t h e development & selection of copper smelting ... · pb and its compounds 10 0.7 0.7 as and...

T h e

Development & Selection of

Copper Smelting Technology

in China

T a n g B i n

A p r . 2 0 1 8

C o n t e n t

Developmental Background of Copper Smelting Technology(CST) in China

Process Selection of Chinese Smelting project

Features and Innovation of CST Development in China

Environmental Protection and Emission in Chinese Smelters

Conclusion

（103 t）Copper supply & demand world wide in recent years

Item 2011 2012 2013 2014 2015 2016 2017

Output 19160 19830 20760 22827 23077 23460 23510

Consumption 19220 19700 20550 22811 22931 23400 23730

Supply & Demand Balance

-60 130 210 116 146 60 -220

Copper supply & demand of China in recent years

Item 2011 2012 2013 2014 2015 2016 2017

Output 5185 5617 6179 6884 7369 7648 8000

Consumption 7330 7680 9150 9660 9930 10310 11923

Net import 2678 3133 2912 3324 3466 3203 3923

（103 t）

C o n t e n t





Conclusion

Introduced

Tech.

Traditional

tech. in Early

Time

Self-depend

Innovation

Digestion

and

innovation

Plant

Modernization、

Handle complex ore material

Multi-metal recovery

Less pollution,

low consumption

Large-scale

Targets for CST Advancement

Technology Development：

All the world-leading process and equipment are gathered in China

CST Development Process

Some large-scale copper smelter put into operation

▶ Reverberatory furnace smelting + CF converting —— Daye, Baiyin Copper

▶ Electric furnace + CF converting —— Yunnan Copper, Jinchuan Copper

▶ Blast furnace smelting + CF converting —— Tonglin, shenyang

▶ Blast furnace smelting + CF converting —— Fuchunjiang, Yantai

CST in Early Period

（1949 -- 2000）

Noranda Smelting TSL smelting Flash Smelting

Upgrading Period of CST -- Introduced technology

（1980 — 2010）

Four Features:

High-intensity smelting

Smart control system

Rotation-suspension burner

No electric furnace

Technological development of pyrometallurgy ——Flash smelting

Upgrading of Flash Smelting Tech. in China

Online automation control system

FSF+PS, design capacity：80kt/a copper

Khatoon Abad Copper Smelter

Technological development of pyrometallurgy —— Flash smelting technology

export

Philippine Associated Smelting & Refining Corporation (PASAR) Expansion

Project, Expanded from 170kt/a to 300kt/a cathode copper

Technological development of pyrometallurgy — Flash smelting technology export

“3+2” Smelters

Double Flash technology developing in China

High availability,

Good parameters

Cooperation with Kennecott

First choice more than

400kt/a capacity

Technological development of pyrometallurgy ——double flash smelting

Xiangguang Smelter

Jinguan Smelter


Ningde Smelter of Chalco

Fangchenggang Smelter


Sichuan Hongda Smelter

Flash smelting in China

NO. Owner Capacity Remarks

1 Guixi Smelter (first unit) 90→200→300Kt/a Phase III expansion

2 Jinlong Smelter 80→200→350Kt/a Phase III expansion

3 Yanggu Xiangguang Smelter 400Kt/a

4 Jinchuan Smelter 150Kt/a

5 Guixi Smelter (second unit) 200Kt/a

6 Zijin Smelter 400Kt/a Phase III expansion,ongoing

7 Jinguan Smelter,TNMG 400Kt/a

8 Fangchenggang Smelter of Jinchuan Group. 400Kt/a

9 Baiyin Copper Smelter 250Kt/a ongoing

10 Ningde Smelter of Chalco 400Kt/a ongoing

11 Sichuan Hongda Copper smelter 400Kt/a ongoing

Total 3650/a

Technological development of pyrometallurgy ——TSL smelting

No. Owner Capacity Process Applied

1 Yunnan Copper Smelter 200Kt/a ISA smelting + CF converting

2 Dianzhong Copper Smelter 100Kt/a ISA smelting + CF converting

3 Kunpeng Smelter in Sichuan 100Kt/a ISA smelting + CF converting

4 Jinchang Smelter TNMG 200Kt/a

Ausmelt smelting + CF converting

5 Chifeng Jinjian Smelter 100Kt/a

6 Huludao copper Smelter 100Kt/a

7 Xinjiang Wuxin copper Smelter 100Kt/a

8 Daye copper Smelter 300Kt/a

9 Yuanqu Smelter of

Zhonag’tiao’shan Group

60Kt/a Ausmelt smelting +Ausmelt converting

10 Yun Tin Group Smelter 100Kt/a Ausmelt smelting + Ausmelt converting

Total capacity: 10 units 1240kt/a

TSL smelting in China

Side-blown furnace in Zhejiang Heding Smelter

Technological development of pyrometallurgy ——Side blown smelting

Smelting technology Innovation

▶ Baiyin Furnace Smelting—— Version 1, 2, 3

▶ Side-blown furnace smelting—— Jingfeng process, Heding process

▶ Side-blown furnace smelting + Continous top-blown converting – Chifeng,

Yantai

▶ Bottom-blown smelting + PS Converting

▶ Bottom-blown smelting + Bottom-blown converting

▶ SLS+ SLCR two steps

Side-blown smelting

Bottom-blown smelting

SBF smelting +PS converting; Biggest SBF under operation in China.Capacity: 150kt/a (Phase I),300kt/a (Phase I);Startup year:2014(Phase I),2017(Phase II)

Side blown smelting + Continuous top blown converting

SBF smelting +Continuous top blown converting;

Capacity: 300kt/a (Phase I), 600kt/a (Phase II)

Project Status:Ongoing,Under construction,Plan to put into operation in 2019

SBF smelting +Continuous top blown converting;

Capacity: 100kt/a (Blister);

Project Status:Ongoing,Under construction, Plan to put into operation in 2019

NO. Owner Capacity Process Status

1 Yantai Penghui Smelter 80Kt/a SBF+top-blown converting

2 Yunnan Copper Chifeng Smelter 140Kt/a SBF+top-blown converting 2008, 2014

3 Zhejiang Heding Smelter 150+150Kt/a SBF+PSC 2012, 2017

4 Kangxi Smelter of Jiangxi Copper 50Kt/a SBF+PSC

5 Chizhou GuanHua Copper Smelter 100Kt/a SBF+PSC

6 Huichun Smelter of Zijin Mining Group 100Kt/a SBF+PSC

7 Baiyin Copper Smelter 130Kt/a SBF+PSC Expansion

8 Baiyin Copper Smelter 250Kt/a SBF+PSC Ongoing

9 Chifeng Jinjian Smelter 260Kt/a SBF+PSC Ongoing

10 Chifeng Smelter of Yunnan Copper

Group

400Kt/a SBF+top-blown converting Ongoing

11 Nanguo Copper Smelter 300Kt/a SBF+top-blown converting Ongoing

12 Yantai Guoxing Smelter 200Kt/a SBF+top-blown converting Ongoing

13 Qiqiha’er Smelter of Zijin Mining Group 150Kt/a SBF+bottom-blown converting Ongoing

Total 2460kt/a

Side blown smelting in China

Technological development of pyrometallurgy ——bottom-blown furnace

Smelting

Furnace

PSC

Rotary AF

Oxygen Plant

Blending House

Anode

Copper

Anode

Copper

Blister

Matte

GAS

Acid Plant

Early SBF Process：Bottom-blown smelting+PSC+ AF

Bottom blown smelting + Bottom blown converting

Blending

System

Matte

SLS

SLCR

Casting Wheel

system

Anode

Copper

Anode

copper

Material

blend

Acid Plant

Waster Water Treatment

GAS

Acid

GAS

Slag Flotation

Slag concentrateElectrolysis

Anode

slime

Gold, silver, lead,

seleniumCathode copper

Two steps has been invented by Dongying Fangyuan Company, and put into

operation in Sep. 2015 with handling 1.5 million ton metal ore material.

Julong Geermu 400kt/a Copper Smelter

Ongoing

400kt/a cathode copper, Two steps,SLS+SLCR

Bottom blown smelting in China

NO. Owner Output Process Status

1 Hengbang Smelter in Shandong 100Kt/a BBRs + PSC

2 Shuikoushan Smelter 100Kt/a BBRs + PSC

3 Yimen Smelter of Yunnan Copper Group 100Kt/a BBRs + PSC

4 Yuguang Smelter in Henan 120Kt/a BBRs + BBRc

5 Baotou Huading Copper Smelter 100Kt/a BBRs + BBRc

6 Qinghai Copper Smelter 100Kt/a BBRs + BBRc

7 Zhongtiaoshan Smelter 350Kt/a BBRs + BBRc Ongoing

8 Henan Jincheng Smelter 100Kt/a BBRs + BBRc

9 Copper Smelter of Zhongjin Gold Corp. 280Kt/a BBRs + FCF

10 Dongying Fangyuan Smelter 300Kt/a SLS+SLCR

11 Julong Smelter in Tibet 400Kt/a SLS+SLCR Ongoing

Total 1750kt/a

C o n t e n t





Conclusion

Emission Limits in Recent Years in China

Main Pollutant

TIME

1997~2010 2010 Until now 2013 Until now

Normal Emission Limit Special Emission Limit

Waste

Gas

SO2 850 400 100

Particulate 100 80/50* 10

NOX 240 240 100

Acid Mist 45 40 20

Hg and its

compounds1 0.012 0.012

Pb and its

compounds10 0.7 0.7

As and its

compounds/ 0.4 0.4

NO ITEMIFC

StandardUSA

StandardGermanStandard

JapaneseStandard

Chilean Standard

Chinese Standard

Normal Emission

Limit

Special Emission

Limit

1 SO2 ＜200650ppm

（1857mg/m3）500

q = K×10-3×He2

K means regional ratio

He means the effective height of

stack

Greenfield: 200ppm

（571mg/m3）

Brownfield: 400ppm（1143

mg/m3）

400 100

2Particu

late1~5 50 20

Normal area: 150Special area: 80

30 80/50 10

Pollution Source PollutantPlant 1

(FS+FC)

Plant 2

(FS+FC)

Plant 3

(FS+FC)

Plant 4

(SBF+PSC)

Fugitive gas

SO2 14~26 / / 21~69

Particulate 7.2~20.9 / / /

Gas from acid-

making

SO2 41~68 30.2~147.6 97 2~58

Particulate / / 36.43-4

~12

Time range for data Apr to Oct 2017Jan.1st 2016 to Dec.10

2017May 2017 June 2017

Data source Monitoring data of state-controlled emissions

State-controlled gas comparison chart in Chinese typical smelters (Unit: mg/Nm3 )

Pollutant UnitPlant 1

(FS+FC)

Plant 2

(FS+FC)

Plant 3

(FS+FC)

Plant 1

(SBF+PSC)

SO2 t/a 331.68 2744.22 1062.95 1550

NOX t/a 253.22 / / 377.57

Comparison on Environmental Approval Data of Total Pollutant

in Typical Double-flash Smelters

Note:

1. Data sourced from Environmental Impact Report and Approval Documents

2. There was no NOX limits for emission in the state when plant 1 and 2 are approved

C o n t e n t





Conclusion

Smelting Converting Refining

1 FSF CF AF

2 FSF FCF AF

3 SBF CF AF

4 SBF TCC AF

5 BBS FCF AF

6 BBS BBC AF

7 SLS SLRC

8 TSL CF AF

▶ Short process and continuous converting become more and more popular

▶ Environmental restriction, PS Converter modification

New Project Plant 1 Plant 2 Plant 3 Plant 4 Plant 5

Process Double flash Double flash Double flash Double flash Flash + CFContinuous

smelting

Capacity（kt） 400 450 400 400 300 200

Process Flow Whole processWhole process + 50kt

scrap copper system

No precious metal

and dust treatment

No precious metal

and dust treatment

No precious metal

and dust treatment Whole process

Foundation

base

Marine

reclamation land

with pile depth as

47m

Yellow river plain

with pile depth as

24m

Hills landscape with

pile depts as 23m

Coastal area

Shallow foundation

Mountain landscape

Shallow foundation

Kashgar

landscape

Shallow

foundation

Occupational

land (acre)860

1480 including scrap

system and railways

1498

Railways prepared

3097

including scrap

system and

railways

820 900

Year of

Construction2016-2018 2005-2011 2009-2013 2011-2014 2009-2016

Starts from

2015

Investment

(100m)

37.47

(estimated)

48

(Phase 1 + II)40 69 33

28

(estimated)

Investment for

copper per

tonnage

(100m)

0.936 1.067 1.000 1.725 1.178 1.400

C o n t e n t





Conclusion

Principle for determining project scale

Material Source: Benchmarking, joint venture, outsourcing

Conditions for construction

Market demand: Overseas, Domestic

The selection of process in copper smelter is related to multiply factors.

There is no best, only the most appropriate.

T h a n k Y o u

A p r . 2 0 1 8