of lead and tin products
FIELD OF THE INVENTION The present invention relates to the production by pyrometallurgy of non-ferrous metals, in particular lead (Pb) and tin (Sn), and optionally in combination with the production of copper (Cu), from primary sources and / or secondary basic materials. More specifically, the present invention relates to the production and recovery of high purity lead products and a high purity tin product from a mixture containing predominantly lead and tin.
BACKGROUND OF THE INVENTION The metal lead is an important non-ferrous raw material in modern industry, and has been since ancient times. Today's lead market is mainly based on its use in the lead battery, and in particular the lead acid battery. The use of lead in other areas of application including lead sheet for construction, lead as a radiation barrier, as dead weight, as protection for underwater cables, as ammunition and as an alloy metal in brass, is insignificant to its use in the car -industry.
Lead has been mined since 5000 BC, from the ancient Egyptians; For centuries it was extracted from primary raw materials, mainly galena (lead sulphide - PbS). Minerals rich in lead are common with other metals, especially silver, zinc, copper, and sometimes gold. In modern society, lead has also become the most recycled of all commonly used metals. Lead is also often present in secondary base materials, in combination with other metals. For example, the lead present in brazing materials is combined with significant amounts of other metals, mainly tin, and hard lead can easily contain up to 18% by weight of other metals, of which antimony is the most common. The recovery of high purity lead products from primary and secondary feedstocks therefore requires the separation of lead from other metals and the refining of lead or a mixture of lead with other non-ferrous metals in order to obtain a high purity, high purity lead product.
Tin is also a valuable non-ferrous metal. Many tin end uses are sensitive to impurities and require a high purity tin quality. This applies, for example, to the preparation of high-quality lead-free solder, in the manufacture of semiconductor compounds such as tin nitride, antimony telluride, tin arsenide and superconducting alloys.
In particular, silver is undesirable as a tin metal impurity. Significant presence of silver in tin metal deteriorates the mechanical properties of tin metal. The presence of silver in tin used in the tinning of steel further creates the risk of galvanic corrosion occurring, which would corrode the tin can wall from the inside to the outside surface. This is a major problem for cans for use in the food industry.
One of the objectives in the production of a high purity tin product is to remove significant amounts of predominantly lead, and to some extent minor amounts of antimony, from the high performance tin product.
Guo-Bin Jia et al, “Deeply removing lead from Pb-Sn alloy with vacuum distillation,” in Transactions of Nonferrous Metals Society of China, English edition, Vol. 23, no. 6, June 1, 2013, pages 1822-1831, concerns the thorough removal of lead from tin by vacuum distillation to obtain lead-free solder, as an alternative to the traditional method for this separation, which includes electrolysis and crystallization. The paper first describes small scale experiments with vacuum distillation in batches on a crude lead material with a lead content of 77.99% by weight and on a crude tin product containing 12.21% by weight lead. The basestocks contain 0.0386 wt% and 0.3384 wt% antimony, respectively, and further contain minor amounts of Cu, Bi, As, Fe and Ag. The evolution of the levels of lead and tin in the volatile constituents and in the residual constituents obtained after 20, 40, 60 and 80 minutes of vacuum distillation at 4 different temperatures in the range of 900 ° C to 1100 ° is reported. C.
Continuous experiments in an industrial context are also described, also at the University of Kunming and presumably based on the same basic materials.
The raw lead material was separated into a top stream lead product of greater than 99.5% purity containing about 0.05% tin.
The residue, which contained 8% lead and about 91% tin, was said to be suitable for blending with crude tin material and purified by another distillation.
The lead in the crude tin could not be removed directly from 12.21% to 0.01% in one distillation and was therefore distilled twice.
In a first distillation of these two, the lead content in the crude tin could be reduced to 0.2% by distilling away a volatile component containing 10-12% tin and about 88% lead.
However, the amount of volatile component was very small and the by-product was considered suitable to be mixed with crude lead for further refining.
The residue from that first distillation was subjected to the second distillation of the two, during which the lead in the tin was removed to less than 0.01%. The composition of the volatile component from that second distillation was said to be 70% Pb and 30% Sn.
By-product was also considered suitable to be mixed with the raw lead material for further refining.
Based on the results of the experiments, the document proposes a 3-step vacuum distillation sequence, each further distillation step treating the residue obtained from the previous step, to separate a raw lead material of 80% / 20% Pb / Sn in a crude lead product with> 99% Pb as the top stream from the first stage, and a refined tin of> 99.5% containing <0.01% Pb as a residue from the 3rd stage.
The overhead stream byproducts from the second and third distillation steps should be recycled and mixed with the raw lead feedstock fed to the first distillation step.
The document does not describe, and is not interested in, what happens to the other components of the feed, including antimony.
Chinese Patent CN102492861 discloses a process for the production of refined tin from raw tin of a variety of origins comprising at least 83.80% by weight and up to 96% by weight Sn, the process comprising a sequence of two vacuum distillation steps in series, wherein an overhead product from the first distillation was subjected to a second vacuum distillation step to recover most of the entrained tin in the secondary crude tin bottoms product from the second vacuum distillation step, with that secondary crude tin being recycled to the first vacuum distillation step. The process also produced a lead-antimony alloy as the top product of the second vacuum distillation step, and by vacuum treatment also a crude arsenic by-product containing 91-99% by weight of As. The raw tin feed was subjected to a centrifugation step in which the iron content was reduced and a step in which sulfur was added to remove copper before the first vacuum distillation. The refined tin obtained as the bottom product from the first vacuum distillation step was further refined to the purity of at least 99.95% by weight required by industrial standard GB / T 728-2010 by treating the refined tin with aluminum to further reduce the traces of arsenic and antimony, and to remove the remaining aluminum in a subsequent step.
Chinese Patent CN101570826 discloses a process for separating lead from tin by three vacuum distillation steps in series, wherein the downstream step is performed on the bottom product of the upstream step. The document focuses only on the separation between Pb and Sn and on obtaining a refined tin containing at most 0.005 weight% lead. The document does not provide details about the nature of the small amount of “other” or where those materials end up. In each step, an amount of so-called “foam” is secreted, again no details are revealed.
Chinese Patent CN101570827 also concerns the separation of Pb from Sn, now in the presence of an amount of antimony (Sb). In the described two-stage vacuum distillation process, also this time the bottom stream of the first stage is redistilled in the second stage to obtain as a final bottom product a crude tin containing 99 +% Sn, while the so-called tin-lead-antimony alloy 5 which is obtained. as top flow in the second stage is returned to the first stage. Again, this document appears to be interested only in obtaining high purity of the tin product and in obtaining high recoveries of metal in each stage, and generally in the two stage process.
Also described in Chinese Patent CN104651625, vacuum distillation processes in 2 and 3 stages, in which in the last stage the overhead stream or streams from the previous stages are redistilled. The top flow condenser from the last stage in each process is split into 2 sections, which operate at different temperatures and lead to 2 different top products, with the first and hottest condensate still containing Sn and recycled to the final distillation stage, while the second and coldest condensate contains a significantly lower content of Sn and is removed as Pb-Sb alloy.
The above documents focus on separation problems that are greatly simplified compared to the problems associated with the recovery of non-ferrous metals from secondary feedstocks, especially as part of the recovery of other non-ferrous metals in co-production with copper. In that particular industry, the diversity of basic materials is enormous and the availability of individual sources of basic materials can vary quickly and widely. The methods described above do not offer the flexibility required in this industry to produce high-quality products whose quality is sufficiently high, but are also fairly constant over time. There therefore remains a need for a method with improved flexibility for the acceptability of basestocks as compared to the methods described above.
WO 2018/060202 A1 describes the vacuum distillation of a solder type base stock into a lead stream as a top stream and a tin stream as a bottoms, including the pretreatment of the brazing type stock to remove contaminants that could disturb the downstream vacuum distillation. The top product is disclosed further refined by conventional means to form a high purity "soft lead" product, without sacrificing further details. The bottoms are declared suitable for further upgrading to commercially significant amounts of several of the metals present, particularly the tin, antimony and residual lead, but possibly including other metal values such as silver (Ag). WO 2018/060202 A1 does not provide details on how that is done. The document in question concerns the feasibility of a vacuum distillation step in which lead is vaporized from a solder-type base material. It does not address the problem of widely varying availability of feedstock in the non-ferrous metal recovery industry.
It is an object of the present invention to obviate or at least alleviate the above-described problem, and / or to provide improvements in general.
SUMMARY OF THE INVENTION According to the invention there is provided a method as defined in any of the appended claims.
In one embodiment, the present invention provides a metal composition comprising, on a dry weight basis: ° at least 0.08% by weight and at most 6.90% by weight lead (Pb), ° at least 0.01 and preferably not less than 0.50% by weight and not more than 3.80% by weight of antimony (Sb), ° at least 92.00% by weight and not more than 98.90% by weight of tin (Sn), ° at least 96, 00% by weight of tin, lead and antimony together, ° not less than 1 ppm by weight and not more than 500 ppm by weight of copper (Cu), ° not more than 0.0500% by weight of silver (Ag),
° not more than 0.40% by weight of arsenic (As), ° not more than 0.1% of the total of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W), ° no more than 0.1% aluminum (AI), ° no more than 0.1% nickel (Ni), ° no more than 0.1% iron (Fe), and ° no more than 0.1% zinc (Zn).
In one embodiment, the present invention provides a method for producing a soft lead product, a hard lead product and a tin product, the method comprising: a) providing a crude solder composition comprising primarily large amounts of lead and tin, along with a small amount of antimony , b) a first distillation step that mainly separates lead from the crude solder composition of step a) by evaporation, thereby producing a first concentrated lead stream as an overhead product and a first bottoms product enriched in tin, the first concentrated lead stream forming the basis to obtain the soft lead product, C) if silver is present in the crude solder composition, optionally a fractional crystallization step performed on the first bottoms product from step b) to separate silver from tin and produce a bleed product from the liquid end of the crystallizations tap enriched in silver, and a first tin-enriched product from the crystal end of the crystallization step, d) a second distillation step which mainly separates lead and antimony by evaporation from the metal composition of the present invention selected from the first tin enriched product from step c) and the first bottoms product from step b}, producing a second concentrated lead stream as top product and producing a second bottoms product, the second bottoms forming the basis for obtaining the tin product, e) a third distillation step which by evaporation mainly separates lead enantimony from the second concentrated lead stream from step d), producing as a top product a third concentrated lead stream and a third bottoms product, the third concentrated lead stream forming the basis for obtaining the hard lead product.
Applicants have found that the metal composition of the present invention is highly suitable as an intermediate stream of the process of the present invention, more particularly as the feed of the second distillation step d) to be separated, in a single distillation step in which the majority of the lead and antimony are removed by evaporation, resulting in a tin concentrate residue that can be purified without difficulty by chemical means to become a high purity tin product, while the top stream of the distillation step forms a distillate well suited to be extracted from it. to derive, by means of an additional distillation step in step e), a high quality hard lead product, more in particular a lead product containing antimony in the range 2-15% by weight.
Applicants have found that the presence of lead in the metal composition of the present invention, as prescribed, contributes significantly to this suitability because in the distillation step d) as described, the lead acts as a carrier for entraining the top stream. most of the antimony. A higher presence of lead in the metal composition of the present invention therefore leads to a lower content of antimony in the bottom stream of the distillation step d) to which it is subjected.
Applicants have found that the same logic as for antimony also applies when silver is present in the composition of the present invention. The distillation step d) can be carried out in such a way that most of the silver in the feed to step d) is carried along to the top stream and thus removed from the bottom residue, in which preferably only a limited amount of silver is present. A higher presence of lead therefore also leads, for the same reasons, to a lower content of silver in the bottom stream of the distillation step d) to which the composition is subjected.
However, Applicants have found that the lead content in the metal composition of the present invention can be kept limited, in accordance with the upper limit as indicated. Applicants have found that additional lead or lead-containing feedstock can be mixed with the metal composition of the present invention to form the feedstock for the distillation step d). This brings the advantage that the metal composition of the present invention can carry more tin, which is more valuable than lead, for the same volumetric throughput upstream in the production of the metal composition of the present invention. That benefit is therefore directly linked to a possible increased economic benefit to the practitioner of the process. This argument does not negate the advantage of respecting the lower limit as indicated for lead in the composition of the present invention, because any lead present does not have to be supplied by adding an additional feed to the distillation step d).
Applicants prefer that antimony is present in the metal composition of the present invention in the range as indicated. This entails the advantage that the composition is suitable as a base material to derive a hard lead product therefrom together with the high purity high quality tin product. The object of the method of the present invention is to produce a hard lead product as a third high value product, together with the soft lead product and the tin product. The indicated minimum presence of antimony ensures the ability to obtain the hard lead product.
Applicants note that the stated limits of the range for the presence of tin in the metal composition of the present invention generally result from the limits stated for the other components, and from the optional presence, in addition, of other elements that are acceptable. The total content of tin, lead and antimony together in the metal composition of the present invention should fall within the range indicated. The lower limit as indicated reduces the potential presence of other elements, particularly elements not indicated as part of the present invention, which may be less desirable in further processing of the metal composition and entail an additional burden in deriving it. of the targeted high-quality products. In one embodiment, the metal composition of the present invention includes, in addition to the elements discussed in this document for the composition, any other element discussed or indicated in a concentration that is no more than an unintended impurity, and without affecting the technical effects that are the object of the present invention, in particular the smooth operation of the vacuum distillation step performed on the composition, and the ability to produce high quality commercial grade products as derivatives.
Applicants have found that silver can be present in the metal composition of the present invention, provided that its content is limited. As set forth above in the Background of the Invention section, high levels of silver are undesirable in high quality, commercial grade tin products. Applicants have found that silver can be acceptable in the composition up to the upper limit as indicated because silver can be made to pass preferentially to the top stream when the composition is subjected to the distillation step d) as described. The Applicants have found that the levels as prescribed are acceptable because the distillation step d) can be carried out such that the level of silver in the bottom residue is sufficiently low for the high quality tin product derived therefrom to meet the specifications of high purity marketable high quality tin products .
Applicants have also found that the presence of arsenic, within the limits as indicated, is acceptable in the metal composition of the present invention. Applicants have found that the distillation step d) can be carried out such that also most of the arsenic ends up in the overhead product, from which it can end up as an acceptable minority component in the final hard lead product, along with the antimony. Applicants have found that the small amount of arsenic that can remain in the bottoms residue in the distillation step d) results in a level that can be further reduced by further refining that stream with chemical means, as described later in this document, to achieve the desired tin product as one of three high performance products produced by the method of the present invention.
In addition, the metal composition of the present invention has a low content of the specific elements which, under the operating conditions of the downstream distillation steps d) and e), can form solid metal-metal or intermetallic compounds through reactions between each other or with tin, and which form can adhere to the equipment and interfere with the distillation operations.
The metal composition of the present invention comprises a significant but also limited amount of antimony. The prescribed amount of antimony is acceptable because that amount of antimony can be easily distilled away from the tin by establishing suitable distillation conditions in step d) such that the antimony evaporates along with the lead, which is generally more volatile than antimony. Acceptance of antimony broadens the acceptability criteria for the base materials of the upstream processes from which the metal composition of the present invention can be obtained.
Applicants have found that the method of the present invention has the advantage of being able to incorporate a raw solder as a base material whose composition can vary widely without requiring a change in operation and / or control objectives for driving and / or checking the different process steps.
For example, the first distillation step b) may still focus entirely on the evaporation, as selectively as possible, of most of the incoming lead, to produce a top product of the quality required to derive the high-quality soft lead product from it by means of the downstream soft lead refining steps, in which most of the tin and antimony from the feedstock is retained in the first bottoms product as the bottoms residue. Distillation step b) can thus focus on the evaporative removal of mainly lead, while entraining as little antimony, silver and tin with the evaporating lead as possible. The process sequence is capable of incorporating the antimony and the tin in the further distillation steps d) and e), as well as the silver which may be present at a level that would contaminate the high value tin product and / or that the inclusion of the optional step c) would account for the recovery of the silver in an additional by-product stream.
The second distillation step d) can still focus entirely on leaving a tin-enriched product as a residue suitable for deriving therefrom the high-value tin product by the downstream tin refining steps, with the majority of the lead and antimony from its base material in the second concentrated lead stream is charged as its top stream. The step d) can thus be focused on producing a residue of the desired purity of tin. Thanks to the downstream distillation step e), the process is capable of processing any distillate obtained as the top product from step d).
The third distillation step e) can still focus entirely on the selective evaporation of antimony, and lead, if any, from the feedstock to the third concentrated lead stream as its overhead stream. Step e) can thus be focused on producing a top stream containing as much of the antimony as possible,
and arsenic, if present, and can vaporize the amount of lead as a carrier necessary to achieve that operating objective. The third bottom product obtained from distillation step e) is a stream that is highly suitable for recycling at the most suitable location in the process of the present invention.
If present, the fractional crystallization step can be fully focused on the removal of silver from the main tin stream, such that the content of silver in the final high quality tin product will be sufficiently low and in accordance with customer expectations. Applicants prefer, when the content of silver in the first bottoms product is at least 120 ppm by weight, that the fractional crystallization step be included in the process of the present invention, because they believe that the economic benefits of the additional silver-enriched by-product outweigh the additional burden and operating costs of the crystallization step, including the additional attention of the operating technicians this step requires and because this additional step helps the downstream second distillation step d) more easily achieve its operating objective as above explained. Applicants have found that the presence of significant amounts of lead in the optional fractional crystallization step c) is conducive to separating the silver in a liquid tapping product, as an additional by-product of the process of the present invention, from the majority of the tin which is recovered as part of the product on the crystal side of the crystallization step c).
An important advantageous technical effect of the process of the present invention is its ability to smoothly handle a wide range of feedstream compositions without having to adjust the operating objectives for the majority of the individual process steps. The wide range of effortlessly acceptable feedstream compositions makes the product of the present invention also have a relatively wide range of acceptable compositions.
The flexibility in base materials of the method of the present invention with respect to the solder base material entails the additional advantage that the process steps upstream of the method of the present invention are capable of incorporating a wide range of raw materials.
BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows a flow chart of a larger general method comprising a preferred embodiment of the method of 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 thereto, but is determined solely by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some elements may be enlarged for illustrative purposes 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, are used in the specification and claims to distinguish between similar elements, and not necessarily to describe a sequential or chronological order. The terms are interchangeable in appropriate circumstances, and the embodiments of the invention may function in sequences other than those described or illustrated herein. Furthermore, the terms top, bottom, top, bottom, and the like are used in the description and claims for descriptive purposes, and not necessarily to describe relative positions. The terms so used are interchangeable in appropriate circumstances, and the embodiments of the invention described herein may function in orientations other than those described or illustrated herein. The term "comprising", as used in the claims, is not to be construed as being limited to the means enumerated in its context. He does not exclude other elements or steps. The term should be interpreted as the required presence of the listed properties, numbers, steps or components, but does not preclude the presence or addition of one or more other properties, numbers, steps or components, or groups thereof. Thus, the scope of the phrase "an item comprising means A and B" need not be limited to an article composed only of components A and B. It means that in the context of the present invention, A and B are the only relevant components. Accordingly, the terms "comprise" or "include" also include the more restrictive terms "consist essentially of" and "consist of". Accordingly, when “comprise” or “contents” is replaced by “consist of”, these terms represent the basis of preferred, but constrained embodiments, which are also provided as part of the contents of this document relating to the present invention.
Unless otherwise specified, all value ranges listed in this document include the range up to and including the indicated endpoints, and the values of the ingredients or components of the compositions are expressed in weight percent, or weight%, of each ingredient in the composition.
Terms such as "weight percent,", "weight%", "wt%" "percent by weight," "% by weight," "ppm by weight", "ppm by weight", "wtppm" or “ppm” and variations thereof, as used in this document, refer to the concentration of a substance as the weight of that substance divided by the total weight of the composition and multiplied by 100 or 1000000 as appropriate, unless something otherwise specified It should be understood that the terms "percent," "%," used herein are intended to be synonyms of "percent by weight," "percent by weight" etc.
It should further be noted that, in the present description and the appended claims, the singular forms “a”, “the” and “it” may also refer to plural matters, unless the contents clearly indicate otherwise. For example, reference to a composition comprising "a compound" includes a composition having two or more compounds. It should also be noted that the term "or" is generally used in the sense that "and / or" implies, unless the content clearly indicates otherwise.
Furthermore, each compound used here can be interchangeably discussed by its chemical formula, chemical name, abbreviation, etc.
Most of the metal streams in the process of the present invention contain a high proportion of lead, often in combination with a significant amount of tin. Such currents have a relatively low melting point and have been used for centuries to attach one solid to another solid, through a process often referred to as “soldering”. Such currents are therefore often referred to as so-called "solder" currents or "solder", and that term is also used in this document to designate such currents.
Among the target metals recovered by the present invention, Sn and Pb are considered to be "the brazing metals". These metals are distinguished from other metals, particularly the two other target metals copper and nickel, as well as from iron in that mixtures containing large amounts of these metals generally have a much lower melting point than mixtures containing large amounts of copper and / or contain nickel. Such compounds were used millennia ago to form a permanent bond between two pieces of metal by first melting the “solder”, then applying and solidifying. To this end, the solder had to have a lower melting temperature than the metal of the pieces that were connected by it. In the context of the present invention, by a solder product or a solder metal composition, two terms used interchangeably herein, are meant metal compositions in which the combination of the solder metals, i.e. the content of Pb plus Sn, constitutes the major part of the composition. ie at least 50% by weight and preferably at least 65% by weight. The solder product may further contain minor amounts of the other target metals copper and / or nickel, and non-target metals such as Sb, As, Bi, Zn, Al and / or Fe, and / or elements such as Si.
Unless otherwise noted, amounts of metals and oxides in this document are expressed in accordance with common pyrometallurgic practice. 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 a chemically bound form, usually in an oxidized form (oxidation state> 0). For the metals which can be relatively easily reduced to their elemental form, and which can exist 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 or scratch is indicated, where the majority of such metals may in fact be present in an oxidized and / or chemically bound form. Therefore, in the composition of the metal mixture as feed to step (a), the content of Fe, Zn, Pb, Cu, Sb, Bi is expressed as elemental metals. Less noble metals are more difficult to reduce under nonferrous pyrometallurgical conditions and are mostly in an oxidized form. These metals are usually expressed in terms of their most common oxide form. Therefore, in slag or scratch compositions, the content of Si, Ca, Al, Na is usually expressed as SiO2, CaO, Al2O3, Na2O, respectively.
In one embodiment of the present invention, the metal composition of the present invention comprises at least 0.09 wt.% Or even at least 0.10 wt.% Lead, preferably at least 0.15 wt.%, More preferably at least 0.20 wt%, even more preferably at least 0.50 wt%, preferably at least 0.75 wt%, more preferably at least 1.00 wt%, even more preferably at least 1 , 50% by weight, preferably at least
2.00 wt%, more preferably at least 2.50 wt%, even more preferably at least 3.00 wt%, preferably at least 3.50 wt%, more preferably at least 4, 00 weight%, even more preferably at least 4.50 weight% lead. Applicants have found that a small amount of lead is easily acceptable and even desirable in the metal composition of the present invention because lead promotes the evaporation of antimony in a downstream vacuum distillation step. Due to its relatively high volatility, the lead dilutes the vapor phase in the distillation step, thereby extracting more antimony from the residual liquid, thus acting as a kind of carrier for the antimony. The same logic as for antimony applies to any silver that may be present in the composition. As a result, the lead promotes the removal of antimony and / or silver from the main tin stream and thereby contributes to the ultimate obtaining of a high quality tin product of higher purity.
In one embodiment of the present invention, the metal composition of the present invention comprises at most 6.80 weight% lead, preferably at most 6.50 weight%, more preferably at most 6.00 weight%, with even more preferably at most 5.50% by weight of lead, preferably at most 5.00% by weight, more preferably at most 4.50% by weight, even more preferably at most 4.00% by weight of lead. With lower amounts of lead in the metal composition of the present invention, when produced by a fractional crystallization step, Applicants have found that the volume of tapped by-product can be kept lower and the concentration of silver in the bleed stream can be kept higher. This has the advantage that silver can be efficiently recovered from more dilute feedstocks, while at the same time producing a bleed stream that is sufficiently rich in silver to allow effective and efficient recovery of the silver therefrom. The lower volume and higher silver content of the bleed stream are also beneficial to the efficiency and effectiveness of the process steps for recovering the silver from the bleed stream.
An additional benefit of respecting the upper limit on the presence of lead in the composition of the present invention is that more space is left in the same amount of composition for handling a higher volume of tin by the same equipment. Since the economic upgrading of tin to a high quality product is higher than that of lead, limiting the lead in the composition opens the possibility of increased profitability based on tin production. Applicants have found that, if more lead is nevertheless desired in the second distillation, which incorporates as part of its feed the metal composition of the present invention, it may be preferable to mix lead or a suitable lead-containing fresh feed directly into the feed of the distillation, rather than requiring more lead to be present in the composition of the present invention, because of the potential negative effect on tin production.
In one embodiment of the present invention, the metal composition of the present invention comprises at least 0.75% by weight, preferably at least 1.25% by weight, more preferably at least 1.50% by weight, preferably at least 1.75% by weight, more preferably at least 1.80% by weight, even more preferably at least 1.90% by weight, preferably at least 1.95% by weight, more preferably at least 2, 00 wt%, even more preferably at least 2.10 wt% antimony. Optionally, the metal composition comprises at most 3.70 wt% antimony, preferably at most 3.50 wt%, more preferably at most 3.20 wt%, even more preferably at most 3.00 wt%, preferably at most 2.75% by weight, more preferably at most 2.50% by weight, even more preferably at most 2.25% by weight, preferably at most 2.15% by weight, more preferably at most 2.10 wt%, even more preferably at most 2.00 wt% antimony. Applicants have found that such an amount of antimony is easily acceptable in the metal composition because the antimony can be evaporated in a downstream vacuum distillation step, and ultimately a high quality tin product of high purity can be obtained without difficulty, while the top stream of this distillation step provides valuable value. high quality hard lead product can be obtained.
In one embodiment of the present invention, the metal composition of the present invention comprises at least 92.50 wt% tin, preferably at least 93.00 wt%, more preferably at least 93.50 wt%, with even more preferably at least 94.00 wt%, preferably at least 94.50 wt%, more preferably at least 95.00 wt%, even more preferably at least 95.50 wt%, preferably at least 96.00 wt%, more preferably at least 96.50 wt%, even more preferably at least 97.00 wt%. This brings the advantage of a higher yield of high purity high quality tin product when the metal composition of the present invention is further processed by distillation to remove more volatile components such as lead and antimony, and refining the second bottoms product obtained. from that distillation step into a high-quality tin product.
Optionally, the metal composition of the present invention comprises at most 98.80% by weight or tin, preferably at most 98.70% by weight, more preferably at most 98.50% by weight, even more preferably at most 98, 25% by weight, preferably at most 98.00% by weight, more preferably at most 97.50% by weight, even more preferably at most 97.25% by weight, preferably at most 97.00% by weight %, more preferably at most 96.50 wt%, even more preferably at most 96.25 wt%, preferably at most 96.00 wt%, more preferably at most 95.75 wt%, even more preferably at most 95.50 wt%, preferably at most 95.25 wt%, more preferably at most 95.00 wt%, even more preferably at most 94.50 wt% preferably at most 94.00 wt%, more preferably at most 93.50 wt%, even more preferably at most 93.00 wt% tin.
Applicants have found that lower tin materials are more readily available from a wider range of sources, and thus at more attractive terms.
Thus, a lower required level of tin in the metal composition of the present invention entails the advantage of imparting greater flexibility in base material to the process producing the composition.
In one embodiment, the metal composition of the present invention comprises at least 96.25% by weight of tin, lead and antimony together, preferably at least 96.50% by weight, more preferably at least 96.75% by weight, more preferably at least 97.00 wt%, even more preferably at least 97.25 wt%, preferably at least 97.50 wt%, more preferably at least 97.75 wt%, even more preferably more preferably at least 98.00 wt%, even more preferably at least 98.25 wt%, preferably at least 98.50 wt%, more preferably at least 98.75 wt%, even more preferably more preferably at least 98.90% by weight, even more preferably at least 99.00% by weight of tin, lead and antimony together.
Optionally, the metal composition of the present invention comprises at most 99.95% by weight of tin, lead and antimony together, preferably at most 99.75% by weight, more preferably at most 99.50% by weight, even more preferably at most 99.25 wt%, even more preferably at most 99.00 wt%, preferably at most 98.75 wt%, more preferably at most 98.50 wt%, even more preferably at most 98.25 wt%, even more preferably at most 98.00 wt%, preferably at most 97.75 wt%, more preferably at most 97.50 wt%, even more preferably at most 97.25% by weight, even more preferably at most 97.00% by weight of tin, lead and antimony together.
Applicants prefer that the total of tin, lead, and antimony in the composition is above the lower limit as indicated because it implies that the presence of other elements is lower.
With a few exceptions, most of those other elements are undesirable at levels higher than unintended impurities, and if they are too prominent, they can create additional burdens in the processing of the metal composition of the present invention, or loss of value for at least one of the high-quality products derived from it.
Applicants allow the sum of tin, lead and antimony to not necessarily represent the full 100% of the composition of the present invention, as some other elements are also acceptable, usually at limited levels, as discussed elsewhere in this document.
Applicants point out that the effects produced by the present invention are related to the separation by distillation of the metal composition of the present invention, and to the derivation of higher purity, high quality products therefrom by pyrometallurgical means. Therefore, only those elements that are known to affect the effects in question need to be discussed and, where appropriate, can be taken into account in defining the present invention.
In one embodiment, the metal composition of the present invention comprises at most 0.0450 weight% silver, preferably at most 0.0400 weight%, more preferably at most 0.0350 weight%, even more preferably at most 0 , 0 300 wt%, even more preferably at most 0.0250 wt%, preferably at most 0.0200 wt%, more preferably at most 0.0175 wt%, even more preferably at most 0 0.150 weight%, even more preferably at most 0.0125 weight% silver. Silver is undesirable as a contaminant in high commercial grade tin products for reasons discussed elsewhere in this document. Applicants have found that it is therefore better to limit the presence in the metal composition of the present invention to the upper limit as indicated, as that facilitates the process of obtaining a high quality tin product as a derivative.
In one embodiment, the metal composition of the present invention comprises at most 0.35 wt% arsenic, preferably at most 0.30 wt%, more preferably at most 0.250 wt%, even more preferably at most 0.200 wt. %, even more preferably at most 0.175% by weight,
preferably at most 0.150 weight%, more preferably at most 0.125 weight%, even more preferably at most 0.100 weight%, even more preferably at most 0.075 weight% arsenic.
Since some of the arsenic in the metal composition of the present invention is highly likely to end up in the tin-rich downstream stream that is refined to a high value product, Applicants prefer to recognize the presence of arsenic in the metal composition according to the the present invention as indicated.
However, Applicants have found that a certain amount of arsenic may be acceptable in the metal composition of the present invention due to downstream processing.
This brings the advantage that upstream processes can take up feed streams containing arsenic.
Applicants therefore prefer that the metal composition of the present invention comprises at least 0.0001 wt% arsenic, preferably at least 0.0010 wt%, more preferably at least 0.0050 wt%, with even more preferably at least 0.0100% by weight, even more preferably at least 0.0150% by weight, preferably at least 0.0200% by weight, more preferably at least 0.0250% by weight, with even more preferably at least 0.0300 weight%, even more preferably at least 0.0350 weight%, preferably at least 0.040 weight%, more preferably at least 0.045 weight%, even more preferably at at least 0.050 wt.%, even more preferably at least 0.055 wt.% arsenic.
Applicants have found that the downstream process as described in this document for the metal composition of the present invention is capable of handling the amounts of arsenic as indicated without any problems.
That ability brings the advantage that the process producing the metal composition of the present invention is capable of incorporating feedstock containing arsenic.
The inventors have found that in particular chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti), tungsten (W), copper (Cu), nickel (Ni), iron (Fe), zinc ( Zn) and aluminum (Al), are metals whose presence in the feed to a vacuum distillation step can lead to the interfering metal-metal compounds during the vacuum distillation. Of those potentially disturbing metals, Cu, Ni, Fe, Zn and / or Al are usually the most important to be kept under control. This is because it is more economical to recover tin and / or lead from feedstocks containing Cu, Ni, Fe, Zn and / or Al. Iron and / or aluminum can also, for process reasons, be introduced into the global process upstream of the tin and / or lead recovery step. The presence of Cu, Ni, Fe, Zn and / or Al in the intermediate product from which the tin and / or lead is to be recovered is therefore more likely, and is the result of choices in the upstream process steps and of the selection of the feed materials for the upstream process steps, which are usually of a pyrometallurgical nature.
The inventors have found that the identified problems can be significantly alleviated, and even avoided altogether, by keeping the concentration of these metals in the feed to the distillation step within certain limits where the feed is separated into more concentrated streams by evaporation of at least some of the lead.
The inventors have further found that these potentially harmful metals, and in particular copper, need not be completely excluded from the distillation feed in order to make the feed suitable for vacuum distillation. For example, the inventors have found that the problems identified can be reduced to a practical and economically acceptable level when small amounts of copper remain in the feed to the distillation step. This finding has the advantage that feed streams can be processed that occur as the by-product of the recovery of copper from primary and / or secondary feedstocks, in particular from secondary feedstocks, and more importantly from feedstocks that are end-of-life materials. use cycle.
In one embodiment, the metal composition of the present invention comprises at least 2 ppm by weight of copper, more preferably at least 3 ppm by weight, even more preferably at least 4 ppm by weight, even more preferably at least 5 ppm by weight of copper, preferably at least 6 ppm by weight, more preferably at least 7 ppm by weight, even more preferably at least 8 ppm by weight, even more preferably at least 9 ppm by weight of copper, preferably at least at least 10 ppm by weight, more preferably at least 12 ppm by weight, even more preferably at least 14 ppm by weight, even more preferably at least 15 ppm by weight of copper, preferably at least 16 ppm by weight, more preferably at least 18 ppm by weight and even more preferably at least 20 ppm by weight copper. Applicants have found that the amounts of copper indicated herein can be left in the metal composition of the present invention without sacrificing the utility of the metal composition of the present invention as a feed stream to the vacuum distillation step, and thus without significantly reducing or eliminating the resulting effect, ie without increasing the risk that a vacuum distillation step performed on the metal composition of the present invention would no longer be able to operate in continuous mode for extended periods without encountering problems of metal-metal compounds comprising copper that the distillation operations would can hinder. Applicants have found that the identified problems can be reduced to a practical and economically acceptable level if the small amounts of copper, as indicated, remain in the metal composition of the present invention when used as feed to the distillation step.
The higher allowable content of copper in the metal composition of the present invention, as indicated above, also entails the advantage that the upstream processes from which the feed stream of the process of the present invention is derived have a high freedom of operation. These processes may even be aimed at the pyrometallurgical recovery of copper metal. The processes that produce a by-product according to the metal composition of the present invention can recover high value metals such as tin and / or lead from a much wider variety of possible base materials, primary as well as secondary, including metallic materials at the end of their use cycle.
In one embodiment, the metal composition of the present invention comprises at most 450 ppm by weight of copper, preferably at most 400 ppm by weight, more preferably at most 350 ppm by weight, even more preferably at most 300 ppm by weight, with even more preferably at most 250 ppm by weight, preferably at most 200 ppm by weight, more preferably at most 150 ppm by weight, even more preferably at most 125 ppm by weight, even more preferably at most 100 ppm by weight, preferably at most 80 ppm by weight, more preferably at most 60 ppm by weight, even more preferably at most 40 ppm by weight, even more preferably at most 20 ppm by weight, preferably at most 15 ppm by weight, more preferably at most 10 ppm by weight, even more preferably at most 7 ppm by weight of copper. Applicants have found that the lower the concentration of copper in the metal composition of the present invention, the lower the risk of metal metal compound formation when the metal composition of the present invention is subjected to vacuum distillation to remove at least part of the lead. and antimony in the composition by evaporation. Applicants have further found that the lower the presence of copper in the metal composition of the present invention, the lower the concentration of copper in the product streams from the downstream vacuum distillation. This reduces the burden in further removing copper from those streams on their way to become high performance products, especially in terms of the consumption of chemicals and the amounts of by-products formed, which are preferably upstream of the process in accordance with the present invention. are recycled, and thus also in reducing the potentially damaging effects of those chemicals in recirculation, such as by breaking down the refractory material in a pyrometallurgical process step.
In one embodiment, the metal composition of the present invention comprises at most 0.10% by weight of the total of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W) together, preferably at most 0.010 weight%, more preferably at most 0.005 weight%, even more preferably at most 0.0010 weight%, preferably at most 0.0005 weight%, more preferably at most 0.0001 weight -% of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W) together.
Applicants have found that the risk of forming potentially interfering metal-metal compounds is reduced by keeping the presence of these compounds below lower limits.
In one embodiment, the metal composition of the present invention comprises at least 0.0001 weight% of the total of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W) together, preferably at least 0.0005 wt%, more preferably at least 0.0010 wt%, even more preferably at least 0.0020 wt%, preferably at least 0.0030 wt%, more preferably at least 0.0050% by weight, even more preferably at least 0.010% by weight of the total of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W) together.
Applicants have found that, in order to achieve a successful distillation operation, it is not essential to remove these compounds to very low levels, such as below their detection limit of about 1ppm by weight.
Applicants, on the other hand, have also found that the removal of these compounds to very low levels requires significant additional effort, process steps, chemicals and attention, and that the additional yield in the distillation operation does not justify the magnitude of those extras.
Applicants have found that it is therefore advantageous to keep the presence of these compounds within two measurable limits, as indicated above.
In one embodiment, the metal composition of the present invention comprises at most 0.10 wt.% Zinc (Zn), preferably at most 0.010 wt.%, More preferably at most 0.0050 wt.%, Even more preferably at most 0.0010 wt%, preferably at most 0.0005 wt%, more preferably at most 0.0001 wt% zinc.
Applicants have found that vacuum distillation performed on the metal composition of the present invention can be particularly sensitive to the presence of zinc.
Zinc, to begin with, is able to form metal-metal compounds, thereby contributing to the problem as discussed.
Zinc is also a quite volatile metal, and any zinc present may also become at least partially part of the vapor phase in the distillation equipment.
The heating in the distillation equipment is very often generated electrically, by passing an electric current through heating electrodes within the distillation equipment.
Applicants have found that controlling the presence of zinc within prescribed limits reduces the risk of electrical discharges occurring between two points of these heating electrodes, which may be close to each other and where there is a voltage difference between them.
Such electrical discharges represent a short circuit in the electrical circuit of the heating installation and are often a cause of a forced immediate shutdown.
In the absence or defective fuses, they can cause damage to the transformer and the DC / AC converter in the electrical system.
The discharges damage and can even destroy the electrodes, and in addition can also burn through the wall of the melting furnace, especially when they occur between an electrode and the wall of the melting furnace.
In one embodiment, the metal composition of the present invention comprises at least 0.0001 wt% zinc (Zn), preferably at least 0.0005 wt%, more preferably at least 0.0010 wt%, even more preferably at least 0.0050 wt%, preferably at least 0.010 wt%, more preferably at least 0.050 wt% zinc.
Applicants have found that it is not necessary to remove zinc to excessively low levels in order to sufficiently alleviate the problems that zinc can cause during the vacuum distillation of the metal composition of the present invention. Applicants have found that small amounts of zinc, as indicated, may therefore be left in the metal composition as feedstock for a vacuum distillation. The applicants have found that the desired low levels of zinc in the high-quality end products can be achieved without problems with the specified limits.
In one embodiment, the metal composition of the present invention comprises at most 0.10 wt.% Nickel (Ni), preferably at most 0.050 wt.%, More preferably at most 0.010 wt.%, Preferably at most 0.0050 wt. %, more preferably at most 0.0010% by weight of nickel (Ni). Nickel is a metal that is present in many of the available raw materials for the recovery of non-ferrous metals, especially in secondary feedstock, and especially in end-of-use materials. Thus, it is important in the recovery of non-ferrous metals that the process is capable of handling the presence of nickel. In addition, the pyrometallurgical processes for recovering non-ferrous metals often consume significant amounts of iron as a chemical process substance. It is advantageous to be able to use secondary media containing materials for that purpose. In addition to large amounts of iron, these materials can also contain small amounts of nickel. It is advantageous to be able to handle those types of process chemicals as well. However, nickel is also a metal that can form metal-metal bonds during vacuum distillation. Applicants have found that keeping the amount of nickel present in the metal composition of the present invention within the stated limits can sufficiently reduce the risk of the formation of nickel-containing metal-metal compounds during vacuum distillation of the metal composition. Applicants have further found that it is preferable to reduce the nickel content in the feed to the vacuum distillation step, rather than removing larger amounts of nickel downstream in the process. Such downstream removal of nickel is usually performed in conjunction with the removal of arsenic (As) and / or antimony (Sb), and involves a risk of generating the highly toxic gases arsine (AsHs) and / or Stibine (SbHs). Removing nickel within the specified limits therefore reduces the downstream risk of toxic gas formation, and is thus also a safety and industrial hygiene measure. In one embodiment, the metal composition of the present invention comprises at least 0.0005 weight% nickel (Ni), preferably at least 0.0010 weight%, more preferably at least 0.0050 weight%, preferably at least 0.010 wt%, more preferably at least 0.050 wt% nickel (Ni). Applicants have found that it is not essential to remove nickel to very low levels, such as below the 1 ppm by weight detection limit. Applicants have found that keeping the amount of nickel present in the metal composition of the present invention within the stated limits is capable of sufficiently reducing the risk of the formation of nickel-containing metal-metal compounds during vacuum distillation of the metal composition. the present invention, and also avoids an increased downstream safety and industrial hygiene risk associated with arsine and / or stbin gas generation, while also avoiding unnecessary effort in cleaning the metal composition of the present invention to to prepare them as feedstock for a vacuum distillation.
In one embodiment, the metal composition of the present invention comprises at most 0.10 wt.% Iron (Fe), preferably at most 0.070 wt.%, More preferably at most 0.050 wt.%, Even more preferably at most 0.010 wt. %, preferably at most 0.0050% by weight, more preferably at most 0.0040% by weight, even more preferably at most 0.0030% by weight of iron. Iron is a metal present in many of the available raw materials for the recovery of non-ferrous metals, especially in secondary feedstocks, and especially in end-of-use materials. In addition, the pyrometallurgical processes for recovering non-ferrous metals often consume significant amounts of iron as a chemical process substance. Iron is a metal that can form metal-metal bonds during vacuum distillation. Applicants have found that keeping the amount of iron present in the metal composition of the present invention within the stated limits is capable of sufficiently reducing the risk of ferrous metal-metal compound formation during vacuum distillation of the metal composition. In one embodiment, the metal composition of the present invention comprises at least 0.0001 wt% iron (Fe), preferably at least 0.0002 wt%, more preferably at least 0.0003 wt%, even more preferably at least 0.0005 wt%, preferably at least 0.0010 wt%, more preferably at least 0.0015 wt%, even more preferably at least 0.0020 wt% iron. Applicants have found that it is not essential to remove iron to very low levels, such as below the 1 ppm by weight detection limit. Applicants have found that keeping the amount of iron present in the metal composition of the present invention within the stated limits is capable of a sufficiently large reduction in the risk of the formation of iron-containing metal-metal compounds during vacuum distillation of the metal composition, while also avoiding unnecessary effort in cleaning the metal composition of the present invention to prepare it as a feedstock for a vacuum distillation.
In one embodiment, the metal composition of the present invention comprises at most 0.10% by weight of aluminum (Al), preferably at most 0.050% by weight, more preferably at most 0.010% by weight, even more preferably at most 0, 0.0050 wt%, even more preferably at most 0.0010 wt%, preferably at most 0.0005 wt%, more preferably at most 0.0001 wt% aluminum. Aluminum is a metal present in many available raw materials for the recovery of non-ferrous metals, especially in secondary feedstocks, and especially in end-of-use materials such as beverage can waste. In addition, the pyrometallurgical processes for the recovery of non-ferrous metals can utilize aluminum as a chemical process substance, such as aluminum granulate, for the removal of copper from liquid metal streams of the solder type. Aluminum is a metal that can form metal-metal bonds during vacuum distillation. Applicants have found that keeping the amount of aluminum present in the metal composition of the present invention within the stated limits is capable of sufficiently reducing the risk of the formation of aluminum-containing metal-metal compounds during vacuum distillation of the metal composition. the present invention.
In one embodiment, the metal composition of the present invention comprises at least 0.0001 wt% aluminum (Al), preferably at least 0.0002 wt%, more preferably at least 0.0003 wt%, even more preferably at least 0.0005 wt%, preferably at least 0.0010 wt%, more preferably at least 0.0015 wt%, even more preferably at least 0.0020 wt% aluminum. Applicants have found that it is not essential to remove aluminum to very low levels, such as below the detection limit of 1 ppm by weight. Applicants have found that keeping the amount of aluminum present in the metal composition of the present invention within the stated limits is capable of sufficiently reducing the risk of the formation of aluminum-containing metal-metal compounds during vacuum distillation of the metal composition. the present invention, while also avoiding unnecessary efforts in cleaning the metal composition of the present invention to prepare them as a feedstock for a vacuum distillation. In one embodiment, the metal composition of the present invention is a molten liquid. The present invention relates to the behavior of the metal composition of the present invention as a molten liquid in the pyrometallurgical steps of the process of the present invention, in particular the behavior as a boiling liquid, and how certain elements can influence that behavior. Thus, any difficulties with crystal structures when the streams solidify as part of the process of the present invention on cooling are more or less limited to specific points in the process, where, for example, a molten liquid is poured into anodes as a feedstock for a electrolysis step, or as part of the fractional crystallization step, or when the final high value products are poured into ingots or other marketable shapes.
In one embodiment of the present invention, the metal composition of the present invention comprises at least 10 or even 15 ppm by weight of silver (Ag). Preferably, the metal composition of the present invention comprises at least 20 ppm by weight of silver, more preferably at least 30 ppm by weight, even more preferably at least 40 ppm by weight, preferably at least 50 ppm by weight, more preferably preferably at least 60 ppm by weight, even more preferably at least 70 ppm by weight, preferably at least 80 ppm by weight, more preferably at least 90 ppm by weight, even more preferably at least 95 ppm by weight of silver . Optionally, the metal composition comprises at most 450 ppm by weight of silver, preferably at most 400 ppm by weight, more preferably at most 350 ppm by weight, even more preferably at most 300 ppm by weight, even more preferably at most 250 ppm by weight, preferably at most 200 ppm by weight, more preferably at most 150 ppm by weight, even more preferably at most 120 ppm by weight, even more preferably at most 110 ppm by weight, preferably at least at most 100 ppm by weight, more preferably at most 90 ppm by weight of silver. Applicants have found that a limited amount of silver, as indicated, is acceptable in the metal composition of the present invention because most of it can be evaporated and distilled away from the main influx along with the lead and antimony that evaporate in the downstream vacuum distillation step. , such that ultimately a high-purity tin product can be obtained that meets customer expectations and is also suitable for more demanding end uses. Allowing a certain amount of silver in this stream relaxes the operational objectives of the upstream process steps that produce the rich metal composition of the present invention. On the other hand, the applicants have found that a limited amount of silver is acceptable, and that additional efforts to remove the silver content to very low limits are not justified. Applicants therefore prefer that the metal composition of the present invention comprises at least the minimum content of silver indicated above.
In one embodiment of the present invention, the metal composition of the present invention comprises at least 100 ppm by weight and at most 1000 ppm by weight of indium (In). Preferably, the metal composition of the present invention comprises at least 200 ppm by weight of indium, more preferably at least 300 ppm by weight, even more preferably at least 400 ppm by weight. Optionally, the metal composition of the present invention comprises at most 900 ppm by weight of indium, preferably at most 800 ppm by weight, more preferably at most 700 ppm by weight, even more preferably at most 600 ppm by weight, preferably at most at most 500 ppm by weight, more preferably at most 400 ppm by weight of indium. Applicants have found that the indium can be evaporated in the distillation step, with the result that most of the indium is removed from the tin product precursor as a distillation residue, and that only a small amount of indium can be allowed as only a minor impurity. get into the high purity high quality tin product. Applicants have found that the resulting indium content in the high purity high quality tin product is acceptable for commercialization. In addition, the small amount of indium present in the final tin product has the advantage of lowering the temperature where a phenomenon called "pest" may occur.
Tin pest is an autocatalytic conversion at sufficiently low temperatures from the white beta form of continuous solid tin to the gray alpha tin powder form, which can give the white tin surface a dull gray appearance and possibly, due to the autocatalytic nature of the conversion, even lead to physical disintegration of the tin metal article into a gray powder.
In one embodiment of the method of the present invention, the solder mixture provided in step a) meets at least one and preferably all of the following conditions: comprising at least 45% by weight of lead (Pb) comprising of at least 10% by weight tin (Sn) ° comprising at least 90% by weight tin and lead together ° comprising at least 0.42% by weight of antimony (Sb), and ° comprising at least 0 0.0010 weight% silver (Ag). Preferably, the solder mix comprises at least 50% by weight of lead, more preferably at least 55% by weight, even more preferably at least 60% by weight, even more preferably at least 65% by weight, preferably at least 70% by weight of lead, and optionally at most 95% by weight of lead, preferably at most 90% by weight, more preferably at most 85% by weight, even more preferably at most 80% by weight, preferably at most 75 weight% lead.
Applicants have found that a higher amount of lead is beneficial to the performance of the process steps producing the solder mix because the lead brings the advantage of higher density, and therefore better physical separations.
Applicants prefer to stay below the upper limit as indicated to allow for more tin, which is more valuable than lead, such that a higher economic value can be obtained by incorporating the solder mixture into the process according to the present invention.
In one embodiment, the solder mixture comprises at least 15% by weight of tin, preferably at least 20% by weight, more preferably at least 22% by weight, even more preferably at least
24% by weight, preferably at least 26% by weight, more preferably at least 28% by weight, even more preferably at least 30% by weight of tin. Applicants have found that a higher amount of tin in the solder lowers the melting point of the mixture, making it easier to handle with less heating energy. More tin in the solder mix also results in a higher production of the high performance tin product, and therefore a higher economic value of the production by the method of the present invention. In one embodiment, the solder mixture comprises at least 91% by weight of tin and lead together, preferably at least 92% by weight, more preferably at least 93% by weight, even more preferably at least 94% by weight, even more so more preferably at least 95% by weight, preferably at least 96% by weight, more preferably at least 96.5% by weight, even more preferably at least 97% by weight, even more preferably at least 97, 5 wt%, preferably at least 98 wt%, more preferably at least 98.5 wt%, even more preferably at least 98.7 wt% tin and lead together. The solder mixture is a feed stream for the recovery of high purity tin and lead by the process of the present invention. A higher content of tin and lead together therefore increases the amount of high value products that can be recovered from the solder mix, and reduces the amount of generally inferior by-product streams that can result from the further purification of the distillation products into high value product streams.
In one embodiment, the solder mixture comprises more than 0.42% by weight of antimony (Sb), preferably at least 0.43% by weight, more preferably at least 0.45% by weight, even more preferably at least 0, 47% by weight, preferably at least 0.50% by weight, more preferably at least 0.55% by weight, even more preferably at least 0.60% by weight, even more preferably at least 0, 65% by weight, preferably at least 0.75% by weight, more preferably at least 1.0% by weight, even more preferably at least 1.5% by weight, preferably at least 2.0% by weight %, more preferably at least 2.5% by weight of antimony (Sb). Applicants have found that the solder mix can contain measurable, and even significant, amounts of antimony, within the stated limits, without the presence of antimony significantly impeding the capabilities of the process. Applicants have found that this provides additional operational benefit to the upstream processes from which the feed stream for the process of the present invention is derived. By allowing an amount of antimony in the brazing mixture to be produced as an intermediate stream, and as a feedstock for the method of the present invention, the respective upstream processes are capable of incorporating an amount of raw materials in which antimony is present. Antimony can be present in various primary and / or secondary base materials for non-ferrous metals, as well as in many materials at the end of their use cycle. For example, antimony may be present in lead, which has been used for plumbing since the time of the Romans. Those materials can now be released as breakdown materials, often in combination with copper for pipes and other purposes, and with tin and lead for the solder joints. Allowing an amount of antimony in the solder mix enables the upstream processes to accept such mixed materials at the end of their use cycle. Applicants have found that significant concentrations of antimony are acceptable in the braze mix without causing significant difficulty for the process of the present invention, nor for the downstream processes to further upgrade the currents generated by the vacuum distillation steps.
In one embodiment, the solder mix comprises at least 20 ppm by weight of silver (Ag), preferably at least 50 ppm by weight, more preferably at least 100 ppm by weight, even more preferably at least 125 ppm by weight and even even more preferably, at least 150 ppm by weight of silver. Applicants have found that silver can be acceptable in the process streams of the present invention in amounts significant for such a precious metal,
without hindering the practicability of the process, because it was found that silver did not readily form metal-metal bonds during vacuum distillation. This tolerance to silver allows the upstream processes that produce the solder mixture which is the suitable feed stream for the method of the present invention, and which is the source of the tin-rich metal composition of the present invention, to incorporate base materials containing silver. . The silver tends to concentrate in the first bottoms from which it can be recovered by the fractional crystallization step. The recovery of silver from the bottom stream of the solder mix distillation should therefore provide additional economic value for the process of the present invention.
In one embodiment of the method according to the present invention, the third bottoms product is at least partially and preferably completely recycled to the feed of second distillation step d) and / or to the feed of the fractional crystallization step. Applicants have found that the third bottoms product has an extremely suitable composition to be recycled to at least one of the indicated locations upstream in the process of the present invention, due to its high purity in terms of valuable metals and low content of unintended metals in the third bottoms. This has the advantage that the valuable metals can be recovered in the designated high-quality products without high process costs. Applicants prefer to make the selection of the process site for recycling the third bottoms product dependent on the silver content of the stream, because the fractional crystallization step is capable of removing silver and thereby the accumulation of silver in the stream. prevent the process beyond acceptable levels.
In one embodiment of the method of the present invention, a fresh feed containing lead is added to the feed of the second distillation step d). This has the advantage that the evaporation of antimony is promoted in the second distillation step, thereby improving the quality of the separation that can be obtained in the second distillation step. In one embodiment of the method of the present invention, a fresh feed containing lead is added to the feed of the third distillation step e). Applicants have found that some amount of lead is also desirable in the feed to the third distillation stage, because the lead promotes the evaporation of antimony. This has the advantage that the evaporation of antimony is promoted in the third distillation step, thereby improving the quality of the separation that can be obtained in the third distillation step. The lead dilutes the vapor phase in the distillation step and thus acts as a kind of carrier for the antimony. As a result, the lead promotes the recovery of most of the antimony in the third concentrated lead stream and thereby contributes to the efficient production of the high quality hard lead product. For example, the second concentrated lead stream may contain about 40/40/20 weight% Pb / Sn / Sb. Applicants have found that this feed composition can be further improved. Applicants prefer to dilute the feedstock for the third distillation step by adding lead-containing fresh feed to about 10-12 weight% Sb and / or 18-10 weight% Sn. Applicants have found that this produces more vapor phase in the third distillation step, and also lowers the melting point of the feed. This allows for better removal of Sb to the third concentrated lead stream as the top stream of the Sn remaining in the third bottoms. The additional advantage is that if the third bottoms product is recycled to a location upstream of the second distillation stage, the better separation in the third distillation stage reduces the amount of antimony circulating over the second and third distillation stages.
In one embodiment, the method of the present invention further comprises the step of removing at least one contaminant selected from the metals arsenic and tin from the third concentrated lead stream, thereby producing a purified hard lead stream as the hard lead product. Applicants have found that the third concentrated lead stream can be further refined by means known in the art to obtain a purified hard lead stream as the hard lead product.
In one embodiment of the method of the present invention, the at least one impurity selected from arsenic and tin is removed by treating the third concentrated lead stream at a temperature of less than 600 ° C with a second base and a second oxidant, resulting in the formation of a fourth supernatant scratch containing a metalate compound of the respective contaminant metal, followed by the separation of the fourth supernatant scratch from the purified hard lead stream.
The third concentrated lead stream is preferably contacted with a combination of NaOH and NaNOs. The chemical process aimed at with these chemicals can be represented by the following reactions: 5 Pb + 6 NaOH + 4 NaNO: 3 -> 5 Na2PbO3 + 2 Ns + 3 H: O (1) 5 Nas2PbOs + 4 As + 2 NaOH -> 4 NasAsO4 + 5 Pb + H: O (I) Na2PbOs3 + Sn -> Na2SnO3 + Pb (IN) Crucial for this chemical process is the formation of the intermediate sodium plumbate (Na: PbOs) by reaction (|). This plumbate as intermediate is capable of reacting with the impurities As and / or Sn according to the respective reactions (II) to (III) and each time entraps them in the respective sodium metalate compound, while releasing the Pb again. The sodium metalate compounds formed are sodium arsenate and sodium stannate, respectively.
The respective sodium metalate compounds collect in a supernatant phase, commonly referred to as the "scratch" or sometimes also "slag". Those terms are often used interchangeably, although the term "slag" is generally used for a liquid phase, while "scratch" usually means a phase of a less fluid, firmer consistency. The term “snail” is more common in the context of the production of non-
ferrous metals with a high melting point, such as copper, and thus usually refers to a fluid, which often mainly comprises metal oxides. The term "scratch" is more commonly used in the context of lower melting point non-ferrous metals such as Sn, Pb, Zn, Al, which are often in solid or dust form. However, the boundary between these two terms in terms of consistency is not always clear.
The fourth supernatant scratch can be skimmed, and processed further, preferably in an upstream process step, to recover at least some of its components.
The hard lead refining step is preferably carried out at a temperature of at most 550 ° C, preferably at most 500 ° C, more preferably at most 450 ° C and optionally at least 370 ° C, preferably at least 390 ° C, with more preferably at least 400 ° C. Respecting the stated temperature upper limit has the advantage that the feed stream, since that stream usually becomes available from the third vacuum distillation step at a temperature of about 960-970 ° C, is cooled. This cooling has the advantage that any copper that has ended up in the top condensate of the third vacuum distillation step can come out of solution and can float to the surface, so that it can be removed by skimming, possibly together with the skimming of the fourth supernatant scratch. Performing this step at a temperature that meets the lower limit brings the advantage of faster reaction kinetics. Any additional copper remaining after cooling and skimming can be removed by adding sulfur to form a scratch containing CuS, and that scratch containing CuS can also be removed from the liquid metal by skimming.
In one embodiment of the method of the present invention, the fourth supernatant scratch comprises at most 1.0% by weight of chlorine, and preferably at most 1.0% by weight of total halogens.
Applicants have found that the stated low content of chlorine and / or other halogens in the fourth supernatant scratch makes the scratch more suitable for introduction into an upstream pyrometallurgical process step, preferably to a process step in which at least one of the sodium metalates of Sn and As can be reduced to the respective metal Sn or As, preferably also getting the Pb in its elemental form.
The fourth supernatant scratch is more acceptable in a pyrometallurgical process step due to its limited chlorine and / or halogen content. The low chlorine content of the scratch reduces the risk of valuable metals being entrained in the exhaust gas of a pyrometallurgical process step in which an exhaust gas is produced, and thus also reduces the risk of sticky solid deposits forming on cooling devices, filters and other pieces of equipment in the exhaust gas treatment equipment associated with such a pyrometallurgical process step.
In one embodiment of the method of the present invention, the fourth supernatant scratch is recycled to a process step upstream of the first vacuum distillation step.
This entails the advantage that the metal values, in particular any entrained lead, can be easily recovered as part of one of the intended high-quality products of the method according to the present invention. Much of the lead entrained in the fourth supernatant scratch may preferably become part of the high performance soft lead product or, if necessary, be recycled to the third concentrated lead stream to become part of the high performance hard lead product.
The advantage of this scratch recycle capability is that it allows for a general process of much lower complexity, especially when compared to the highly complex wet chemical recovery ranges described in U.S. Patent No. 1,674,642.
The suitability of the fourth supernatant scratch to be recycled to a pyrometallurgical process step makes it possible to simultaneously remove, in a single process step, more than one impurity from the first concentrated lead stream, in this case As and Sn together.
This represents a significant improvement over the many complex lead refining steps described in the art.
In one embodiment of the method of the present invention, the second oxidant is an oxidant that is stronger than air.
Applicants preferably use an oxidant stronger than air containing 21% oxygen by volume.
Applicants have found that the selection of a sufficiently strong oxidant has the advantage that the desired chemical processes proceed faster.
The higher reaction kinetics entails the advantage that a shorter residence time is required to obtain a desired conversion, such that a smaller reaction vessel can be used, or that a given reaction vessel can handle a higher flow rate.
In one embodiment of the method of the present invention, the second oxidant is selected from NaNO3, Pb (NO3) 2, KNOs, ozone, nitric acid, sodium and potassium manganate, sodium and potassium (per) manganate, chromic acid, calcium carbonate (CaCOs) , sodium and potassium dichromate, preferably NaNO3, CaCO3, Pb (NOs) 2 or KNO3, more preferably NaNOs.
Applicants note that the oxidants in this list are most suitable, and the preferred elements of the list are even more suitable.
In one embodiment of the method of the present invention, the second base is selected from NaOH, Ca (OH): and Na: CO: and combinations thereof, preferably NaOH.
Applicants have found that the use of a strong base contributes to fast reaction kinetics and thereby allows smaller reaction equipment and, consequently, lower capital costs.
Since the process does not require selective removal of any of the target impurities, the second base need not exhibit, nor be made selective, for a specific element of the group Zn, As and Sn.
Applicants prefer a (hydr) oxide as the second base, as it avoids additional by-products such as CO 2. The build-up of carbon dioxide can lead to foaming on the bath and to a scratch of much greater volume, which can spill over and pose a safety risk. Applicants prefer to use NaOH because it does not generate carbon dioxide like sodium carbonate, and because of its wider availability. Applicants prefer to use sodium hydroxide in solid form because it facilitates phase separation between the masses to be skimmed off and the molten lead stream. Sand can be added to stiffen the scratch and make it easier to remove. Applicants have found that NaOH as the second base has the advantage of promoting agglutination of the floating scoop masses, which facilitates the selective removal of the fourth supernatant scratch. In one embodiment of the method according to the present invention, in addition to NaOH and NaNOs, an amount of Ca (OH) »is also added as a reagent for treating the third concentrated lead stream. Applicants have found that this improves the physical characteristics of the scratch as it becomes "drier" and less adheres to the equipment. A "drier" scratch is a scratch that contains less liquid, the latter being entrained molten lead from the underlying liquid phase. A “drier” scratch therefore brings the advantage of an improved separation between lead and scratch, and that less (metallic) lead is removed with the fourth supernatant scratch and has to be recovered.
In one embodiment of the method of the present invention, the weight ratio of second base to second oxidant is in the range of 1.5: 1.0 to 4.0: 1.0, preferably in the range of 1.8: 1 to 2.5: 1 when NaOH is used as the second base and NaNO: is used as the second oxidant, respectively, and recalculated by stoichiometry for when other compounds are used as second base and / or second oxidant, wherein the weight ratio of second base to second oxidant is preferably at most 2.90 for when NaOH is used as the second base and NaNO: is used as the second oxidant, respectively, and recalculated by stoichiometry for when other compounds are used as second base and / or second oxidant.
Applicants have found that respecting this prescribed range for the ratio of second base to second oxidant brings the advantage that the viscosity of the fourth supernatant scratch is sufficiently high, but that the scratch does not become too hard.
Applicants prefer to stay below the upper limit of the ratio as indicated, which has the advantage of limiting the build-up of heat of reaction and avoiding overheating in the hard lead refining step.
The smaller amount of strong base also makes the fourth supernatant scratch more acceptable for recycle to an upstream pyrometallurgical process step, because the NaOH or other strong base is corrosive to the refractory lining of the equipment of that step.
Less NaOH or less of the other base can therefore result in less wear and damage to the refractory lining of the equipment to which the fourth supernatant scratch is recycled.
In one embodiment of the method of the present invention, the second base and the second oxidant are mixed together before they are introduced into the treatment.
This brings the advantage of a simplified and easier addition of the chemicals, as compared to the contact and / or addition methods described in the art.
The Applicants have found that this treatment step can be performed in a single operation without any problems.
In particular, when the fourth supernatant scratch is intended to be recycled to a pyrometallurgical process step, Applicants have found that the recovered impurity and lead present in sodium plumbate, if any, left over from reaction (I) and which has not been reacted away by any of the reactions (II) to (Ill), and with lead that may have been physically entrained with the fourth supernatant scratch after its separation from the refined hard lead product, can be processed together and recovered without any problems. The method of the present invention is also less sensitive than the methods in the art to a limited presence of lead, entrained or in the form of its oxide salt, in the scratch. Such additional lead recycle represents only a limited inefficiency in the process, provided the amounts are kept within limits.
In one embodiment of the method of the present invention, the third concentrated lead stream comprises at least 0.50 wt.% And at most 15.0 wt.% Antimony. The presence of antimony in the range as indicated has the advantage of enhancing the properties of the high performance hard lead product derived from the third concentrated lead stream in view of the end uses where hard lead is preferred over soft lead.
In one embodiment, the method of the present invention includes the fractional crystallization step. This brings the advantage that the process also produces a by-product that is rich in silver and which can contribute to the economic value of the products produced by the process of the present invention. In one embodiment of the process of the present invention, a suitable fresh feed is also added as an additional feed to the crystallizer step.
In one embodiment of the method of the present invention, the feed to the fractional crystallization step comprises at least 0.1 wt.% And at most 20.0 wt.% Lead.
Applicants have found that the presence of lead in the range as indicated brings significant benefits.
One advantage is that a minimal presence of lead, as indicated, in the feed to the fractional crystallization step is a process stimulus for the fractional crystallization step.
A mixture of 38.1 wt.% Pb and 61.9 wt.% Sn has a melting temperature of only 183 ° C, ie lower than the melting temperatures of pure lead (327.5 ° C) and of pure tin (232 ° C) . The 38.1 / 61.9 percent Pb / Sn mixture is called a eutectic composition. When a molten binary mixture of tin and lead with a composition different from the eutectic composition is cooled, crystals are formed which have a composition even more different from the eutectic composition, leaving a liquid phase with a composition closer to the eutectic composition. eutectic composition. The applicants have found that this phenomenon makes it possible to separate a suitable mixture of lead and tin, by fractional crystallization, into, on the crystal side, a product enriched in Sn or Pb, and on the liquid side, a product with a composition closer to the eutectic composition. The minimal presence of lead in the starting material thus makes it possible to separate a tin product of higher purity at the crystal end from a liquid product containing more lead than the starting material by fractional crystallization.
Applicants have further found that, with a lead / tin mixture containing more tin than the eutectic composition of tin with lead, and if that mixture further contains relatively small amounts of silver, the silver tends to be left behind in a fractional crystallization of the mixture. to stay with most of the lead in the liquid phase, and that is tin crystals with a much lower content of silver and lead. Applicants have found that the lead acts as a carrier for the silver. Applicants have further found that, in such a fractional crystallization process, the concentration of the silver can be increased from a lower content in the feed mixture to a higher content in the liquid crystallizer product.
Applicants have further found that when the amount of lead in the feed to the fractional crystallization step is maintained below the upper limit as indicated, the increase in the concentration of silver from feed stream to liquid crystallizer product can be significantly improved. Applicants have found that this allows the processing of feedstocks containing relatively low concentrations of silver, and yet, at the same time, obtaining a limited volume product stream that is significantly enriched in silver such that that stream becomes suitable for further processing with the with a view to recovering the silver.
Preferably, the amount of lead in the feed to the fractional crystallization step is at least 0.15 wt.%, Preferably at least 0.20 wt.%, More preferably at least 0.30 wt.%, Even more preferably at least. at least 0.40 wt%, even more preferably at least 0.50 wt%, preferably at least 0.60 wt%, more preferably at least 0.70 wt%, even more preferably at least at least 0.80 wt%, preferably at least 0.90 wt%, and more preferably at least 1.00 wt%. The lead stimulates the fractional crystallization step, and acts as a solvent for the silver that the step aims to remove from the main raw tin stream. The silver tends to lag most of the lead and enter the bleed stream, and the composition of the bleed stream approaches the eutectic composition of 38.1 wt% / 61.9 wt% Pb / Sn. Respecting this lower limit for the presence of Pb promotes the feasibility of the fractional crystallization step, for example by ensuring that there is sufficient liquid phase present in the crystallizer steps where good and intimate contact between liquid and crystals is desired to obtain a effective separation. Preferably, the feed to the fractional crystallization step comprises at most 20.0 weight% Pb, preferably at most 18.0 weight%, more preferably at most 16.0 weight%. even more preferably at most 14.0 wt%, preferably at most 12.0 wt% Pb, preferably at most 10.0 wt%, more preferably at most 8.0 wt%. even more preferably at most 7.5% by weight, preferably at most 6.5% by weight of Pb, preferably at most 6.0% by weight, more preferably at most 5.5% by weight. even more preferably at most 5.25% by weight, preferably at most 5.00% by weight, more preferably at most 4.90% by weight. even more preferably at most 4.80% by weight, preferably at most 4.00% by weight, more preferably at most 3.00% by weight. even more preferably at most 2.00 wt% Pb, preferably at most 1.50 wt% Pb. With lower amounts of lead in the feed to the fractional crystallization step, Applicants have found that the volume of first silver-enriched liquid bleed product can be kept lower and the concentration of silver in the bleed stream can be kept higher. This has the advantage that silver can be recovered from more dilute feedstocks, while at the same time producing a first silver-enriched liquid tapping product that is sufficiently rich in silver to allow effective and efficient recovery of the silver therefrom. The lower volume and higher silver content of the first silver-enriched liquid draw-off product is also beneficial to the efficiency and effectiveness of the process steps for recovering the silver from the first silver-enriched liquid draw-off product. In one embodiment of the method of the present invention, the concentration of lead in the feed to the fractional crystallization step is at least 3.0 and preferably at least 5.0 times the concentration of silver in the feed to the fractional crystallization step, preferably at least 4.0, more preferably at least 5.0, even more preferably at least 6.0, and even more preferably at least 7.0 times the concentration of silver in the feed. Applicants have found that respecting this lower limit for the ratio of the concentration of lead to silver in the feed to the fractional crystallization prevents the composition of the first silver-enriched liquid tap product from approaching a eutectic composition in the ternary diagram of lead / tin / silver.
In one embodiment of the method of the present invention, the feed to the fractional crystallization step comprises at least 10 ppm by weight of silver (Ag), preferably at least 20 ppm by weight, more preferably at least 25 ppm by weight, including more preferably at least 30 ppm by weight, even more preferably at least 50 ppm by weight, preferably at least 100 ppm by weight, more preferably at least 200 ppm by weight, even more preferably at least
300 ppm by weight, even more preferably at least 500 ppm by weight, preferably at least 750 ppm by weight, more preferably at least 1000 ppm by weight, even more preferably at least 1100 ppm by weight, even more preferably more preferably at least 1200 ppm by weight of silver, and optionally at most 0.85 weight% silver, preferably at most 0.80 weight%, more preferably at most 0.75 weight%, even more preferably at most 0.70 wt%, even more preferably at most 0.65 wt%, preferably at most 0.60 wt%, more preferably at most 0.55 wt%, even more preferably at most 0.50 wt%, even more preferably at most 0.45 wt%, preferably at most 0.40 wt%, more preferably at most 0.35 wt%, even more preferably at most 0.30% by weight, even more preferably at most 0.25% by weight, preferably at most 0.20% by weight, more preferably at most n at most 0.175% by weight or at most 1750 ppm by weight, even more preferably at most 1600 ppm by weight, even more preferably at most 1500 ppm by weight.
A higher content of silver in the crude tin mixture as feed to the fractional crystallization step has the advantage that more silver is available to be recovered, and that the first silver-enriched liquid bleed product from the fractional crystallization step may contain more silver, and thus not only can represent a higher economic value, but also that the recovery of silver from it can be made more efficient and effective.
Respecting the upper limit for the content of silver entails the advantage that the tapping composition has a lower risk of approximating the eutectic composition in the ternary diagram for Pb / Sn / Ag.
The upper limit on the silver in the crude tin mixture as feed to the fractional crystallization step also has the advantage that it allows a significant increase in concentration from feed stream to first silver enriched liquid bleed product from the crystallizer, such that the process is able to to include feedstocks with a lower content of silver, ie which can be very dilute with respect to Ag.
In one embodiment of the method of the present invention, the first tin-enriched product comprises at least 0.10% by weight of lead, preferably more than 0.10% by weight, more preferably at least 0.15% by weight, even more preferably, at least 0.20 weight% lead. This has the advantage that this stream is more suitable as feedstock for the second distillation step in which lead and antimony are to be removed by evaporation from the main stream, and in which the more volatile lead promotes the evaporation of antimony by diluting the vapor phase in the distillation step. The lead thus acts as a kind of carrier for the antimony. Applicants have found that the lead, in combination with the antimony and after the third distillation step, yields a top product suitable for deriving a high quality hard lead product.
In one embodiment of the method of the present invention, the feed to the fractional crystallization step further comprises at least 1 ppm by weight of at least one metal selected from copper, iron, bismuth, nickel, zinc, gold, indium and arsenic. The presence of traces of copper and iron are a strong indication that the solder mixture has been obtained as a by-product of copper production by a pyrometallurgical process. Accepting small amounts of the listed metals provides feedstock flexibility for the upstream processes that provide the braze mix as the base stock for the first distillation step. Applicants have found that many of the listed metals exhibit a tendency to at least partially end up in the first silver-enriched liquid draw-off product of the crystallization step, and sometimes even concentrate in the first silver-enriched liquid draw-off product, and therefore less often than not. be removed at least partially from the main tin stream, from which a high purity tin product can then be more easily derived.
In one embodiment of the method of the present invention, the feed to the fractional crystallization step comprises at least 99.0% by weight together of tin, lead, antimony and silver, preferably at least 99.1% by weight, more preferably at least at least 99.1% by weight. least
99.2% by weight, even more preferably at least 99.3% by weight, even more preferably at least 99.4% by weight, preferably at least 99.5% by weight, more preferably at least 99.6% by weight, even more preferably at least 99.7% by weight together of tin, lead, antimony and silver. This has the advantage that the feed to the fractional crystallization step contains less of other materials, which could potentially place a burden on the further processing of the crystallizer products and / or could form a contamination in at least one of the high-value products which can be derived therefrom.
In one embodiment of the process of the present invention, the second bottoms product is further refined to obtain a high purity high quality tin product. Applicants have found the second bottoms product to be highly suitable for further refining to obtain a high purity tin product of excellent economic value.
In one embodiment of the method of the present invention the second bottoms product is treated with aluminum metal, preferably in stoichiometric excess to the amount of antimony present, preferably in combination with mixing and cooling the reacting mixture to less than 400 ° C followed by separating the scratch containing Al / Sb / As formed by the treatment. Applicants have found that the aluminum readily forms solid metal-metal compounds with trace impurities in the tin stream, especially with antimony. Applicants prefer to use a stoichiometric excess of aluminum because it is more effective in removing antimony and removes any remaining aluminum with little trouble, as described later in this document. Mixing and cooling stimulates the reaction and aids the separation of the formed solids from the molten tin. Applicants prefer to cool to a temperature of about 250 ° C because they have found that it provides a better balance between reaction kinetics promoted by high temperatures and improved separation promoted by lower temperatures.
The formed scratch, containing Al / Sb / As, can be skimmed off and recycled to an upstream pyrometallurgical process step.
Applicants prefer to collect the scratch containing Al / Sb / As in steel drums that are closed and sealed to avoid contact of the scratch with water, which could lead to the formation of the highly toxic arsine gases and / or stibine.
The aluminum is preferably added in granular form, which provides a large surface area without causing dust problems.
Applicants prefer to add the granules to a bath without vigorous mixing, preferably static, to prevent wet granules from exploding from the sudden contact with the hot liquid tin.
In an embodiment of the method according to the present invention, the second bottom product, after the treatment with aluminum and preferably also after the removal of the scratch containing Al / Sb / As, is treated with a third base, which is preferably selected from NaOH, Ca (OH) 3 and NasCO3 and combinations thereof, more preferably NaOH, followed by separating the scratch containing base formed by the treatment.
Applicants prefer to skim off the scratch containing Al / Sb / As before the addition of the third base in order to require less of that base.
Applicants prefer to use NaOH as the third base because it forms a sodium aluminate scratch that is more acceptable for recycling to an upstream pyrometallurgical process step.
Applicants prefer to perform this treatment iteratively, in successively repeated steps, and based on an analysis of the aluminum content in the tin stream, in order to save on the consumption of chemicals.
The contemplated chemistry can generate hydrogen gas, so Applicants prefer to throw a quantity of sulfur grains onto the reacting liquid such that the sulfur ignites at the high process temperatures and burns the hydrogen that may have evolved from the reaction.
The scratch can be stiffened by adding silicon dioxide, preferably in the form of sand.
In one embodiment of the method of the present invention, after the treatment with the third base, the second bottom product is treated with sulfur, followed by the separation of the scratch containing S formed by the treatment. The sulfur reacts with the sodium and forms a Na2S scratch. At the end of this treatment, Applicants prefer to intensify the stirring speed to attract more oxygen from the ambient air, oxidizing the sulfur remaining after the reaction, and the sulfur oxides that are formed can easily escape from the liquid end product.
In one embodiment, the method of the present invention comprises the step of removing at least one impurity selected from the metals arsenic, tin and antimony from the first concentrated lead stream obtained in the first distillation step b), whereby a purified soft lead stream is produced as the soft lead product. Applicants have found that, by means known in the art, a high performance soft lead product can be derived from the first concentrated lead stream by removing arsenic, tin and / or antimony therefrom. Preferably, Applicants perform this soft lead refining step as described in copending patent application number EP19154606.8.
In one embodiment of the method of the present invention, the at least one impurity is removed by treating the first concentrated lead stream at a temperature of less than 600 ° C with a first base and a first oxidant, resulting in the formation of a third supernatant scratch containing a metalate compound of the respective contaminant metal, followed by separating the third supernatant scratch from the purified soft lead stream, which becomes the high performance soft lead product of the process of the present invention.
The first concentrated lead stream is preferably contacted with a combination of NaOH and NaNOs. The chemical process contemplated with these chemicals is the same as outlined above, with reactions (I) through (Ill), with the addition of the following reaction: NazPbO; + 3 H2O + 4 Sb -> 4 NaSbO3 + 6 NaOH + 5 Pb (IV) 5 The sodium metalate compounds formed now also include sodium antimonate as the target compound. The respective sodium metalate compounds collect in the third supernatant scratch. This scratch can be skimmed off and processed further, preferably in an upstream pyrometallurgical process step, to recover at least some of its components.
In one embodiment of the method according to the present invention, the soft lead refining step is performed at a temperature of at most 550 ° C, preferably at most 500 ° C, more preferably at most 450 ° C and optionally at least 370 ° C, preferably at least 390 ° C, more preferably at least 400 ° C. Respecting the stated temperature upper limit has the advantage that the feed stream, since that stream usually becomes available from the first distillation step at a temperature of about 960-970 ° C, is cooled. This cooling has the advantage that any copper that has ended up in the first concentrated lead stream as the top stream of the first vacuum distillation step can come out of solution and float, so that it can be removed by skimming, possibly together with the skimming of the third supernatant scratch. Performing this step at a temperature that meets the lower limit brings the advantage of faster reaction kinetics. Any additional copper remaining after cooling and skimming can be removed by adding sulfur to form a scratch containing CuS, and that scratch containing CuS can also be removed from the liquid metal by skimming.
In one embodiment of the method of the present invention, the first oxidant is stronger than air. Applicants preferably use an oxidant that is stronger than air
21 volume% oxygen. The applicants have found that the selection of a sufficiently strong oxidant has the advantage that the desired chemical processes proceed faster. The higher reaction kinetics entails the advantage that a shorter residence time is required to obtain a desired conversion, such that a smaller reaction vessel can be used, or that a given reaction vessel can handle a higher flow rate.
In one embodiment of the method of the present invention, the third supernatant scratch contains at most 1.0% by weight of chlorine, and preferably at most 1.0% by weight of total halogens.
Applicants have found that the stated low content of chlorine and / or other halogens in the third supernatant scratch makes the scratch more suitable for introduction into an upstream pyrometallurgical process step, preferably to a process step where at least one of the sodium metalates of Sn , Sb and As can be reduced to the respective metal Sn, Sb or As, preferably also getting the Pb in its elemental form.
The third supernatant scratch is more acceptable in a pyrometallurgical process step due to its limited chlorine and / or halogen content. The low chlorine content of the scratch reduces the risk of valuable metals being entrained in the exhaust gas of a pyrometallurgical process step in which an exhaust gas is produced, and thus also reduces the risk of sticky solid deposits forming on cooling devices, filters and other pieces of equipment in the exhaust gas treatment equipment associated with such a pyrometallurgical process step.
In one embodiment of the method of the present invention, the third supernatant scratch is recycled to a process step upstream of the first vacuum distillation step.
This entails the advantage that the metal values, in particular any entrained lead, can be easily recovered as part of one of the intended high-quality products of the method according to the present invention. Much of the lead entrained in the third supernatant scratch may preferably become part of the premium soft lead product or, if necessary, may be made to enter the third concentrated lead stream to become part of the premium hard lead product.
The advantage of this scratch recycle capability is that it allows for a general process of much lower complexity, especially when compared to the highly complex wet chemical recovery ranges described in U.S. Patent No. 1,674,642.
The ability of the third supernatant scratch to be recycled to a pyrometallurgical process step makes it possible to simultaneously, in a single process step, remove more than one impurity from the first concentrated lead stream, in this case As, Sb and Sn together. This represents a significant improvement over the many complex lead refining steps described in the art.
In one embodiment of the method of the present invention, the first oxidant is selected from NaNO3, Pb (NO3) 2, KNOs, ozone, nitric acid, sodium and potassium manganate, sodium and potassium (per) manganate, chromic acid, calcium carbonate (CaCOs) , sodium and potassium dichromate, preferably NaNO3, CaCO3, Pb (NOs) 2 or KNO3, more preferably NaNOs. Applicants note that the oxidants in this list are most suitable, and the preferred elements of the list are even more suitable.
In one embodiment of the method of the present invention, the first base is selected from NaOH, Ca (OH) 3 and Na: CO: and combinations thereof, preferably NaOH. Applicants have found that the use of a strong base contributes to fast reaction kinetics and thereby allows smaller reaction equipment and, consequently, lower capital costs. Since the process does not require selective removal of any of the target impurities, the first base need not exhibit, nor be made selective, for a specific element of the group Zn, As, Sb and Sn. Applicants prefer a (hydr) oxide as the first base, as it avoids additional by-products such as CO 2.
The build-up of carbon dioxide can lead to foaming on the bath and to a scratch of much greater volume, which can spill over and pose a safety risk.
Applicants prefer to use NaOH because it does not generate carbon dioxide like sodium carbonate, and because of its wider availability.
Applicants prefer to use sodium hydroxide in solid form because it facilitates phase separation between the masses to be skimmed off and the molten lead stream.
Sand can be added to stiffen the scratch and make it easier to remove.
Applicants have found that NaOH as the first base has the advantage of promoting agglutination of the floating scoop masses, which facilitates the selective removal of the third supernatant scratch.
In one embodiment of the method according to the present invention, in addition to NaOH and NaNOs, an amount of Ca (OH) »is also added as a reagent for treating the first concentrated lead stream.
Applicants have found that this improves the physical characteristics of the third supernatant scratch, as it becomes "drier" and less adheres to the equipment.
A "drier" scratch is a scratch that contains less liquid, the latter being entrained molten lead from the underlying liquid phase.
A “drier” scratch therefore brings the advantage of an improved separation between liquid lead and scratch, and that less (metallic) lead is removed with the third supernatant scratch and has to be recovered.
In one embodiment of the method of the present invention, the weight ratio of first base to first oxidant used is in the range of 1.5: 1.0 to 4.0: 1.0, preferably in the range from 2: 1 to 3: 1 when NaOH is used as the first base and NaNO: 3 is used as the first oxidant, respectively, and recalculated by stoichiometry for when other compounds are used as the first base and / or first oxidant.
Alternatively, Applicants prefer to use a molar ratio of the first base to the first oxidant in the range of 3.18-8.5, preferably 4.25-6.38. Applicants have found that respecting this prescribed range for the ratio of first base to first oxidant has the advantage that the viscosity of the third supernatant scratch is sufficiently high, but that the scratch does not become too hard.
In one embodiment of the method of the present invention, the weight ratio of first base to first oxidant used is at most 2.90 for when NaOH is used as the first base and NaNO3 is used as the first oxidant, respectively, and recalculated by stoichiometry for when other compounds are used as first base and / or first oxidant. Preferably the applicants employ a ratio of at most 2.80, more preferably at most 2.70, even more preferably at most 2.60, preferably at most 2.50, more preferably at most 2.40 , even more preferably at most 2.30, preferably at most 2.25, more preferably at most 2.20, even more preferably at most 2.15, preferably at most 2.10, more preferably at most at most 2.05, even more preferably at most 2.00. These limits apply to NaOH as the first base and NaNOs as the first oxidant, and can be converted by stoichiometry in case one or more other compounds are used. The limits can also be converted to a molar ratio using the factor “85/40. Applicants prefer to limit the amount of first base, and in particular the amount of NaOH, in view of recycling the third supernatant scratch to an upstream pyrometallurgical process step, because the NaOH or other strong base is corrosive for the refractory lining of the equipment of that step. Less NaOH or less of the other base can therefore result in less wear and tear and damage to the refractory lining of the equipment to which the third supernatant scratch is recycled.
In one embodiment of the method of the present invention, the first concentrated lead stream comprises at least 0.0400 weight% and at most 0.3000 weight% tin. Applicants prefer to have in this stream at least 0.0500% by weight of tin, preferably at least 0.0700% by weight, more preferably at least 0.0800% by weight, more preferably at least 0.0900 weight%, even more preferably at least 0.100 weight% tin. Optionally, applicants prefer to have at most 0.2500 wt% tin present, preferably at most 0.2250 wt%, more preferably at most 0.2000 wt%, even more preferably at up to 0.1500% by weight of tin.
Applicants have found that the presence of the prescribed amount of tin in the first concentrated lead stream as the top stream of the first vacuum distillation step represents an advantageous balance between the amount of Sn to be removed in the soft lead refining step and the amounts of Sb still ending up in the soft lead refining step and must be removed in the soft lead refining step to obtain a purified soft lead stream. Sn is easier to remove in the soft lead refining step than Sb because it reacts more readily (II! Or IV) to form the corresponding sodium metalate.
In an embodiment of the method according to the present invention, the first distillation step b) is carried out at a pressure of at most 15 Pa absolute, preferably at most 10 Pa, more preferably at most 5 Pa, even more preferably at most 1 Pa. , even more preferably at most 0.7 Pa absolute. Applicants have found that a lower pressure is beneficial because it promotes separation of the more volatile metals from the less volatile metals. The additional advantage is that the separation can be performed at a lower temperature compared to the situation when a higher operating pressure is used. This has the advantage that processing is also more energy-efficient.
In one embodiment of the method according to the present invention, the first vacuum distillation step b) is performed at a temperature of at least 800 ° C, preferably at least 850 ° C, more preferably at least 900 ° C, even more preferably at least 930 ° C. Applicants have found that a higher temperature promotes separation of the metals into a vapor phase and a residual liquid phase, for example, because the higher temperature increases the volatility of the more volatile metal or metals. The higher temperature can also increase the difference in volatility between the metal or metals to be vaporized and the metal or metals to be kept in the liquid phase. Applicants have further found that a higher temperature also reduces the risk that metal-to-metal compounds can form and / or adhere to the walls of the equipment, possibly hindering the distillation operations.
The vacuum distillation steps in the process of the present invention can be carried out in batches, and such vacuum batch distillation techniques are described in patents CN101696475, CN104141152, CN101570826, and in Yang et al, Recycling of metals from waste Sn-based alloys by vacuum separation. Transactions of Nonferrous Metals Society of China, 25 (2015), 1315-1324, Elsevier Science Press. The vacuum distillation of metals can also be performed in continuous mode, and such continuous distillation techniques are described in patents CN102352443, CN104651626 and CN104593614. Applicants prefer to perform the first distillation step as described in WO 2018/060202 A1. In one embodiment of the method of the present invention, the feedstock for the first distillation step b) is a crude brazing composition comprising at least 0.16% and optionally at most 10% by weight of the total chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti), tungsten (W), copper (Cu), nickel (Ni), iron (Fe), aluminum (Al) and / or zinc (Zn), where the feed is available is at a temperature of at least 500 ° C, the method further comprising the step of pretreating the crude brazing composition before step b) to form the braze mixture as a feedstock for the first distillation step b), the pretreatment step comprising the steps of f) cooling the crude solder composition to a temperature not exceeding 825 ° C, to produce a bath containing a first supernatant scratch that floats by gravity on a first liquid molten metal phase, 9) adding a c hemic substance selected from an alkali metal and / or an alkaline earth metal, or a chemical compound comprising an alkali metal and / or an alkaline earth metal, attached to the first liquid molten metal phase to form a bath containing a second supernatant scratch due to gravity floating on a second liquid molten metal phase, and h) removing the second scratch from the second liquid molten metal phase.
This brings the advantage that the first distillation step can be performed without the formation of metal-metal compounds which are solid under the operating conditions and which tend to adhere to the distillation equipment and thereby cause operational problems. Applicants prefer to carry out the pre-treatment step as described in WO 2018/060202 A1.
In one embodiment of the method according to the present invention, the solder mixture supplied to the first distillation step b) comprises, by weight: at least 90% tin and lead together, more lead than tin, at most 0.1% of the total of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W), ° maximum 0.1% aluminum (AI) ° maximum 0.1% nickel (Ni) ° not more than 0.1% iron (Fe), and ° not more than 0.1% zinc (Zn).
Applicants have found that the stated upper limits for the elements of the braze mix as feedstock for the first distillation stage provide flawless continuous mode operation of that first distillation stage without problems due to the formation of solid metal-metal bonds.
Applicants have further found that these precautions with respect to the first distillation step also allow the second and third distillation steps to proceed flawlessly and without problems with the formation of metal-metal compounds.
In one embodiment of the method according to the present invention, the braze mixture supplied to the first distillation step b) comprises on a weight basis at least 1 ppm by weight and at most 5000 ppm by weight of copper.
The inventors have further found that the potentially harmful metals, and in particular copper, do not need to be completely removed from the braze mix to make the braze mix suitable for vacuum distillation. For example, the inventors have found that the problems identified can be reduced to a practical and economically acceptable level when small amounts of copper remain in the solder feed to the first distillation step. This finding has the advantage that solder streams can be processed that occur as the by-product of the recovery of copper from primary and / or secondary base materials, in particular from secondary base materials, and more importantly from raw materials that are end-of-life materials. use cycle.
The solder mix also preferably includes at least 0.0001 weight% sulfur (S). Applicants have found that it is not necessary to reduce sulfur levels to very low levels, such as below the 1 ppm by weight detection limit, to achieve the result intended by controlling sulfur content. On the contrary: the presence of sulfur in the solder mixture brings a technical advantage.
Applicants have found that sulfur binds with copper quite readily to form a copper sulfide (such as CuS), and that the copper sulfide is easily separated by gravity from a liquid metal mixture containing the two major components in the process, i.e. tin and lead. The presence of sulfur is therefore able to contribute to the removal of Cu in any process step which aims to separate Cu in a supernatant scratch. Applicants therefore prefer to use S as a chemical process substance in the method of the present invention. Applicants have found that the addition of sulfur-containing chemical compounds, such as pyrite (FeS), may be suitable for this purpose in location where appropriate to help lower the copper content of the braze mix, but Applicants prefer to use elemental sulfur because its use avoids adding one or more additional chemical elements. Therefore, sulfur in any form, and especially elemental sulfur, is a very suitable process substance for the inventors in the removal of some of the undesired metals, especially copper.
The presence of sulfur in the solder mix is therefore a strong indication that the solder mix has been produced as a byproduct of a copper production process. Therefore, there is a high probability that the raw material for the process of the present invention contains measurable amounts of copper as an impurity. The copper content of such effluents can be reduced by several possible process steps, of which the binding of Cu to S is only one. When treated with S for the removal of Cu, there is a very high probability that measurable traces of S remain in the metal mixture. The presence of S in the solder mix therefore provides a strong relationship with the solder mix being produced as a by-product from copper production, preferably with a step comprising treatment with sulfur or a suitable S-containing compound. Applicants have further found that the presence of sulfur in the solder mixture is not harmful if there is also an amount of copper present as indicated. The presence of S can contribute in subsequent cleaning steps to the removal of Cu from the less noble metal streams on their way to an industrially acceptable quality. The S in the braze mix of the present invention is therefore a desirable presence, with advantages manifested downstream.
In one embodiment of the method according to the present invention, at least 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 by a computer program, has the advantage of much better processing, with results that are much more predictable and closer to the goals of the method. . For example, on the basis of temperature measurements, if desired also measurements of pressure and / or level, and / or in combination with the results of chemical analyzes of samples taken from process flows and / or analytical results obtained online, the control equipment in terms of the supply or removal of electrical energy, the supply of heat or a cooling medium, control of a flow and / or a pressure. Applicants have found that monitoring or controlling in this manner is particularly advantageous in steps performed in continuous mode, but that it may also be advantageous in steps performed in batch mode or semi-batch mode.
In addition, the monitoring results obtained during or after performing steps in the method according to the present invention can preferably also be used to monitor and / or control other steps as part of the method according to the present invention, and / or of processes used upstream or downstream of the process of the present invention, as part of a general process in which the process of the present invention is only one part. Preferably the entire process is electronically monitored as a whole, more preferably by at least one computer program. Preferably, the method as a whole is electronically controlled as much as possible. Applicants prefer that the computer control also provides for data and instructions to be passed from one computer or computer program to at least one other computer or computer program or module of the same computer program, for monitoring and / or controlling other processes including, but not limited to, the methods described in this document.
EXAMPLE The following example shows in more detail how the method of the present invention can be carried out and how the intended effect is obtained. The example also shows how the method of the invention can be part of a larger global process that yields more high-quality products. The enclosed Figure 1 shows a flow chart of the method steps and their sequence as performed in this example. The compositions reported in the example are expressed in units of weight, and were the result of analyzes of samples taken daily, the results being averaged over an operating time of 73 days. In Figure 1, the numbers refer to the following elements of the claims:
1. Crude solder composition as feed to the pretreatment step 100
2. NaOH added in the pretreatment step 100
3. Sulfur added in the pretreatment step 100
4. First supernatant scratch from pretreatment step 100
5. Second supernatant scratch from pretreatment step 100
6. Molten braze mix obtained from pretreatment step 100
7. First concentrated lead stream as top stream from vacuum distillation step 200
8. First bottoms from the first vacuum distillation step 200
9. First silver-enriched liquid bleed product from the liquid end of crystallization step 300
10. First tin-enriched product from crystallization step 300
11. Fresh feedstock added to second vacuum distillation step 400
12. Second concentrated lead stream as overhead product from second vacuum distillation step 400
13. Second bottoms from second vacuum distillation step 400
14. Aluminum nuggets to tin refining step 500
15. Third base added in tin refining step 500
16. Sulfur added in tin refining step 500
17. Scratch containing Al / Sb / As from tin refining step 500
18. Scratch containing base from tin refining step 500
19. Scratch containing sulfur from tin refining step 500
20. High purity tin product from tin refining step 500
21. Third concentrated lead stream overhead from third vacuum distillation step 600
22. Third bottoms, from third vacuum distillation step 600
23. Copper added to soft lead refining step 700
24. First base added in soft lead refining step 700
25. First oxidant added in soft lead refining step 700
26. Third supernatant scratch formed in soft lead refining step 700
27. Purified soft lead stream or purified soft lead product from soft lead refining step 700
28. Purified hard lead stream or product from hard lead refining step 800
29. Remains of top product 21 from previous campaigns
30. Second base added in hard lead refining step 800
31. Second oxidant added in hard lead refining step 800
32. Fourth supernatant scratch formed in hard lead refining step 800
33. Fresh feedstock added to crude solder 100 pretreatment step
34. Fresh feedstock added to third vacuum distillation step 600
35. Fresh feedstock added to fractional crystallization step 300
36. Fresh Feed Adds to First Vacuum Distillation Step 200 100 Pretreatment Step 200 First Vacuum Distillation Step 300 Fractional Crystallization Step 400 Second Vacuum Distillation Step 500 Tin Refining Step 600 Third Vacuum Distillation Step 700 Soft Lead Refining Step 800 Hard Lead Refining Step For the analysis of a molten metal stream, a sample of molten metal is taken into a cast metal stream. refrigerated to solidify. One surface of the solid sample is prepared by passing the sample once, or preferably several times, through a Herzog HAF / 2 grinder until a clean and flat surface is obtained. The clean and flat surface of the sample is then analyzed by means of an optical emission spectroscopy (OES) device with breakdown spark of the Spectrolab M type from Spectro Analytical Instruments (US), which is also available from Ametek (DE ), where the parameters, crystals, detectors and tube can be readily selected and adjusted to obtain the most suitable operation for the desired accuracy and / or detection limit. The analysis provides results for several metals in the sample, including copper, bismuth, lead, tin, antimony, silver, iron, zinc, indium, arsenic, nickel, cadmium and even the element sulfur, and that, for most of those metals, up to a detection limit of about 1 ppm by weight.
For the analysis of a scratch, the inventors preferably use a well-calibrated X-ray fluorescence technique (XRF technique), preferably using the XRF spectrometer of the PANalytical Axios type from PANalytical B.V. (NL). This technique is also preferred over the above-mentioned OES for analyzing samples of metals containing significant amounts of impurities, such as stream 6 and streams upstream thereof, in the flow chart in the attached
Figure 1. Also in this technique, the details can be easily selected and adjusted to optimize the results in terms of the most appropriate accuracy and / or detection limit for the purpose of the analysis. The crude solder stock 1 was obtained from the refining of materials containing copper, lead and tin in a copper smelting furnace (not shown) which produces as an intermediate material a "black copper" containing about 85% by weight Cu. This black copper was then subjected in a copper refinery to a series of pyrometallurgical refining steps (not shown) that produce a high purity copper product on the one hand and a number of slag binder products on the other. In the course of the refining process, the crude brazing raw material 1 is recovered from some of those refining slags. Purification of that crude solder was performed through a series of pretreatment steps 100 to remove a significant amount of the metal impurities present, which would otherwise be in danger of being harmful during the downstream vacuum distillation steps. The target impurities of the purification steps are mainly Cu, Fe, Ni and / or Zn, and the purpose of the crude solder purification is that the solder can be further processed smoothly and without problems using vacuum distillation.
The crude solder 1 was available from the upstream refining processes at a temperature of about 835 ° C. In a first step of the purification process sequence 100, the solder was cooled to 334 ° C, which occurred in two steps. In the first cooling step, the crude solder was cooled to about 500 ° C and a first scratch was removed from the surface of the molten liquid metal. In the second cooling step, the crude solder was further cooled to 334 ° C and a second scratch was removed from the surface of the molten liquid metal. The cooling step resulted in the formation of a total scratch containing most of the copper present in the crude solder, which was removed as by-product (not shown) and recycled in one of the upstream pyrometallurgical process steps. The total flow rate and the concentrations of the target metals in the remaining brazing intermediate (flow 1) are shown in Table 1. The copper content in the braze was reduced to an average of 3.0000 weight% by this series of cooling steps and scratch removals. The concentrations of Fe and Zn in the solder were also significantly reduced.
Any scratch phases formed during the cooling process were removed (not shown) and recycled upstream in the process to the melting out step so that the valuable metals contained therein could be valorized as much as possible.
Table 1: The crude solder after the cooling step Weight% Crude solder 1 Bi | 00163 3.0000 0.0007 0.0015 Pb | 69.5000 0.8305 26.7414 0.0028 0.0290 0.0010 0.0515 0.0010 0.0125 0.0025 0.0007 100.1914
In a second part of the purification process sequence 100, solid sodium hydroxide (stream 2) was added to the solder intermediate of Table 1. In this treatment step, zinc was bound by the sodium hydroxide, presumably to form Na 2 ZnO 2, and formed a separate phase which formed as a first supernatant solid scratch separated from the solder, and which was removed as stream 4. As a result, the content of zinc in the solder stream 6 was further reduced.
The amount of sodium hydroxide was adjusted so that the concentration of Zn in the solder was reduced to 13 ppm by weight (Table 2). The scratch formed in this step was also recycled (stream 4) to the upstream smelting step, where zinc can be fumigated and recovered as zinc oxide dust.
In the next part of the purification process sequence 100, after the addition of sodium hydroxide and the removal of the first supernatant solid scratch phase 4, an amount of elemental sulfur was also added (stream 3), which represented about 130% stoichiometry relative to the amount of copper present in the metal phase, to further reduce the copper content of the solder. The elemental sulfur used was a granulated form of sulfur available from Zaklady Chemiczne Siarkopol in Tarnobrzeg (PL). The sulfur 3 reacted mainly with copper to form copper sulfides, which turned into a second supernatant scratch. That second supernatant scratch was then removed as stream 5 and recycled to a suitable upstream process step. After the addition of sulfur in step 100, an additional amount of sodium hydroxide (stream 2) was added to chemically bind any remaining traces of sulfur, and form another scratch. After some time for the reaction to take place, a handful of granular sulfur 3 was sprinkled / spread over the surface of the bath. The sulfur caught fire and burned any hydrogen that might have evolved from the liquid as a byproduct of the reaction. Then, a small amount of white sand was scattered / spread over the bath to dry / stiffen the scratch before removing it from the process (stream not shown in the drawing) and recycling it to an upstream process step. The purified solder thus obtained (stream 6, the flow rate and composition of which are indicated in Table 2) contained only 38 ppm Cu and was further processed as the molten solder mixture obtained from pretreatment step 100 by vacuum distillation in step 200. The second supernatant scratch 5 was reprocessed in the upstream refining process so that the valuable metals contained therein could be valorized.
Table 2: Purified solder for vacuum distillation Weight% Molten solder mixture -6
Bi | 0.0326
0.0038
0.0004
0.0009
Pb | 73.1206
0.8012
25.8694
0.0013
0.0500
0.0871
0.0015
0.0020
0.0202
0.0053
0.0010
99.9973 The molten solder mixture 6 was further processed by vacuum distillation (step 200), at an average temperature of 982 ° C and an average absolute pressure of 0.012 mbar (1.2 Pa). The vacuum distillation step yielded two product streams.
On the one hand, as top stream 7, a first concentrated lead stream was obtained which mainly contained lead, and on the other hand, as the first bottom product 8 of the first distillation step 200, we obtained a product stream containing mainly tin.
The flow rates and compositions of these second distillation product streams 7 and 8 are indicated in Table 3.
Table 3: Product flows from the first vacuum distillation 200 7 8 Bi | 0.0425 0.0014 0.0000 0.0122 0.0000 0.0015 0.0000 0.0028 Pb | 99.5375 1.0055 0.2233 1.9800 0.1006 96.3129 0.0018 0.0001 0.0031 0.1400 0.0746 0.0700 0.0000 0.0043 0.0024 0.0000 0. 0057 0.0460 0.0071 0.0000 0.0014 0.0000 100.0000 99.5767 The first vacuum distillation step 200 was performed in continuous mode, and was able to continue to function for a period of approximately three (3) years without observing any blocking or plugging of the distillation equipment due to the formation of metal-metal or intermetallic compounds.
The first concentrated lead stream 7 became available from the distillation equipment at a temperature of about 562 ° C. The temperature of stream 7 was controlled to about 450 ° C with stirring before the stream was further refined. Successive volumes of 100-120 tons of stream 7 were collected in a reservoir. Those volumes were subjected in batches to the soft lead refining process 700. A sample was taken from each batch and analyzed for the presence of As, Sn and Sb to determine the amounts of solid sodium hydroxide (stream 24) and solid sodium nitrate (stream 25) that were required. to react with the As, Sn and Sb present in the metal phase, and those amounts were added as the first base and first oxidant. The sampling and analysis was repeated over time for the reaction to take place and after removing the third supernatant scratch 26 formed by the reaction. If the result was unsatisfactory, the method step was repeated. For the total volume of soft lead produced during the 73 day operating period, 29.3 tons of sodium hydroxide (401 kg / day) and 15.5 tons of sodium nitrate (212 kg / day) were used in the process to remove most of the the mean 46 kg / day As, 62 kg / day Sn and 138 kg / day Sb, in total mean 246 kg / day of the 3 elements together, present in the feed to step 700 with stream 7. This refining step constituted in each batch a third supernatant scratch phase containing most of the As, Sn and Sb present in the first concentrated lead stream 7 and removed as by-product (stream 26). The third supernatant scratch phase was sampled and analyzed for the presence of chlorine using the method according to the standard DIN EN 14582. The analysis showed that approximately 129 ppm by weight of chlorine was present. The high quality soft lead product 27 was then poured into molds and allowed to solidify and cool to lead ingots.
In most of the batches, a small amount of copper 23 was added in the feed to step 700 to produce an amount of Cu-containing soft lead. The small amount of copper present improves the mechanical properties of the soft lead, making the soft lead more suitable for being rolled into lead film for the construction industry or for plating surfaces with lead. Some batches containing above average levels of Bi were also separately stored as Bi-rich soft lead, which is acceptable in certain end uses and has the advantage of making Bi-containing basestocks more acceptable for the process of the present invention and / or for the upstream processes that provide feedstock for it. This soft lead refining was performed in batches in the same equipment as the hard lead refining discussed later. The transition between the cargoes of soft lead and hard lead produces a quantity of quality intermediate material, which is traded as “unrefined soft lead”. The average daily production rates (spread over the production period of 73 days discussed here) and compositions of the various soft lead end product streams 27 are indicated in Table 4. Table 4: Composition of the soft lead end products 27 (weight%) Soft lead | Unrefined With Cu Bi-rich products 27 soft lead labeled Soft lead Soft lead
[Bi | 0.0905 0.0319 0.0568
0.0001 0.0428 0.0008
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
Pb | 99.6306 99.9026 99.9240
0.2279 0.0000 0.0000
0.0208 0.0006 0.0004
0.0001 0.0001 0.0001
0.0032 0.0034 0.0025
0.0259 0.0002 0.0002
0.0002 0.0000 0.0000
0.0007 0.0001 0.0001
0.0006 0.0003 0.0003
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
99.7727 99.9820 99.9852
The first bottoms 8 from first vacuum distillation step 200 was mixed with the third bottoms 22 from downstream third vacuum distillation step 600 and the mixture was fed to the fourth zone of a first crystallizer with 12 temperature zones.
The crystallizer was a cylindrical vessel, slightly tilted from a fully horizontal position, and included an internal rotating screw to move the formed crystals from the bottom end to the top end of the cylindrical vessel.
The temperature zones were numbered 0 to 11 from the bottom end to the top end.
A temperature profile was established within the crystallizer using appropriate heating and cooling means.
The temperature of zone 3, into which the feed entered, was controlled maintained at about 210 ° C.
The temperature increased in steps from Zone 3 to Zone 11 (230-250 ° C), upwards in the crystallizer, where the tin-rich crystals are removed from the device. The temperature decreased slightly in a downward direction in the crystallizer from zone 3 to zone 0 (199 ° C), but rose again in zone 0, to about 220 ° C, to ensure that the temperature in that zone is always above the liquidus line remained in the phase diagram to prevent solids build-up on the propeller blades, which could otherwise result in necessary technician intervention and a temporary shutdown of the equipment. Before the feed stream was supplied to the crystallizer, the stream was passed through a buffer vessel, with a delay of several hours from production, where mixing compensated for any temperature changes that might have occurred upstream such that the temperature of the feed entering the crystallizer entering zone 3 is fairly constant and any changes take place very slowly. In addition, the temperature of the feed to zone 3 was kept slightly higher than the temperature in zone 3 of the crystallizer to prevent the formation of solids in the feed system. By entering zone 3 of the crystallizer, the feed stream is cooled and enters the range where a stream of this composition separates into a solid phase of small crystals enriched in tin, in equilibrium with a liquid phase that is leaner in tin but richer in lead and precious metals. The increase in the temperature of the liquid moving down in the crystallizer from zone 1 to 0 brought the advantage of preventing the solids build-up on the outside of the blades of the screw in the lower part of the cylindrical container, leaving enough space under the vanes of the screw to allow fluid to flow from the top end of the cylindrical container to the bottom end.
The crystallizer was tilted such that the liquid phase in the vessel was readily able to move from the top end to the bottom end of the device under the force of gravity. The rotating screw in the crystallizer moved the crystals in the opposite direction through the continuous liquid phase contained in the crystallizer. The liquid level in the crystallizer was maintained below the crystal overflow point to minimize liquid entrainment with the first tin-enriched product, but high enough to promote heat transfer from the vessel wall to the contents of the vessel. the barrel.
The crystals arriving at the top end were enriched in tin, and substantially all of the lead and precious metals from the feed was recovered in the liquid first bleed stream exiting the crystallizer at the bottom end.
The first bleed stream further contained tin in a significant amount, but at a concentration below the level of tin in the crystallizer feed.
The Sn crystals were removed from the top end of the first crystallizer and introduced into the fourth zone (again zone 3) of a second crystallizer which also had 12 temperature zones numbered from 0 to 11. The second crystallizer was also used. applied a temperature profile, similar to that in the first crystallizer, which caused further separation of a second liquid draw-off stream from the first tin-enriched crystals before those crystals exited the second crystallizer at the top end (stream 10). The antimony entering with the crystallizer feed mainly follows the path of the main inflow.
The bleed stream from the second crystallizer was recycled to the first crystallizer where it was mixed with the feed.
When the concentration of Pb was considered too high, the second crystallizer bleed stream was temporarily recycled to the upstream vacuum first distillation stage 200 feed to maintain a higher Ag concentration factor from vacuum distillation bottoms stream 8 to net first silver enriched liquid bleed product 9. Also As the concentration of Cu increased in the crystallizer streams, and thus also in the take-off stream of the second crystallizer, this take-off stream was - at least temporarily - preferably recycled to a process step further upstream than the feed to the first crystallizer, at Preferably to feed the first step of the purification process sequence 100, to be mixed with the crude solder composition 1.
The first silver-enriched liquid bleed product exited the first crystallizer as an Sn / Pb alloy by-product containing most of the Ag present in the crystallizer feed.
The flow rates and compositions of the outlet product streams 9 and 10 of the assembly of 2 crystallizers in step 300 are shown in Table 5. It was found that enrichment of Sb was also occurring in the first tin-enriched crystal phase exiting the second crystallizer, but some Sb was also recovered in the first silver-enriched liquid tap product.
The silver-enriched liquid draw-off product 9 of Table 5 represents the net draw-off volume and composition.
Temporarily, and depending on its composition, a recycle of the silver-enriched liquid bleed product was performed from the lower end of the first crystallizer to the feed of the first crystallizer, to further increase the Ag concentration factor of the crystallizer feed (flows 8 + 22) to the net first silver-enriched liquid draw-off product 9. Table 5: Product flows of the crystallizer assembly Weight% | First to First in silver enriched | tin enriched liquid product interception product 10 9
Bi | 0.0079 0.0010
0.2900 0.0014
0.0012 0.0016
0.0215 0.0023
Pb | 16.5000 0.2387
0.4020 2.1000
79.5000 97.0536
0.0042 0.0000
2.8000 0.0100
0.1144 0.0680
0.0001 0.0000
0.1039 0.0411
0.0000 0.0000
0.0000 0.0000
0.0129 0.0034
99.7581 99.5211
The net first silver-enriched liquid draw-off product 9 from the first crystallizer was transferred to a downstream purification step (not shown) to recover all the noble metals as well as the Sn and Pb.
To this end, the silver-enriched liquid tap product was poured into anodes and subjected to an electrolysis step to produce cathodes containing pure Pb and Sn, and the other metals remained in the anode adhesives.
Typical conditions of this electrolysis step are: an electrolyte based on hexafluorosilicic acid (H2SiFe), fluoroboric acid and / or phenyl sulfonic acid; a temperature of about 40 ° C; a current density of 140-200 A / m °; spacing between the electrodes of about 100 mm.
Antimony can be added to the anode composition, typically up to a concentration of about 1.5% by weight. This has the advantage that the anode adhesives remain attached to the anodes and are not dispersed in the electrolyte.
In order to avoid a complete passivation of the anode, which would lead to an inhibition of the electrolysis, periodically and consecutively a portion of the anodes can be removed from the bath, their anode adhesives removed, for example mechanically, and then the cleaned anodes then can be placed back in the cell.
The anodes can also be designed so that the cleaned anodes have become so thin that it is more efficient and / or effective to melt them into new anodes.
These anode adhesives (on average about 180 kg / day) were recovered, for example, by filtration, from the entrained electrolyte, and these anode adhesives contained about 20% by weight silver and also a much smaller concentration of gold, along with most of the other metals that were present in the first silver-enriched liquid tap product, including antimony and optional platinum group metals (PGMs). The anode adhesives were further processed to recover the silver and other precious metals.
The filtrate was recycled to the electrolytic cell.
The first tin-enriched crystals from the second crystallizer were further processed through the second vacuum distillation step 400, performed at an average temperature of 1049 ° C and an average absolute pressure of 0.005 mbar (0.5 Pa). Over the 73 day run period, an amount of 157.6 tons of lead-containing feedstocks 11, averaging about 2.2 tons per day, was gradually added to the first tin-enriched crystals to keep the solidification point of the top product from step 400 low.
The flow rate and composition of stream 11 are indicated in Table 6. Table 6: Additive feedstock in feed to the second vacuum distillation Weight% Pb-containing feedstock 11 [Bi | 0.0299 0.0161 0.0018 0.0003 Pb | 588711 0.0006 41.0558 0.0001 0.0036 0.0015 0.0000 0.0017 0.0002 0.0000 0.0001 99.9827 The second vacuum distillation step 400 yielded two product streams.
On the one hand, we obtained as top product 12 a product stream that mainly contained most of the lead, antimony and silver from the feed, plus a small amount of tin, and on the other hand, as the second bottom product 13, we obtained a product stream that mainly contained tin with only trace amounts of other ingredients.
The flow rates and compositions of these two distillation product streams 12 and 13 are shown in Table 7.
Table 7: Product flows from the second vacuum distillation Weight% | Top current | Soil flow 12 13 Bi | 0.0189 0.0004 0.0000 0.0028 0.0000 0.0019 0.0000 0.0025 Pb | 37.8602 0.0011 13.0000 0.3800 47.7097 99.4584 0.0000 0.0000 0.0560 0.0029 0.3900 0.0178 0.0000 0.0036 0.0000 0.0000 0, 3050 0.0006 0.0001 0.0000 0.0000 0.0000 99.3400 99.8719 The second vacuum distillation stage 400 was run in continuous mode, and was able to continue to function for a period of approximately three (3) years without observing any blockage or plugging of the distillation equipment due to the formation of metal-metal or intermetallic compounds.
The second bottoms 13 from step 400 was further refined in batches in three consecutive steps, which are shown together in the flow chart as tin refining step 500. The first tin refining step consisted of cooling the second bottoms 13 and adding an amount of aluminum nuggets (stream 14). ) to the second bottoms, which had an average temperature of 430 ° C, with stirring, to react with Sb and As and remove those elements to a level that met prevailing international industrial standards.
The amount of Al to be added was based on an analysis of the second bottoms 13, and included an additional amount above the stoichiometric requirement.
After the reaction, the composition was analyzed again, and if the result was unsatisfactory, in particular the content of Sb, an additional amount of Al was added to trigger a second reaction step.
In total, an amount of about 4.3 kg Al per tonne of second bottom product 13 was used on average.
About 30 minutes after the last addition, heating and agitation were stopped and the liquid molten metal composition was allowed to cool.
During cooling, to an average temperature of about 250 ° C, a layer of scratch containing Al / Sb / As was formed, and that scratch was periodically removed from the surface of the molten liquid metal.
The scratch was collected and stored in dry, closed and double-walled steel drums to avoid contact with water or moisture, which could lead to the formation of stibine and / or arsine.
The vessels were removed as by-product (stream 17) and recycled to an upstream pyrometallurgical process step, where they were introduced unopened into a liquid bath of molten metal and / or slag, avoiding any risk of contact with moisture.
After the temperature of the tin product was raised again to about 330 ° C, the molten liquid metal was subjected to a second tin refining step, in which solid sodium hydroxide (stream 15) was added as the third base.
In that treatment step, aluminum was bound by the sodium hydroxide, presumably to form NasAlO3, and formed a separate phase which separated as a supernatant solid scratch from the molten liquid metal and was removed as stream 18. After a period of time every To allow the reaction to take place, a handful of granular sulfur was scattered / spread over the surface of the bath.
The sulfur caught fire and burned any hydrogen that could possibly have evolved from the molten liquid metal as a byproduct of the reaction.
As a result, the content of aluminum in the second bottom product 13 was further reduced.
The amount of sodium hydroxide to be added was adjusted so that the concentration of aluminum in the second bottoms product decreased to less than the detection limit of 1 ppm by weight (Table 8). The scratch formed in this step was also recycled (stream 18) to an upstream pyrometallurgical process step.
In the third and final tin refining step, an amount of elemental sulfur (stream 16) was added to further reduce the copper content of the molten liquid metal and to remove any residual sodium hydroxide from the second tin refining step. The elemental sulfur used was a granulated form of sulfur available from Zaklady Chemiczne Siarkopol in Tarnobrzeg (PL). The sulfur 16 reacted mainly with copper to form copper sulfides and with sodium hydroxide to form Na2SO2, which transitioned to a new supernatant scratch phase. After the addition of sulfur, the stirrer was run for about 10 minutes to oxidize any remaining traces of sulfur and form a new scratch. The scratch was removed from the molten liquid metal as stream 19. The high purity Sn product thus obtained (stream 20, the flow rate and composition of which are indicated in Table 8) contained only 14 ppm Cu and was clumped into lumps. of 22 kg cast, stacked, weighed and tied. The scratch containing sulfur 19 was reprocessed in an upstream pyrometallurgical process step.
Table 8: High purity Sn final product Weight% | High purity Sn Bi | 0.0001 0.0014 0.0004 0.0000 Pb | 0.0008 0.0160 99.9758 0.0000 0.0030 0.0006 0.0001 0.0000 0.0006 0.0000 0.0000 0.0001 99.9989
The overhead product 12 from the second vacuum distillation step 400 was further processed in the third vacuum distillation step 600, performed at an average temperature of 1000 ° C and an average absolute pressure of 0.033 mbar (3.3 Pa). The third vacuum distillation step 600 yielded two product streams.
On the one hand, we obtained as top product 21 a product stream containing mainly lead and antimony, and on the other hand, as the third bottom product 22, we obtained a product stream containing mainly tin and part of the antimony, plus most of the precious metals present in the distillation feed.
The flow rates and compositions of these two distillation product streams 21 and 22 are shown in Table 9. Table 9: Product streams of the third vacuum distillation Weight% | Top current | Soil flow 21 22 Bi | 0.0474 0.0011 0.0000 0.0265 0.0000 0.0004 0.0000 0.0075 Pb | 90.1133 0.7827 9.1014 2.1363 0.5379 96.8647 0.0002 0.0001 0.0100 0.0950 0.4700 0.0730 0.0019 0.0000 0.1860 0.0297 0. 0022 0.0000 0.0013 0.0000 0.0000 0.0000 100.4716 100.0170
The third vacuum distillation step 600 was performed in continuous mode, and was able to continue to function for a period of approximately three (3) years without any blockage or clogging of the distillation equipment due to metal-metal or intermetallic formation being observed. connections.
The third bottoms 22 was recycled to the first crystallizer from upstream step 300, where it was mixed with first bottoms 8 from step 200, to recover the valuable metals contained therein.
The overhead product 21 was further refined in step 800, in batches, in the same equipment used during the soft lead refining step 700 of the first concentrated lead stream as overhead stream 7 from the first vacuum distillation step 200. During the 73 day run, an additional 810 was added. , 2 tons of top product from the third vacuum distillation left over from previous campaigns (stream 29), averaging about 11.1 tons / day, mixed with stream 21 and co-refined. The refining of this hard lead was done in batches in volumes of 100-120 tons total feed. During the 73 days of operation discussed in this example, approximately 9 days were devoted to refining 1159 tons of hard lead, versus approximately 129 tons / day, and the equipment was used for 43 days to refine 4400 tons of the soft lead products as described above average at about 102 tons / day.
The hard lead molten liquid metal feed stream for hard lead refining step 800 was first heated to about 450 ° C with agitation. A sample was taken and analyzed for the presence of As and Sn to determine the amounts of solid sodium hydroxide (stream 30) and solid sodium nitrate (stream 31) that were considered necessary to remove the As and Sn from the molten liquid metal phase, and those amounts were added as the second base and the second oxidant. Over the 73 day operation period considered for this example, a total of 15.2 tons of sodium hydroxide (average 208 kg / day) plus 7.6 tons of sodium nitrate (average 104 kg / day) was added in this refining step for the removing most of the average 26 kg / day As and 32 kg / day Sn that entered step 800 with flows 21 and 29 together. Almost all of the 1502 kg / day of Sb present in the feed streams to hard lead refining step 800 remained in the purified hard lead product 28. This hard lead refining step formed a total fourth supernatant scratch phase containing most of the As and Sn present in the top products 21 and 29 and removed as by-product (stream 32). The fourth supernatant scratch phase was sampled and analyzed for the presence of chlorine using the method according to DIN EN 14582. The analysis showed that approximately 130 ppm by weight of chlorine was present.
The flow rate and composition of the purified running end product stream 28 are indicated in Table 10. Table 10: Composition of the end running hard product Weight% | Hard lead 28 Bi | 0.0550 0.0000 0.0000 0.0000 Pb | 914680 8.9900 0.0192 0.0001 0.0112 0.0025 0.0002 0.0005 0.0005 0.0000 0.0000 100.5472
Thus, this hard lead refining step in step 800 only aimed to remove a total of an average of 58 kg / day of impurities, which is significantly less than the removal intended by step 700.
In addition, the concentrations of As and Sn in the feed to step 800 were also higher than those in the feed to step 700. Step 800 therefore achieves its goals much more easily than step 700. Relative to the total amount (As + Sn + Sb) entering the respective lead refining steps 700 and 800, step 800 consumes significantly less chemicals and also produces significantly less supernatant scratch than step 700, which also has the advantage of putting a less heavy burden on recirculating the supernatant scratch in the upstream pyrometallurgical process.
It was also observed that in step 800 As and Sn could be successfully removed to very low levels, while hardly any Sb needed to be removed.
Having now fully described the present invention, it will be apparent to those skilled in the art that the invention can be practiced with a wide range of parameters within the scope of the claims, without departing from the scope of the invention as defined by the claims.

权利要求:
Claims (46)
[1]
1. Metal composition (10) comprising, on a dry weight basis: ° at least 0.08% by weight and at most 6.90% by weight of lead (Pb), ° at least 0.50% by weight and at most 3.80% by weight of antimony (Sb), ° at least 92.00% by weight and at most 98.90% by weight of tin (Sn), ° at least 96.00% by weight of tin, lead and antimony together, ° at least 1 ppm by weight and at most 500 ppm by weight of copper (Cu), ° at most 0.0500% by weight of silver (Ag), ° at most 0.40% by weight of arsenic (As), ° at maximum 0.1% of the total of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W), ° maximum 0.1% aluminum (AI), ° maximum 0 , 1% nickel (Ni), ° not more than 0.1% iron (Fe), and ° not more than 0.1% zinc (Zn).
[2]
The metal composition of claim 1 which is a molten liquid.
[3]
The metal composition according to claim 1 or 2 comprising at least 10 ppm by weight of silver (Ag).
[4]
The metal composition according to any of the preceding claims comprising at least 100 ppm by weight and at most 1000 ppm by weight of indium (In).
[5]
A method of producing a soft lead product (27), a hard lead product (28) and a tin product (20), the method comprising: a) providing a solder mixture (6) comprising predominantly large amounts of lead and tin, together with a small amount of antimony, b) a first distillation step (200) which by evaporation mainly separates lead from the solder mixture (6) from step a), producing as top product a first concentrated lead stream (7) and a first bottoms product (8) enriched in tin is produced, the first concentrated lead stream (7) forming the basis for obtaining the soft lead product (27), C) if silver is present in the solder mixture (6), optionally a fractional crystallization step (300) which is performed on the first bottoms product (8) from step b) (200) to separate silver from tin and to produce a tapping product (9) from the liquid end of the crystallization step that is enriched silver and a first tin-enriched product (10) from the crystal end of the crystallization step, d) a second distillation step (400) that separates predominantly lead and antimony by evaporation from the metal composition according to any one of the preceding claims selected from the first tin-enriched product (10) from step c) (300) and the first bottoms (8) from step b) (200), producing as the top product a second concentrated lead stream (12) and a second bottoms (13) ) is produced, with the second bottoms product (13) forming the basis for obtaining the tin product (20), e) a third distillation step (600) which by evaporation mainly separates lead and antimony from the second concentrated lead stream (12) from step d) (400), producing a third concentrated lead stream (21) as the top product and producing a third bottoms product (22), the third concentrated lead stream (21) being the base forms to obtain the hard lead product (28).
[6]
The method of claim 5, wherein the solder mix (6) meets at least one and preferably all of the following conditions: • comprising at least 45 weight% lead (Pb), • comprising at least 10 weight percent -% tin (Sn), ° comprising at least 90% by weight of tin and lead together, ° comprising at least 0.42% by weight of antimony (Sb), and ° comprising at least 0.0010% by weight % silver (Ag).
[7]
The method according to claim 5 or 6 wherein the third bottoms product (22) is at least partially and preferably completely recycled to the feed of second distillation step d) (400) or to the feed of the fractional crystallization step (300).
[8]
The method of any of claims 5-7, wherein a fresh lead containing feed (11) is added to the feed of the second distillation step d) (400).
[9]
The method of any of claims 5-8 wherein a fresh lead containing feed (34) is added to the feed of the third distillation step e) (600).
[10]
The method of any one of claims 5 to 9 further comprising the step (800) of removing at least one contaminant selected from the metals arsenic and tin from the third concentrated lead stream (21), wherein a purified hard lead stream when the hard lead product (28) is produced.
[11]
The method of the preceding claim wherein the at least one contaminant is removed by treating the third concentrated lead stream (21) at a temperature of less than 600 ° C with a second base (30) and a second oxidant (31) , resulting in the formation of a fourth supernatant scratch (32) containing a metalate compound of the affected contaminant metal, followed by separating the fourth supernatant scratch (32) from the purified hard lead stream (28).
[12]
The method of the preceding claim, wherein the fourth supernatant scratch (32) comprises at most 1.0% by weight of chlorine, and preferably at most 1.0% by weight of total halogens.
[13]
The method of any of claims 11-12, wherein the fourth supernatant scratch (32) is recycled to a process step upstream of the first vacuum distillation step b) (200).
[14]
The method of any of claims 11-13, wherein the second oxidant (30) is an oxidant stronger than air.
[15]
The method of any one of claims 11-14 wherein the second oxidant (31) is selected from NaNO3, Pb ({NO: 3) 2, KNO: 3, ozone, nitric acid, sodium and potassium manganate, sodium and potassium (per) manganate, chromic acid, calcium carbonate (CaCOs), sodium and potassium dichromate, preferably NaNO: 3, CaCO3, Pb (NOs) 2 or KNO3, more preferably NaNO :.
[16]
The method according to any of claims 11-15, wherein the second base (30) is selected from NaOH, Ca (OH) »and NasCO: and combinations thereof, preferably NaOH.
[17]
The method of any of claims 11-16 wherein the weight ratio of second base (30) to second oxidant (31) is in the range of 1.5: 1.0 to 4, 0: 1.0, preferably in the range of 1.8: 1 to 2.5: 1 when NaOH is used as the second base (30) and NaNO: is used as the second oxidant (31), respectively, and recalculated by stoichiometry for when other compounds are used as second base (30) and / or second oxidant (31), preferably where the weight ratio of second base (30) to second oxidant (31) is at most 2, 90 for when NaOH is used as the second base (30) and NaNO, respectively: is used as the second oxidant (31), and recalculated by stoichiometry for when other compounds are used as the second base (30) and / or second oxidant (31).
[18]
The method of any of claims 11-17, wherein the second base (30) and the second oxidant (31) are mixed together before introducing into the treatment.
[19]
The method of any of claims 5-18, wherein the third concentrated lead stream (21) comprises at least 0.50 wt.% And at most 15.0 wt.% Antimony.
[20]
The method of any of claims 5-19 comprising fractional crystallization step c) (300).
[21]
The method of the preceding claim wherein the feed to fractional crystallization step c) (300) comprises at least 0.1% by weight and at most 20.0% by weight lead.
[22]
The method of any of claims 20-21 wherein the concentration of lead in the feed to the fractional crystallization step c) (300) is at least 3.0 and preferably at least 5.0 times the concentration of silver in the feed to fractional crystallization step c) is (300).
[23]
The method of any of claims 20-22 wherein the concentration of silver in the feed to fractional crystallization step c) (300) is at least 10 ppm by weight and optionally at most 0.85 weight% silver .
[24]
The method of any of claims 5-23, wherein the first tin-enriched product (10) comprises at least 0.10 wt% lead.
[25]
The method of any one of claims 20-24 wherein the feed to fractional crystallization step c) (300) further comprises at least 1 ppm by weight of at least one metal selected from copper, iron, bismuth, nickel , zinc, gold, indium and arsenic.
[26]
The method of any of claims 20-25, wherein the feed to fractional crystallization step c) (300) comprises at least 99.0% by weight combined of tin, lead, antimony and silver.
[27]
The method of any of claims 5-26, wherein the second bottoms product (13) is further refined to obtain a high purity high quality tin product (20).
[28]
The method according to the preceding claim, wherein the second bottoms (13) is treated with aluminum metal (14), preferably in stoichiometric excess to the amount of antimony present, preferably in combination with mixing and cooling the reacting mixture to less than 400 ° C, followed by separating the scratch containing Al / Sb / As (17) formed by the treatment.
[29]
The method according to the preceding claim, wherein the second bottom product (13), after the treatment with aluminum and preferably also after removing the scratch containing Al / Sb / As (17), is treated with a third base (15) , which is preferably selected from NaOH, Ca (OH) 3 and Na: CO: and combinations thereof, more preferably NaOH, followed by separating the scratch containing base (18) formed by the treatment.
[30]
The method of the preceding claim wherein the second bottom product (13), after the treatment with the third base (15), is treated with sulfur (16), followed by separating the scratch containing S (19) that is formed by the treatment.
[31]
The method of any one of claims 5 to 30 further comprising the step of removing (700) at least one contaminant selected from the metals arsenic, tin and antimony from the first concentrated lead stream obtained in the first distillation step b) (200), producing a purified soft lead stream as the soft lead product (27).
[32]
The method of the preceding claim wherein the at least one contaminant is removed by treating the first concentrated lead stream (7) at a temperature of less than 600 ° C with a first base (24) and a first oxidant (25) , resulting in the formation of a third supernatant scratch (26) containing a metalate compound of the respective contaminant metal, followed by separating the scratch (26) from the purified lead stream (27).
[33]
The method of the preceding claim, wherein the first oxidant (25) is an oxidant stronger than air.
[34]
The method of any of claims 31-33, wherein the third supernatant scratch (26) contains at most 1.0 wt% chlorine, and preferably at most 1.0 wt% total halogens.
[35]
The method of any of claims 31-34, wherein the third supernatant scratch (26) is recycled to a process step upstream of the first distillation step b) (200).
[36]
The method of any of claims 31-35 wherein the first oxidant (25) is selected from NaNO3, Pb ({NO: 3) 2, KNO: 3, ozone, nitric acid, sodium and potassium manganate, sodium and potassium (per) manganate, chromic acid, calcium carbonate (CaCOs), sodium and potassium dichromate, preferably NaNO: 3, CaCO3, Pb (NOs) 2 or KNO3, more preferably NaNO :.
[37]
The method according to any of claims 31-36, wherein the first base (24) is selected from NaOH, Ca (OH) »and NasCO: and combinations thereof, preferably NaOH.
[38]
The method of any of claims 31-37, wherein the weight ratio of first base (24) to the first oxidant (25) used is in the range of 1.5: 1.0 to 4 , 0: 1.0, preferably in the range of 2: 1 to 3: 1 when NaOH is used as the first base (24) and NaNO3 is used as the first oxidant (25), respectively, and recalculated according to stoichiometry for when other compounds are used as the first base (24) and / or first oxidant (25).
[39]
The method according to the preceding claim wherein the weight ratio of first base (24) to the used first oxidant (25) is at most 2.90 for when NaOH is used as the first base (24) and NaNO3 is used respectively as the first oxidant (25), and recalculated by stoichiometry for when other compounds are used as the first base (24) and / or first oxidant (25).
[40]
The method of any of claims 5-39, wherein the first concentrated lead stream (7) comprises at least 0.0400% by weight and at most 0.3000% by weight tin.
[41]
The method of any of claims 5-40, wherein the first distillation step b) (200) is performed at a pressure of at most 15 Pa absolute.
[42]
The method of any of claims 5-41 wherein the first distillation step b) (200) is performed at a temperature of at least 800 ° C.
[43]
The method of any one of claims 5-42 wherein the feedstock for the first distillation step b) (200) is a crude solder composition (1) containing at least 0.16% by weight and optionally at most 10% by weight. % of the total amount of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti), tungsten (W), copper (Cu), nickel (Ni), iron (Fe), aluminum (Al) and / or zinc (Zn), the feed being available at a temperature of at least 500 ° C, the method further comprising the step of pretreating (100) the crude solder composition (1) before step b) (200) to form the braze mixture (6) as a feedstock for the first distillation step b) (200), the pretreatment step (100) comprising the steps of f) cooling the crude brazing composition to a temperature not exceeding 825 ° C, to obtain a bath containing a first supernatant scratch (4) which will float by gravity on a first liquid molten n metal phase, g) adding a chemical (2) selected from 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 liquid molten metal phase to form a bath. molds containing a second supernatant scratch (5) that will float by gravity on a second liquid molten metal phase, and h) removing the second scratch (5) from the second liquid molten metal phase.
[44]
The method according to any of claims 5 to 43, wherein the solder mixture (6) fed to the first distillation step b) (200) comprises, by weight: ° at least 90% tin and lead together, ° more lead than tin, ° not more than 0.1% of the total of chromium (Cr), manganese (Mn), vanadium (V), titanium (Ti) and tungsten (W), ° not more than 0.1% aluminum (AI ) ° not more than 0.1% nickel (Ni) ° not more than 0.1% iron (Fe), and
° not more than 0.1% zinc (Zn).
[45]
The method according to any of claims 5 to 44, wherein the solder mixture (6) supplied to the first distillation step b) (200) is at least 1 ppm by weight and at most 5000 ppm by weight by weight. includes copper.
[46]
The method according to any of the claims 5-45, wherein at least part of the method is electronically monitored and / or controlled, preferably by a computer program.

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法律状态:
2020-10-12| FG| Patent granted|Effective date: 20200901 |

优先权:

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EP19154614|2019-01-30|

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