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Xps Pres Coursol Mackey Dias Energy Consumption in Cu Smelting June6th 10
Xps Pres Coursol Mackey Dias Energy Consumption in Cu Smelting June6th 10
Presentation Outline
University of Toronto
Results and discussion Suggestions for further energy reduction in copper sulphide smelting
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Energy Consumption in Cu Smelting Trend over the Last Four Centuries (as MJ/t Cu - feed to metal)
University of Toronto
Energy consumption steadily decreasing Since 1900 energy consumption has dropped by a factor of about 30 times Energy at present time ~ 12,000-15 000 MJ/t Cu
University of Toronto
Studies selected for comparison Kellogg and Henderson (1976), Cochilco (2009), Piret (2009) and Marsden (2008) Results from Kellogg and Henderson (similar to our approach)
Processing Route Electric Energy (MJ/tonne anode) Hot Calcine Reverb [Kellogg76] KH-Outokumpu Flash [Kellogg76] KH-Mitsubishi [Kellogg76] KH-Noranda [Kellogg76] 2,173 7,477 6,904 9,045 Fossil Fuel (MJ/tonne anode) 15,935 6,760 9,306 5,220 Total (MJ/tonne anode) 18,108 14,237 16,210 14,265
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Adopted basic approach of Kellogg and Henderson Selection of four modern flowsheets to compare energy consumption and CO2 emissions Developed four new METSIM models for heat and mass balance Compared energy results amongst the modern and older technologies
Proper definition of concentrate and flux mineralogies Proper thermodynamic properties for molten slag and matte Some thermodynamic data imported from the FactSage software into METSIM Solubility of FeS in Slag
Important for heat balance in smelting vessel
Key recycle streams included Slag concentrate, dust and reverts are important for heat balance of the smelting and converting units
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Standard concentrate and flux used Double absorption acid plant adopted Annual concentrate throughputs used:
Outokumpu/Flash convert: 1.2Mt/year
161 tph @ 85% Online time
Waste heat recovery on smelting vessels, PS converters but not on anode furnaces
University of Toronto
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University of Toronto
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Fossil Fuel Natural gas and coke for heat balance or process requirements (local reduction) Electricity Acid Plant, oxygen production, matte and slag grinding, blowers, secondary gas handling, auxiliary equipments, The power plant efficiency was assumed to be 38%. This factor was applied to convert the electrical energy to thermal energy in the energy balance. Steam credits were applied when excess steam was produced
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Processing Route
Fossil Fuel (MJ/tonne anode) 1,518 4,175 2,498 2,657 15,935 6,760 9,306 5,220
Total (MJ/tonne anode) 10,784 11,078 11,006 12,746 18,108 14,237 16,210 14,265
Flash-Flash (Present work) Isasmelt (Present work) Mitsubishi (Present work) Noranda-Teniente (Present work) Hot Calcine Reverb [Kellogg76] KH-Outokumpu Flash [Kellogg76] KH-Mitsubishi [Kellogg76] KH-Noranda [Kellogg76]
Present work
Kellogg 76
The Flash-Flash, the Isasmelt and the Mitsubishi flowsheets have very similar energy consumption The Noranda/Teniente processes have a somewhat higher energy consumption.
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Difference Between this Study and the Data from Chilean Smelters
University of Toronto
Opportunity ?
The difference in energy consumption represents many millions $US per site !!
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Difference Between the Ideal Condition and Data from Chilean Smelters
University of Toronto
Our calculations do not account for all real life aspects in the energy balance, hence our estimates may be slightly low. A part of the difference is due to ideal conditions used in our calculations (high throughput, steam drying, benchmark oxygen and acid plants,) It is considered that an important part of the difference may be due to plant inefficiencies An energy audit can help in identifying the best opportunities to lower energy consumption
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Main Assumptions to Calculate the Total CO2 Emissions for Each Flowsheet
University of Toronto
Different countries have different ways to produce electricity (hydro, coal, natural gas, fuel oil,), leading to different CO2 emissions per MWh. In our analysis (next slide), we assumed two different scenario The Chilean scenario
0.54t CO2 per MWh (Average for the two main energy grids in Chile employing different energy mixes)
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Calculated CO2 emissions for copper smelting according to type of fuel employed at the power plant
University of Toronto
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Conclusions
University of Toronto
The Flash-Flash, the Isasmelt and the Mitsubishi flowsheets have similar low energy consumption compared to the Noranda/Teniente flowsheet Our work appear consistent with the study from Kellogg and Henderson published in 1976
Today, higher oxygen enrichment are used and more heat recovery was assumed in our cases
This type of modeling can be used to prepare energy audits at smelter sites and identify the opportunities for improvements Fuel and electricity cost will significantly impact the optimal technology selection for a greenfield project
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Discussion
University of Toronto
Better copper recoveries were obtained in flowsheets including slag slow cooling and flotation. Our models can be modified to mix converting, slag cleaning and recycling options to obtain the best configuration for a given site.
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Suggestions for Further Improvements in Energy Efficiency for Copper Sulfide Smelting
University of Toronto
Build smelters at optimal size to minimize energy consumption Lower the energy consumption for acid and oxygen production Develop good use for excess steam from waste heat boilers Utilization of higher oxygen enrichment
Tuyere/lance/concentrate burner design Keep lowering the energy required for oxygen production