University of Toronto University of Toronto

Energy Consumption in Copper Sulphide Smelting

Pascal Coursol, Phillip Mackey and Carlos Diaz

(Consultants-Extractive Metallurgy, Xstrata Process Support)

(Consultant and Adjunct Professor, University of Toronto)

Presented at the Copper 2010 Conference June 7th, Hamburg, Germany

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Presentation Outline
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Trend in energy consumption

Discussion of previous similar studies

Methodology and assumptions Description of the case studies

Outokumpu-Kennecott Isasmelt Mitsubishi Noranda-Teniente Bath Smelting

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)
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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

The present study focuses on energy in sulphide smelting 3

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Previous Studies on Energy Consumption in Sulphide Smelting

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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Methodology Used in this Study

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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

Some Features of the METSIM Models

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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

Fe3O4 solubility in slag and Matte

Important for heat balance in smelting and converting

Key recycle streams included Slag concentrate, dust and reverts are important for heat balance of the smelting and converting units
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Some Key Assumptions Used for the Case Studies

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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

Isasmelt/PS converters: 1.2Mt/year

161 tph @ 85 % Online time

Mitsubish-S, C and CL furnaces: 0.75Mt/year

111 tph @ 85% Online time

Noranda/Teniente/PS Converters: 0.85Mt/year

126 tph @ 85% Online time

Waste heat recovery on smelting vessels, PS converters but not on anode furnaces

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Outokumpu Flash Smelting + Kennecott-Outokumpu Flash Converting

Isasmelt Smelting + PierceSmith Converting

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Mitsubishi Continuous Smelting Process

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Noranda/Teniente Continuous Bath Smelting + Pierce-Smith Converting

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Main Aspects Considered in Energy Balance

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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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Results Compared to Kellogg and Henderson (KH1976)

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Processing Route

Electric Energy (MJ/tonne anode)

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]

9,266 6,903 8,508 10,088 2,173 7,477 6,904 9,045

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
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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
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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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Differences in Electrical Portion for the Four Flowsheets

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Highest fuel, lower electricity

Highest electricity, lower fuel

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Main Assumptions to Calculate the Total CO2 Emissions for Each Flowsheet
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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)

The 100% Coal scenario

0.96t CO2 per MWh (all power from coal)

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Calculated CO2 emissions for copper smelting according to type of fuel employed at the power plant
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Conclusions
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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
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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
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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

Waste heat recovery from anode furnaces and converters

Reduce infiltration and improve waste heat boiler design to allow higher efficiency and low maintenance
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