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Ausmelt C3 converting

Conference Paper · February 2009

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 International Peirce-Smith Converting Centennial
Edited by: Joël Kapusta and Tony Warner
TMS (The Minerals, Metals & Materials Society), 2009

AUSMELT C3 CONVERTING

Jacob Wood, Robert Matusewicz, Markus A. Reuter

Ausmelt Limited
12 Kitchen Road
3175 Dandenong, Australia

Keywords: Cu Converting, Continuous Converting

Abstract

Over the last 20 years, significant improvements in copper smelter productivity have been
realized through the advent of continuous smelting processes. This progress has until recently
however, not been carried through to copper converting. Peirce-Smith converting has been
widely used by the copper industry for 100 years but is limited by its batch nature in achieving
large scale of production. A logical next step is therefore copper converting on a continuous
basis with its inherent environmental benefits. A number of continuous converting technologies
are currently in use or being developed within the copper industry, the majority of these
operating with calcium-ferrite slags. A notable exception however is the Ausmelt Continuous
Copper Converting (C3) technology which has focused on operation with ferrous-calcium-
silicate or loosely called olivine type slags. This paper discusses the merits of the Ausmelt C3
process and the advantages offered in terms of operational flexibility and process control arising
from the use of lime modified iron silicate slags. It also examines the effects of key process
variables pertinent to continuous copper converting from both a theoretical and
experimental/operational perspective.

397
 Introduction

In recent times, the copper industry has experienced a significant drive towards improved
productivity and increased scale of operation. This has been achieved to a large degree through
the use of continuous smelting processes carried out in large, high-intensity vessels, with more
than 60% of primary copper smelter production now occurring in plants with an annual
productivity exceeding 200,000 tpa [1].

Despite this change in philosophy towards continuous smelter operation, copper converting is
still largely carried out in a batch-wise fashion in multiple vessels such as the Peirce-Smith
converter. Whilst this technology is well understood and has been widely employed over the past
100 years, development of a continuous converting process is necessary to realize similar
increases in productivity as those achieved through continuous smelting. This challenge has been
taken up by the copper industry leading to a number of continuous converting processes
currently being applied and developed worldwide (Table I).

Table I – Continuous Copper Converting Technologies

Supplier Technology
Outokumpu / Kennecott Flash
Mitsubishi Top Blown Lance
Ausmelt - C3 Top Submerged Lance
Xstrata - Isaconvert Top Submerged Lance

Notable additions to this list include the Teniente, Noranda and INCO copper converting
processes. Despite having been developed and modified to encompass a number of different
operating philosophies, these technologies have been used primarily for the production of white-
metal or low-grade blister copper (~85% Cu) [2]. This paper only focuses on the former
technologies where matte is converted through to blister copper.

Whilst differing in their approach for achieving matte to blister conversion, the technologies
listed in Table I are all based on the same concept of increasing productivity and scale of
operation through greater vessel availability and feed throughput. Nonetheless, it is interesting to
note that despite this similarity in operating philosophy, a number of key distinctions exist
between the various processes, not least of which is the slag composition targeted during
converting.

Of utmost importance in achieving stable and efficient operation for any copper converting
process is ensuring adequate slag fluidity. This is most commonly realised through control of the
slag composition, temperature and bath oxygen potential. Controlling these parameters also
provides additional benefits in terms of reduced copper losses to slag and suppression of slag
foaming.

Peirce-Smith converting has been typically carried out using iron-silicate (fayalite) slags,
targeting a specific Fe/SiO2 ratio and manageable magnetite (Fe3O4) content. Despite extensive
knowledge and experience having been attained in copper converting with fayalite slags
however, development of continuous converting technologies has to date, focussed on operation
with calcium-ferrite slags.

398
The Mitsubishi continuous converting process has been used for more than 30 years in the
treatment of liquid matte to blister copper [3]. Development of this process has been based on
use of a calcium-ferrite slag [4]. Adoption of this slag system was found to avoid formation of a
solid magnetite crust, as observed during converting with a silica-based fayalite slag [3]. An
additional advantage reportedly arising from the use of a lime-based calcium-ferrite slag
included reduced propensity to slag foaming under the high oxygen partial pressure required for
converting [5]. Further benefits and incentives for using this type of slag have been discussed in
detail by Jahanshahi et al. [6].

The calcium-ferrite slag system was also selected for use in development of the
Outokumpu/Kennecott flash converting process because it offered the best match of a low slag
make, reduced levels of sulphur in blister and minimal tendency to foam [5]. Other key
advantages noted from the use of this slag system were comparatively higher absorption of
impurities such as As, Bi and Sb compared with silica-based slags [3]. Despite these benefits,
issues related to the corrosive nature of calcium-ferrite slags and deposition of solid magnetite
during converting have also been noted [3].

Although not currently in use commercially, the Xstrata IsaconvertTM continuous copper
converting process has been successfully trialled on a pilot-plant scale [7]. Research of this
technology has to date focussed on the calcium-ferrite slag system at copper saturation (i.e. Cu2O
- CaO - Fe2O3) and temperatures of 1250-1300°C [7]. A number of laboratory and pilot-scale
trials were used to compare the suitability of iron-silicate and calcium-ferrite slags during
converting and identified the latter to provide advantages in terms of a very low susceptibility to
foaming and reduced copper losses to slag. Based on these findings and extensive research of
potential slag systems for the IsaconvertTM process, the calcium-ferrite slag system has been
nominated as the most practical for commercial implementation of this technology [7].

The advantages offered by calcium-ferrite slags over traditional silica-based slags have been
widely publicised and include a reduced slag volume, lower copper losses, high fluidity and
more efficient removal of impurities from blister copper [8]. Nonetheless, these slags are also
associated with increased refractory wear [5], have limited silica solubility, low lead capacity
and in some cases too high a fluidity [8] as has been summarized in Table II, in which italics
indicate a drawback while bolds highlights advantages [9].

Table II – Comparison of Converting Slag Systems

Ferrous-Calcium-
Property Iron-Silicate Calcium-Ferrite
Silicate
Viscosity High Low Medium
Copper entrainment High Low Medium
Holding Capacity/Solubility:
x Neutral oxides Medium Medium Low
x Acidic oxides Low High High
x PbO High Low Medium
x FeS Low High High
x Fe3O4 Low High Medium
Tendency to foam High Low Medium
Slag volume Medium Low Medium
Refractory wear rate Medium High Medium
Copper recovery from slag High Low High

399
Despite the apparent benefits linked to use of calcium-ferrite slags and the fact that all competing
continuous copper converting technologies have adopted this slag system, development of the
Ausmelt C3 process has focussed on use of ferrous-calcium-silicate slags. This decision was
made based on Ausmelt’s extensive experience in copper converting and was reasoned to offer
advantages over other slag systems including:

x An ability to control magnetite precipitation.

x Operator familiarity with the slag system due to its similarity with conventional copper
smelting slags.
x A less aggressive slag resulting in reduced refractory wear.
x Better capacity for copper recovery from the slag.

Based on an evaluation format as presented by Matusewicz et al. [9] (originally proposed by

Yazawa – see reference in [9]), comparison of the iron-silicate, calcium-ferrite and ferrous-
calcium-silicate slag systems was undertaken by Ausmelt and applied to TSL technology to
evaluate the potential advantages and disadvantages offered by each (Table II).

The Ausmelt C3 process operates with the continuous feeding of solid (typically granulated)
copper matte along with silica and limestone fluxes as required. During converting, oxygen-
enriched air is injected via a centrally located lance, submerged in the slag layer of the bath.
Application of the C3 process has been successfully carried out on both pilot-plant and
commercial scales.

This has facilitated in achieving a good understanding of lime-modified fayalite slags under the
conditions occurring during copper converting and of key variables pertinent to the C3 process.
Optimization of slag chemistry and refinement of operating practices has also been achieved as a
result of this work. A simplified representation of the SiO2 - FeOx - CaO phase diagram is
presented in Figure 1 at 1300oC. This illustrates the comparative size of the slag liquidus phase
field for the three (3) major slag systems relevant to copper converting. Clearly evident from the
figure is the vastly enlarged slag liquidus region for ferrous-calcium-silicate compositions
compared with both the calcium-ferrite and iron-silicate slag systems.

Figure 1 – Simplified Representation of Converting Slag Systems at 1300oC [9].

400
 Ferrous-Calcium-Silicate Slags

Olivine slags are well understood and have been widely used in ferrous metallurgy for many
decades [10]. Use of ferrous-calcium-silicate slags in copper systems is more recent and has been
proposed and identified as a potential future development within the copper industry by
numerous authors [8-12]. Studies of ferrous-calcium-silicate slags in the context of copper
metallurgy have identified the potential for balancing the advantages and disadvantages of silica-
based and calcium-ferrite slags through lime modification of fayalite slags. It has also been
reported that ferrous-calcium-silicate slags are characterized by a low copper solubility in slag
and equivalent impurity removal ability from blister copper as calcium-ferrite slags [10].

The use of ferrous-calcium-silicate slags during continuous copper converting has attracted an
increasing level of interest in more recent times. Pilot-scale testwork conducted at the Codelco
Alto Norte Smelter in Chile concluded olivine-type slags to offer superior performance
compared with other slag systems during the continuous converting of high-grade solid copper
matte using a Teniente converter [13].

A good study of ferrous-calcium-silicate slags under conditions occurring during copper

converting has also been carried out by Nikolic et al. [8]. These authors recently identified the
potential for these slags to be used in the IsaconvertTM process. Whilst this assessment is
somewhat in conflict with previous publications concerning this technology, it further
emphasizes growing attention within the copper industry concerning the potential application of
ferrous-calcium-silicate slags during continuous copper converting.

In support of earlier work, an in depth theoretical confirmation of the suitability for using
ferrous-calcium-silicate slags in the Ausmelt C3 process has been carried out with the aid of
FactSageTM software [14]. This work focused on the effects of process variables critical to
achieving stable and efficient operation during continuous copper converting. Simulation of the
SiO2 - FeOx - CaO - Cu2O slag system was carried out over the temperature range 1250°C -
1350°C and at oxygen partial pressures (pO2) of 10-6 atm and 10-8 atm. The presence of
compounds such as alumina (Al2O3) and magnesia (MgO) was not considered for sake of
simplicity. Modeling of this system considered the presence of copper oxide (Cu2O) in
concentrations similar to those occurring during continuous converting (i.e. 15-20 wt. %). The
importance of this compound in constraining magnetite formation and therefore in ensuring a
suitable slag liquidus region under blister copper making conditions has been recognized by
Vartiainen and Kytö [10].

The ternary phase diagram for the SiO2 - FeOx - CaO - Cu2O system at 1250°C and pO2 of
10-6 atm (Figure 2) was used as a basis for comparison in completing this investigation. Evident
from this diagram is the relatively small operating window (represented by the shaded ‘Slag-
liquid + Cu-liq’ phase field) and the relatively reduced possibility of operating with either a
fayalite or calcium-ferrite slag composition under these conditions.

Figure 3 presents the ternary phase diagram at 1250°C for the same slag system, but this time at
an oxygen partial pressure of 10-8 atm. The lighter shaded region in this diagram outlines the
‘Slag-liquid + Cu-liq’ phase field under these conditions. To enable comparison of the relative
size of this region with that under more oxidizing conditions (i.e. a pO2 of 10-6 atm), the darker
shaded region from Figure 2 has also been included.

401
Clearly apparent from the figure is the vastly enlarged potential operating window at a lower
pO2, which has significant implications during converting. This highlights the importance of
controlling the oxygen potential to ensure adequate slag fluidity and flexibility in composition
for efficient and effective vessel operation.

Figure 2 – Ternary Phase Diagram for the SiO2 - FeOx - CaO - Cu2O Slag System
at 17.6% Cu2O in slag, 1250°C and pO2 = 10-6 atm [14].
(Note that the calcium-ferrite area is not colored as it does not cover the area C3
operates in, however it is molten at the given conditions.).

Figure 3 – Ternary Phase Diagram for the SiO2 - FeOx - CaO - Cu2O Slag System
at 17.6% Cu2O in Slag, 1250°C and pO2 = 10-8 atm [14].
402
The effects of temperature on the size of the ‘Slag-liquid + Cu-liq’ region are illustrated in
Figure 4. This figure contains the phase diagram for the SiO2 - FeOx - CaO - Cu2O slag system at
the same oxygen potential as Figure 2 (i.e. pO2 = 10-6 atm) but in this instance at a temperature
of 1350°C. Evident from examination of Figure 4 is the very large range of liquid slag
compositions as indicated by the lightly shaded region in the diagram.

Figure 4 – Ternary Phase Diagram for the SiO2 - FeOx - CaO - Cu2O Slag System
at 17.6% Cu2O in Slag, 1350°C and pO2 = 10-6 atm [14].

Another feature of this diagram which is worth highlighting is suppression of the ‘Slag-liquid +
Spinel + Cu-liq’ phase field in the bottom right hand corner of the diagram. Operation at higher
temperatures would therefore be expected to provide benefits in terms of reduced magnetite
development and consequently improved slag fluidity and reduced propensity to foaming. These
findings underline the strong role of temperature in ensuring an ‘open’ operating window for
optimal process control during converting.

Pilot-Scale and Commercial C3 Trial

Various applications of batch converting have already been commercialized by Ausmelt, e.g. at
the Zhong Tiao Shan (ZTS) Non-Ferrous Metals Corporation facility in Houma in China and at
Anglo Platinum for the converting of nickel/copper matte in their PGM recovery facility in
Rustenburg, South Africa.

Investigation and development of the Ausmelt C3 continuous converting process has been
carried out on a pilot-scale, many trials being completed, each approximately 8 hours in duration.
This work focused on understanding the operating conditions and slag chemistry providing low
copper levels in slag, manageable slag fluidity and overall ease in operation. Intentional variation
in the composition of copper matte feed and fluxing practices enabled investigation of numerous
slag compositions, providing feedback on workable and unstable regions of the phase diagram,
this work confirming the in-field observations of Ausmelt personnel during many pilot and
commercial operations. A range of normalized slag compositions examined during the pilot-plant
testwork have been plotted on the phase diagram for the SiO2 - FeOx - CaO - Cu2O system at an
403
oxygen potential of 10-8 atm and temperature of 1300°C (Figure 5). Evident from this figure is
the scattering of points within the lightly shaded ‘Slag-liquid + Cu-liq’ phase field, highlighting
the large number of slag compositions studied. Points lying outside the region may be attributed
to conditions that are not represented by the thermodynamic conditions used for drawing the
phase diagram.

Figure 5 – Ternary Phase Diagram for the SiO2 - FeOx - CaO - Cu2O Slag System
at 17.6% Cu2O in slag, 1300°C and pO2 = 10-8 atm .
(Selected normalized slag compositions investigated during pilot-scale C3
testwork are marked on diagram) [14].

Key observations from the pilot-scale trials included:

x Successful control of blister sulfur levels at or below 0.2 wt. % whilst operating with a
target copper concentration in slag of 15-20 wt.%,
x Acceptable levels of magnetite generation and minimal propensity to slag foaming, and
x Good process flexibility and resilience to disturbances/variations in feed composition and
operating conditions.

Commercial application of the Ausmelt Continuous Copper Converting process has also been
achieved at the Zhong Tiao Shan (ZTS) Non-Ferrous Metals Corporation facility in Houma,
China. Modification of operating practices for the Ausmelt TSL converter from batch to
continuous operation was successfully achieved in September 2007, and demonstrated a capacity
increase of more than 35%. During this testwork, fluxing practices were adjusted to the desired
ferrous-calcium-silicate slag composition. The resultant slag composition was found to improve
slag fluidity considerably leading to reduced accretion build-up and greater ease in
handling/tapping.

In addition to successfully demonstrating operation of C3 on a commercial scale, the trials

completed at ZTS enabled optimization of fluxing and operating/control practices, highlighting
the economic viability of the process. Examination of overall process performance and flexibility
404
with differing slag compositions assisted in reducing flux additions leading to numerous benefits,
most notably a reduced slag make and hence lower copper losses to slag. Tapping of blister
copper and slag with the lance submerged and without a termination in feeding was also
investigated and successfully carried out during the testwork.

Currently, ZTS are operating their converter using a modified C3 process due to limitations with
the capabilities of existing plant equipment and ancillary systems. Nonetheless, implementation
of a continuous converting philosophy at this facility has contributed to not only an increase in
productivity but also greater ease in operation and control of the process.

Conclusions

In spite of a trend towards use of calcium-ferrite slags in competing continuous copper

converting technologies, Ausmelt has focused on adoption of a ferrous-calcium-silicate slag
system in development of its C3 process. Theoretical examination of this slag system under the
conditions occurring during converting has highlighted the effects of both temperature and
oxygen potential on the range of slag compositions permitting stable and efficient operation. This
work has been used to optimize operating practices and to complement findings from pilot-scale
and commercial C3 testwork.

Trials of the C3 process have indicated the use of ferrous-calcium-silicate or loosely called
olivine type slags to offer a significantly enlarged operating window of slag compositions
compared with fayalite and calcium-ferrite slags. This has important implications in terms of the
operational flexibility and resilience of the process to variations/disturbances in feed composition
and operating conditions. The commercial scale Ausmelt C3 trials at ZTS highlight the numerous
benefits of this process in terms of enhanced productivity, reduced maintenance and labor
requirements and a simpler operating philosophy.

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