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Energy Efficiency of the Outotec® Ausmelt Process for Primary Copper

Smelting

Article in JOM: the journal of the Minerals, Metals & Materials Society · March 2017
DOI: 10.1007/s11837-017-2322-x

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JOM, Vol. 69, No. 6, 2017
DOI: 10.1007/s11837-017-2322-x
Ó 2017 The Minerals, Metals & Materials Society

Energy Efficiency of the OutotecÒ Ausmelt Process

for Primary Copper Smelting

JACOB WOOD,1,2 JOEY HOANG,1 and STEPHEN HUGHES1

1.—Outotec Pty Ltd, 12 Kitchen Rd, Dandenong, VIC 3175, Australia. 2.—e-mail:
[email protected]

The global, non-ferrous smelting industry has witnessed the continual

development and evolution of processing technologies in a bid to reduce
operating costs and improve the safety and environmental performance of
processing plants. This is particularly true in the copper industry, which has
seen a number of bath smelting technologies developed and implemented
during the past 30 years. The OutotecÒ Ausmelt Top Submerged Lance Pro-
cess is one such example, which has been widely adopted in the modernisation
of copper processing facilities in China and Russia. Despite improvements in
the energy efficiency of modern copper smelting and converting technologies,
additional innovation and development is required to further reduce energy
consumption, whilst still complying with stringent environmental regulations.
In response to this challenge, the Ausmelt Process has undergone significant
change and improvement over the course of its history, in an effort to improve
its overall competitiveness, particularly with respect to energy efficiency and
operating costs. This paper covers a number of recent advances to the tech-
nology and highlights the impacts of these developments in reducing energy
consumptions for a range of different copper flowsheets. It also compares the
energy efficiency of the Ausmelt Process against the Bottom Blown Smelting
process, which has become widely adopted in China over the past 5–10 years.

INTRODUCTION APPLICATION OF THE OUTOTECÒ

AUSMELT PROCESS
For more than a century, the non-ferrous metals
processing sector has evolved continually to meet Over a period of more than 40 years, the Ausmelt
the demand for improved safety, environmental Process has been used for processing copper, nickel,
performance, quality and productivity. Following a lead, tin, zinc and precious metal-bearing feeds. It has
recent period of high metals prices and strong achieved widespread commercial acceptance and been
profitability, companies active in this field are now adopted in over 50 non-ferrous commercial smelting
facing more challenging economic conditions cou- projects. In the copper industry, the Ausmelt Process
pled with increasing pressure to reduce carbon has been used for processing concentrates, matte,
dioxide emissions, which has led to a renewed focus scrap, electronic waste along with complex materials
on further reducing operating costs and the con- such as flue dusts, residues and polymetallic concen-
sumption of fossil fuels through improved energy trates.1 In the past 15 years, there has been an
efficiency. This paper provides a summary of how explosion in uptake of the technology in copper
the OutotecÒ Ausmelt Top Submerged Lance (TSL) (Fig. 1) due to:
Process (henceforth Ausmelt Process) has been
adapted to meet such demands, focusing in partic-  A simple, low-cost plant configuration with flex-
ular on developments providing for reduced energy ibility to process a range of feed materials and
and fossil fuel consumption in the production of expand capacity without major modification to
copper. systems and equipment

(Published online March 27, 2017) 1013

1014 Wood, Hoang and Hughes

Fig. 1. Ausmelt Process cumulative feed processing capacity.

 The ability to independently control the process paign life and a reduction in the cost and
energy balance and bath oxygen potential to duration of furnace reline activities.
achieve operation under a wide range of condi-  Ausmelt Lance operation with high oxygen
tions enrichment (80%) resulting in lower electrical
 A highly automated, continuous operation with- energy consumptions for the plant compressors,
out tapping using an underflow weir, meaning a offgas system and sulfuric acid plant and a
reduced labor requirement, improved safety and reduction (or in some cases elimination) of fossil
lower operating costs fuel usage in the metallurgical process.
 Intense bath mixing and agitation providing for  Injection of partially or completely dried feed
high specific smelting rates and the efficient materials via the Ausmelt lance to reduce both the
removal of impurities such as Pb, Zn and As process fuel requirement and electrical energy
 Minimal fugitive gas and dust emissions and consumption due to a lower offgas volume.
thus excellent environmental performance as a
result of the well-sealed furnace and offgas
system. TECHNOLOGY BENCHMARKING
Efforts to improve the competitiveness of the
AUSMELT PROCESS DEVELOPMENTS Ausmelt process have also included benchmarking
of different plant flowsheets to compare fossil fuel
The Ausmelt Process has achieved a strong
and electrical energy consumptions in a manner
market position in the global copper industry,
similar to that conducted by Coursol et al.2,3 This
achieving widespread adoption in the modernisa-
paper in turn also acknowledges the early life cycle
tion of numerous brownfield Chinese copper smel-
assessment work of Kellogg and Henderson.4 This
ters via the replacement of multiple blast/
benchmarking exercise also included a comparison
reverberatory furnaces at a relatively low initial
of the energy efficiency of Ausmelt technology
capital investment. In spite of this widespread
against the Bottom Blowing Smelting (BBS) or
adoption, Outotec has continued to explore oppor-
Shuikoushan (SKS) process, implemented in a
tunities to improve the technology, focusing partic-
number of recent Chinese copper smelting projects.5
ularly on enhancing its energy efficiency via a
The key objective of this work was to compare
reduction in fossil fuel consumption. Recent devel-
different flowsheet variants using data from a range
opments aimed at improving the overall competi-
of sources, rather than undertake a detailed com-
tiveness of the Ausmelt Process described by Wood
parison against previous process benchmarking
et al.1 are summarized below:
studies. As such, the results may differ from those
 An intensely cooled Ausmelt Furnace design reported elsewhere, due to differences in scope,
incorporating Outotec continuous-cast, copper scale of operation, concentrate composition and the
elements, providing for increased furnace cam- underlying assumptions applied.
Energy Efficiency of the OutotecÒ Ausmelt Process for Primary Copper Smelting 1015

Fig. 2. Technology benchmarking flowsheet and battery limits.

Using Outotec HSCÒ software, a number of depending on the specific nature of each flowsheet
copper flowsheets were simulated for the annual examined, with outputs including blister copper,
treatment of 1 M dry metric tonnes of copper sulfuric acid, steam and a low-Cu content discard
concentrate with 25% Cu and a relatively high slag/tailings. The design basis and battery limits for
gangue content, typical of that currently treated by the benchmarking exercise are illustrated in Fig. 2,
smelters around the world.6 Consumables (fluxes whilst details relating to the nature of inputs,
and fossil fuels) and utilities (air, oxygen and consumables and outputs from the overall flowsheet
electricity) were introduced on an as-needed basis, are provided in Table I.

Table I. Benchmarking inputs, consumables and outputs

Concentrate 25.0% Cu, 26.5% Fe, 30.0% S, 10.0% moisture
Silica flux 94.3% SiO2, 0.7% Fe
Limestone flux 96.4% CaCO3, 1.3% SiO2, 0.2% Fe
Coal 70.5% FC, 14.5% VM, 13.0% Ash, 2% H2O, GCV: 30.0 MJ/kg
Coke 81.0% FC, 3.0% VM, 14.0% Ash, 2% H2O, GCV: 32.0 MJ/kg
Burner LDO 85.6% C, 11.7% H, 0.2% N, 2.5% S, GCV: 43.5 MJ/kg
Oxygen 99.6% O2, 0.4% N2
Air 20.6% O2, 77.4% N2, 2.0% H2O
Sulfuric acid Sulphuric acid > 99.4% H2SO4
Acid plant tailgas <300 ppm SO2
Blister copper >99.0% Cu, <0.3% S
WHB steam Saturated at 5.4 MPa
1016 Wood, Hoang and Hughes

The first flowsheet evaluated in the benchmark- summarized previously, incorporated within the
ing work (Flowsheet 1) combined Ausmelt smelting flowsheet design. Notable features different to the
and Pierce-Smith converting with an electric fur- Flowsheet 1 included:
nace for matte-slag separation (Fig. 3). The config-
uration and operating parameters for the Ausmelt  Concentrate pre-treatment in the dryer using
Smelting Furnace (ASF) in this flowsheet were steam from the ASF WHB to reduce the moisture
typical of existing plants, installed in the period content slightly to around 8%, allowing for
2005–2010 and therefore did not include many of autogenous smelting without coal introduction,
the aforementioned technology developments from even with the increased heat losses associated
the past 5 years. with the intensely cooled furnace.
Key features of Flowsheet 1 are summarized  Granulation of matte tapped from the ESF
below: enabling ‘‘de-coupled’’ operation of the smelting
and Ausmelt Continuous Copper Converting
 As-received concentrates processed in the ASF (C3) processes.
with a lance air oxygen enrichment of 65% and
small quantity of coal used to achieve the target Flowsheet 3 looked at the replacement of the ESF
operating temperature of 1180°C with a Slag Concentrator (SC) to improve the
 Matte and slag separation in the Electric Set- overall copper recovery (Fig. 5). Once again, appli-
tling Furnace (ESF), with molten matte trans- cation of a high lance air oxygen enrichment and an
ferred to the Pierce Smith Converters (PSC) and intensely cooled furnace configuration were used to
the low-Cu content slag discarded or sold improve the energy efficiency of the overall
 PSC slag crushed or granulated and recycled to flowsheet, with key characteristics of the design
the ASF along with dusts from all furnaces being:
 SO2 rich offgas from both the ASF and PSC  Processing of undried concentrates, fluxes, gran-
treated in the Sulfuric Acid Plant (SAP) ulated ACF slag, recycle dusts and concentrate
 Steam from the ASF and PSC Waste Heat from the slag concentrator in the intensely
Boilers (WHB) used for the generation of elec- cooled ASF, without the need for coal addition
trical power or in the copper refinery.  Processing of the smelting slag (including some
Flowsheet 2, depicted in Fig. 4, examined the entrained matte) via slow cooling, grinding and
application of Ausmelt smelting and continuous flotation to generate a slag concentrate, which is
converting, with the technology developments recycled to the smelting furnace

Fig. 3. Flowsheet 1 (ASF + ESF + PSC).

Energy Efficiency of the OutotecÒ Ausmelt Process for Primary Copper Smelting 1017

Fig. 4. Flowsheet 2 (ASF + ESF + ACF).

Fig. 5. Flowsheet 3 (ASF + SC + ACF).

1018 Wood, Hoang and Hughes

Fig. 6. Flowsheet 4 (BBS + SC + PSC).

Table II. BBS furnace design parameters

Design Referenced data Reference(s)

Furnace availability 86.6% (7586 h/year) 7590 h/year 8
Furnace heat loss 3.6 MW 3.6 MW 8
Matte composition 68% Cu 68–75% Cu 2, 6–11
Slag composition Fe/SiO2 = 1.8 Fe/SiO2 = 1.4–2.2 2, 6–11
3.5% Cu 2–4% Cu 6–8 , 10, 12
Bath temperature 1200°C 1150–1200°C 7, 8, 10, 13
Ingress air flow 4700 Nm3/h 4670 Nm3/h 8
Infiltration air 30,000 Nm3/h 28,824 Nm3/h 8
Oxygen enrichment 70% 70–75% 7–11, 13, 14
Injection pressure Air = 700 kPa Air = 600–800 kPa 2, 15
O2 = 600 kPa O2 = 400–700 kPa 6, 13, 15, 16
Dust generation 1.5% 1.0–2.5% 7–9, 11, 13

Table III. Energy consumption factors

Item Energy consumption factor Reference(s)

3
Process air 97 kWh/kNm (700 kPa) Authors
40 kWh/kNm3 (150 kPa) Authors
Process oxygen 321 kWh/tonne O2 (600 kPa) 2
250 kWh/tonne O2 (150 kPa) Authors
Offgas fan 8.5 kWh/kNm3 Authors
Secondary gas fan 2 kWh/kNm3 2
Acid plant (646.8 9 %SO2 + 63.7) kWh/tonne Acid 2
Slag concentrator 60 kWh/tonne slag Authors
Steam dryer 2 tonnes steam/tonne moisture removed 2
Slag granulation 3 kWh/tonne slag 2
Matte granulation 9 kWh/tonne matte 2
Furnace cooling watera 9 kWh/tonne Cu Authors
a
Includes overall furnace cooling water system.
Energy Efficiency of the OutotecÒ Ausmelt Process for Primary Copper Smelting 1019

Table IV. Flowsheet fuel and energy consumptions

Flowsheet 1 Flowsheet 2 Flowsheet 3 Flowsheet 4

Smelting
Electrical (kWh/t Cu)a 320 318 330 413
Fuel (MJ/t Cu)b 1941 112 111 78
Settling
Electrical (kWh/t Cu)a 164 115 0 0
Fuel (MJ/t Cu)c 427 448 0 0
Converting
Electrical (kWh/t Cu)a 132 106 111 100
Fuel (MJ/t Cu)b 343 535 527 341
Acid Plant
Electrical (kWh/t Cu) 374 297 298 370
Concentrator
Electrical (kWh/t Cu) 0 0 160 162
Total
Electrical (kWh/t Cu) 990 836 899 1045
Fuel (MJ/t Cu) 2711 1095 638 419
Cu recovery (%) 98.1 97.8 99.3 99.3
a
Includes WHB, ESP and Offgas fan.bIncludes holding burner fossil fuel consumption.cIncludes ESF coke reductant consumption.

 Granulation of matte tapped directly from the close to the mine site.
ASF, with this subsequently treated in the ACF 3. The advantages offered by Ausmelt C3 in terms
of a stable, decoupled process operation
Flowsheet 4 illustrated in Fig. 6 considered the providing for improved campaign life and a
combination of BBS and Pierce-Smith converting consistent, high-strength offgas stream at a
used in a number of recent Chinese copper projects.6 comparable energy consumption to Peirce-Smith
Assumptions and data used in developing this converting.
flowsheet are detailed in Table II and were based
on available published literature covering the Results from benchmarking work also highlighted a
technology. number of inherent advantages of Ausmelt technol-
For each of the flowsheet simulations, electrical ogy over the BBS process, including:
energy and fossil fuel consumptions were calculated
for key process units using typical energy consump- 1. Decreased electrical energy consumptions due
tion factors detailed in Table III. This provided a to:
direct comparison of the energy efficiency of the  Use of low pressure of process air and oxygen.
different flowsheets and consequently, between the  Lower infiltration air volumes and thus a
Ausmelt and BBS technologies which are sum- smaller and more concentrated offgas flow
marised in Table IV.  Operation with a higher oxygen enrichment
Key points of interest from the results presented in the intensely cooled Ausmelt furnace
in Table IV include:
2. Increased flexibility to treat both high- and low-
1. Higher electrical energy and fossil fuel consump- grade concentrates and to introduce par-
tions in Flowsheet 1 due to operation with lower tially/completely dried concentrate feed depend-
lance air oxygen enrichment, highlighting the ing on the process energy balance.
opportunity for existing Ausmelt copper smelters 3. Scope for operation within a wide oxygen
to reduce their operating costs and carbon inten- enrichment range, compared with the limited
sity via an expansion in oxygen plant capacity. operating range (65–75%) in the BBS process
2. Reduced electrical energy consumption in the due to issues around lance/tuyere life.
ESF compared with the slag concentrator, but 4. Higher availability of the intensely cooled Aus-
also a lower copper recovery and higher fossil melt furnace utilizing Outotec continuous cast
fuel consumption due to the use of coke reduc- copper elements.
tant. It is worth noting, however, that the costs
and difficulties of tailings storage or disposal As such, the Ausmelt process has a 14–20% lower
must also be considered in evaluating the electrical energy consumption and approximately
potential benefits offered by the slag concentra- 7% reduction in overall energy costs at an energy
tor, particularly when smelters are not located price of USD$30/GJ (10c/kWh equivalent).
1020 Wood, Hoang and Hughes

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