You are on page 1of 18

Control Procesos

Metalurgia del Cu
Ren Bustamante
Octubre 2017
USACH

5.3.2 Steady-state
operation

Steady-state operation of a flash furnace entails:


(a) feeding solids and blast at a constant rate
(b) drawing S02-rich gas from the gas uptake at a constant
rate
(c) tapping matte from the furnace on a scheduled basis or
as-needed by the
(d) tapping slag from the furnace on a scheduled basis or
when it reaches a converters prescribed level in the
furnace.

5.4 Control (Fig. 5.3) de


Biswas y Davenport
Copper
The Outokumpu flash furnace operator must smelt concentrate at a steady, specified rate
while:
(a) producing matte of specified Cu grade
(b) producing slag of specified SiOz content
(c) producing slag at specified temperature
(d) maintaining a protective coating of magnetite-rich slag on the furnace interior.

5.4. I Concentrate throughput rate and matte


grade controls

Basic Outokumpu flash furnace strategy is to charge dried concentrate mix to


the furnace at a prescribed rate and to base all other controls on this rate.
Having chosen concentrate feed rate, the flash furnace operator must next select
the grade (% Cu) of his product matte, Le. the extent of Fe and S oxidation.
It is selected as a compromise between:
(a) maximizing SO2 evolution in the flash furnace (where it is captured efficiently) and:
(b) keeping enough Fe and S in the matte so that subsequent converting can
operate auto
thermally while melting its required amount of Cu scrap and smelter recycle materials.
Physically, matte grade is set by adjusting the:
O7 -in - blast input rate
concentrate feed rate
ratio until the target matte composition is obtained. A large ratio gives extensive
Fe and S oxidation and high-grade (Le. high % Cu) matte. A small ratio gives
the opposite. Physically, the ratio is controlled by adjusting the rates at which
air and oxygen enter the furnace, constant concentrate feed rate.

5.4.2 Slag composition control


The iron oxide formed by concentrate oxidation is fluxed with SiOz to form
liquid slag. The amount of Si02 is based upon the slag having (i) a low
solubility for Cu and (ii) sufficient fluidity for easy tapping and a clean
matteislag separation. It is
controlled by adjusting the rate at which flux is fed to the solids feed dryer.
An Si02/Fe mass ratio of 0.7 to 1.0 is used.
5.4.3 Temperature control
Matte and slag temperatures are measured as matte and slag flow from the
furnace. Disposable thermocouple probes and optical pyrometers are used.
Matte and slag temperatures are controlled by adjusting:
(a) the rate at which N2 coolant enters the furnace (mainly in air)
(b) hydrocarbon burner combustion rates.
Slag temperature is adjusted somewhat independently of matte temperature by
adjusting settler hydrocarbon burner combustion rates.

Matte and slag temperatures are typically 1250C. They are chosen for
rapid
matteislag separation and easy tapping. They are also high enough to
keep matte
and slag molten during transport to their destinations. Excessive
temperatures
are avoided to minimize refractory and cooling jacket wear.
5.4.4 Reaction shaft and hearth control (Davenport et al., 2001)
Long flash furnace campaign lives require that magnetite-rich slag be
deposited
in a controlled manner on the furnaces walls and hearth. Magnetite slag
deposition is encouraged by:
(a) highly oxidizing conditions in the furnace
(b) low operating temperature
(c) low Si02 concentration in slag.

Fundicin Ventanas
Sistema de Captacin de Gases
Secundarios y Fugitivos

Esquemas de Captacin, Confinamientos


Gases Fugitivos

Confinacin, Captura
Para evitar que los gases fugitivos se
escapen, es necesario confinarlos,
acorralarlos, arrinconarlos, encerrarlos,
aislarlos)
Los medios estructurales, y de proceso,
que permite lograr estos objetivos son:
Campanas
Cabinas
Las cubiertas
El aire infiltrado
10

Cabina de Captacin Gases Sangra MB


CT

11

Confinacin, Captura
Este aire, si se infiltra a una velocidad 1
m/s posee el empuje necesario, y en sentido
contrario, al de los gases que se quieren fugar.
Y lo anterior suceder si el gas, al interior del
encerramiento, se encuentra a una presin
menor que la exterior y existan las debidas
aberturas por donde pueda ingresar el aire
ambiente.
La diferencia de presin que produce dicha
infiltracin es del orden de -4 -8 mm c.a.,
compatible con los diseos de los
encerramiento propuestos.
12

Cabinas Captacin Gases Sangria HE

Conduccin de Gases a Filtros de Manga,


Trayectoria

P&ID Control del Proceso

15

Filosofa de Control (o de Operacin) Estrategia de


Control, Metodologa

16

Filosofa de Control (o de Operacin) Estrategia de


Control, Metodologa
Por medio del controlador de presin (PIC-N o), se mide la
presin de la captacin de gases del proceso de sangrado.
El controlador de presin tiene las siguientes funciones:
Efectuar la medicin comparativa, a partir de los valores de
presin medidos en las inmediaciones de las campanas de
captacin, y transmitidas por los transmisores
Ajustar el valor de proceso (PV) al valor del set point (SP) de
presin de gases en los ductos de captacin
El sistema recibe la seal desde los transmisores de presin
PIT (2 valores) el de captacin Olla y el de captacin Piquera
El sistema compara los valores proporcionados por los
transmisores con el valor de Set Point y controla a su vez a
los variadores de frecuencia

17

Enfriamiento y Conduccin a
Limpieza
El aire infiltrado es el que permite trasladar
los gases al lugar de su limpieza y debe
hacerlo a una velocidad en el rango 15 <
Velocidad 25 < m/s para minimizar la
sedimentacin del polvo contenido en el ducto
que los traslada
Por otro lado el aire infiltrado, a temperatura
ambiente, deber ser tal que enfre los gases
fugitivos en un rango 50 < Temperatura <
80C), necesario para la precipitacin del
arsnico.
18

You might also like