Ni-Co 2021: The 5th International Symposium on Nickel and Cobalt: Pyrometallurgy I
Sponsored by: The Metallurgy & Materials Society of the Canadian Institute of Mining, Metallurgy and Petroleum, TMS Extraction and Processing Division, TMS: Hydrometallurgy and Electrometallurgy Committee, TMS: Pyrometallurgy Committee
Program Organizers: Corby Anderson, Colorado School of Mines; Dean Gregurek, RHI Magnesita; Mari Lundström, Aalto University; Christina Meskers, SINTEF; Prabhat Tripathy, Batelle Energy Alliance (Idaho National Laboratory); Fiseha Tesfaye, Metso Metals Oy, Åbo Akademi University; Yuanbo Zhang, Central South University; Sari Muinonen, Glencore; Graeme Goodall, XPS- Glencore; Shijie Wang, Coeur Mining, Inc
Wednesday 8:30 AM
March 17, 2021
Room: RM 43
Location: TMS2021 Virtual
8:30 AM
One-step Extraction of Nickel from Nickel Sulfide Concentrates by Iron Addition: Fanmao Wang1; Sam Marcuson1; Leili Khajavi2; Mansoor Barati1; 1University of Toronto; 2University of British Columbia
The conventional nickel smelting and refining is the dominant strategy for nickel production from the sulfide nickel ores. The main disadvantages are the significant amount of SO2 emissions during smelting and complex refining processes. In this paper, the authors investigated a solid-state nickel extraction method that recovered nickel values into ferronickel alloy and simultaneously retained the bulk of sulfur of the nickel sulfide concentrate in the solid iron sulfide, thus mitigating the potential SO2 emissions. The results showed that after heat treatment at 1073 K (800 oC) for 240 min, the residual nickel concentration in the resulting sulfide was only 0.6 mass pct and that in the ferronickel alloy was averaging 16 mass pct. The experimental data were in good agreement with the thermodynamic evaluations. Furthermore, the materials and energy balance were assessed for the thermal treatment process.
8:50 AM
Continuous Improvement of Process Advisor Optimizing Furnace Model: Peter Björklund1; David Grimsey2; Mikko Korpi1; Miikka Marjakoski3; 1Outotec; 2BHP; 3Boliden
The Outotec® Process Advisor has successfully been used for automatic control of flash smelting furnace setpoints continuously for 5 years. This is one contribution that has enabled record long furnace campaign life due to the improved matte temperature control, which has prevented matte infiltration into the hearth. Building on this success, the Process Advisor has been enhanced to further utilize the online dynamic heat and material balance model also for other purposes than direct process control. This paper covers some of the latest improvements taken into use after the initial startup. These include, for example, an online maximum feed rate estimator, which continuously updates the maximum feed rate possible for the operator and an online matte level estimator to get a better matte level estimate also between sounding.
9:10 AM
Fluxing Optimisation and Control Improvements at the Kalgoorlie Nickel Smelter: David Grimsey; Eric Grimsey1; Peter Björklund2; 1Curtin University; 2Outotec
Significant cost reduction and control improvements have been achieved through a fluxing optimisation programme at the Kalgoorlie Nickel Smelter. Improvement opportunities were identified through thermodynamic modelling (FACTSage 6.4) and implemented via an advanced furnace control model (Outotec Process Advisor). The approach of combining fundamental system understanding with an advanced control model has been instrumental in enabling the success of the programme. This paper details the thermodynamic modelling results, identification of improvement opportunities, implementation and evidence of the improvements achieved.
9:30 AM
Preparation of Refractory Materials by Co-sintering of Ferronickel Slag and Ferrochromium Slag: Thermodynamic Analysis: Foquan Gu1; Yuanbo Zhang1; Zhiwei Peng1; Huimin Tang1; Zijian Su1; Tao Jiang1; 1Central South University
During the past ten years, the stainless-steel industry has undergone rapid development around the world. At the same time, a great quantity of stainless-steel slag (mainly ferronickel slag and ferrochromium slag) was co-generated. It is urgent to seek an efficient method for the comprehensive utilization of ferronickel slag and ferrochromium slag. In this study, the feasibility of preparing refractory materials by co-sintering of ferronickel slag and ferrochromium slag was evaluated based on thermodynamic analysis. The thermodynamic results showed that by co-sintering of ferronickel slag and ferrochromium slag in the presence of magnesia, the phase composition of the system is forsterite, spinel and perclase, which is beneficial to prepare high refractoriness of the refractory materials. The experimental results verified those findings, a refractory material with refractoriness of 1780 °C, bulk density of 2.30 g/cm3, apparent porosity of 16.19%, and compressive strength of 89.18 MPa could be obtained.
9:50 AM
PGM Furnace Design, Construction, Improvement and Performance Optimisation: Isobel McDougall1; Gerrit de Villiers1; Hugo Joubert1; Burger van Beek2; John Davis2; Trevor Goff2; 1Tenova Pyromet; 2Sibanye-Stillwater
Tenova Pyromet designed, supplied and commissioned a 12 MVA circular electric furnace for Sibanye-Stillwater (previously Lonmin) in South Africa. The furnace has been operating successfully since its commissioning in 2012. The paper provides an overview of the furnace performance and campaign life history, and explores the innovative design concepts and improvements implemented. Of particular interest is the use of a novel sidewall lining design that utilizes indirect cooling to remove excess heat from the matte/slag tidal zone without the need to use water-cooled copper. Furthermore, the performance of Tenova’s Söderberg electrode column designed for base metal applications, limiting water use above the furnace, is discussed. In addition, the joint development and performance of an uncooled cast iron matte taphole faceplate is presented. Potential future design innovations to further improve smelter operating safety are discussed.