MMC Norilsk Nickel, Norilsk, Russia:

L. V. Krupnov, Deputy Head of the Science and Technology Directorate – Chief Metallurgist, Candidate of Technical Sciences, e-mail: krupnovlv@nornik.ru

Gipronikel Institute LLC, Saint Petersburg, Russia:
R. A. Pakhomov, Senior Researcher at the Pyrometallurgy Laboratory, Research & Development Department, Candidate of Technical Sciences, e-mail: PakhomovRA@nornik.ru

Peter the Great St. Petersburg Polytechnic University, Saint Petersburg, Russia:

R. V. Starykh, Associate Professor, Candidate of Technical Sciences, e-mail: kafedra-cm@yandex.ru

MMC Norilsk Nickel’s Polar Division, Nadezhda Metallurgical Plant named after B. I. Kolesnikov, Norilsk, Russia:
S. A. Grizman, Deputy Chief Engineer Responsible for Process and Ecology

The use of man-made deposits and fine ore concentrates in the flash smelter process, as well as the poorer quality of the raw materials observed (due to a higher share of particles smaller than 10 μm) lead to a higher amount of entrained dust and causes accretion in the slag end, uptake shaft and waste heat boiler. A higher dust entrainment is associated with a higher recycle, lower energy capacity of the raw materials and poorer recovery of non-ferrous metals. Numeric modelling of the heat and mass exchange processes in the gas environment of the settler and uptake shaft helped determine how different sizes and locations of the spoiler can change the gas flow parameters of the flash smelter. The modelling study showed that a 500 mm wide (the width of the settler) and 270 mm high spoiler mounted on the fire side of the settler at least 2,000 mm away from the entry to the uptake shaft could help reduce the amount of entrained dust by as much as 20% (relative) depending on the size and density of gas-dust particles. On the basis of the above calculations, a series of pilot tests was conducted on Line 1 of Nadezhda Metallurgical Plant in July 2019. Using various analysis techniques (such as thermal imaging of the surface in the spoiler area, the gas temperature, the gas flow rate, as well as methods used in analytical chemistry, scanning electron microscopy and X-ray spectral microanalysis), the authors of this paper examined the effect produced by the mounted spoiler on the gas flow. The authors would like to thank the leadership and the operations personnel of Nadezhda Metallurgical Plant for their support and great contribution to the pilot tests performed.

1. Bacedoni M., Moreno-Ventas I., Rios G. Copper Flash Smelting Process Balance Modeling. Metals. 2020. Vol. 10, Iss. 9. pp. 1–18.
2. Ma B., Wang C., Chen Y., Xing P. An Innovative Oxygen-Enriched Flash Smelting Technology for Lead Smelting and Its Industrial Application. 9^th International Symposium on High-Temperature Metallurgical Processing. 2018. pp. 31–42.
3. Miettinen E. Thermal conductivity and characteristics of copper flash smelting flue dust accretions. PhD thesis, Helsinki University of Technology, Espoo, 2008. 87 p.
4. Vieira L., Marques M., Leite F. Flash furnace thermal control at Paranapanema. Proceedings of the 15^th International Flash Smelting Congress. Helsinki, 2017.
5. Takashi Kimura. Copper Smelting and Refining at Saganoseki Smelter. Journal of MMIJ. 2007. Vol. 123, Iss. 12. pp. 626–629.
6. Yasuda Y., Chida H., Motomura T. Flash Smelting Furnace Renewal and Productivity Improvement in the Saganoseki Smelter and Refinery. Journal of MMIJ. 2020. Vol. 136, Iss. 8. pp. 88–98.
7. Sanchez A., Ramos M., Garcia J. Improvements carried out in the FSF up-take shaft and waste-heat boiler — a review over Atlantic Copper’s history. Proceedings of the 15^th International Flash Smelting Congress. Helsinki. 2017.
8. Jian-Ping H., Zheng-Bin W., Jin-Jun F. The overview of progress at Jinlong smelter in recent years. Proceedings of the 15^th International Flash Smelting Congress. Helsinki. 2017.
9. Keytshokayl D. S. Up-take shaft scull formation control at BCL smelter. Proceedings of the 13^th Flash Smelting Congress. Botswana, 2011. pp. 1–26.
10. Krupnov L. V., Pakhomov R. A., Starykh R. V., Talalov V. A. The changing dynamics of the gas-dust flow in the flash smelter at Nadezhda metallurgical plant due to addition of a shield. Part 1. Model calculations. Tsvetnye Metally. 2021. No. 10. pp. 63–71. DOI: 10.17580/tsm.2021.10.09.
11. Krupnov L. V., Starykh R. V., Petrov A. F. Forming mechanism of refractory accretion in the falsh smelters of “Nadezhda” Metallurgical Plant. Tsvetnye Metally. 2013. No. 2. pp. 46–51.
12. Johto H., Latostenmaa P., Peuraniemi E., Osara K. Review of Boliden Harjavalta nickel smelter. Extraction. 2018. pp. 81–87.
13. Talalov V. A., Krupnov L. V., Rumyantsev D. V., Starykh R. V., Petrov A. F. Research of gas flow movement in flash smelting furnace of Nadezhda metallurgical plant by mathematical modeling methods. Tsvetnye Metally. 2015. No. 5. pp. 86–90. DOI: 10.17580/tsm.2015.05.17.
14. Starykh R. V., Morgoslep V. I., Krupnov L. V., Tozik V. M., Pakhomov R. A. et al. Method of processing fine-dispersed raw material in a flash smelting furnace. Patent RF, No. 2740741. Applied: 23.05.2020. Published: 20.01.2021. Bulletin No. 2. 15. Vanyukov A. V., Bystrov V. P., Vaskevich A. D. et al. Liquid bath smelting. Ed. by A. V. Vanyukov. Moscow : Metallurgiya, 1988. 208 p.
16. Mechev V. V., Bystrov V. P., Tarasov A. V. et al. Autogenous processes of nonferrous metallurgy. Moscow : Metallurgiya, 1991. 412 p.
17. Shapunov I. E., Bargman M. A., Volkov A. P., Kiselev B. N., Shurchkov V. P. Oxygen-torch-smelting furnace. Patent USSR, No. 1062489А. Applied: 19.04.82. Published: 23.12.83. Bulletin No. 47.
18. GOST 17.2.4.06–90. Nature protection. Atmosphere. Methods for determination of velocity and flowrate of gas-and-dust streams from stationary sources of pollution. Introduced: 01.01.1991.
19. Levin E., Robbins C. R., McMurdie H. F. Phase diagrams for ceramists supplement. The American Ceramic Society, Columbus. Ohio. 1969. 625 p.
20. Velyuzhenets G. A., Yertseva L. N., Tsemekhman L. Sh., Fomichev V. B. Substantial composition of dusts at Nadezhdinskiy metallurgical plant. Tsvetnye Metally. 2010. No. 9. pp. 31–36.
21. Velyuzhenets G. A., Tsemekhman L. Sh. Examining the composition and dust content of gases generated by the major metallurgical sites of MMC Norilsk Nickel’s Polar Division. VINITI of RAS, Manuscript No. 300-В2013, 28/10/2013. 46 p.
22. Ertseva L. N., Ryabko A. G., Evgrafova A. K., Algunova E. A. The material composition of copper ore oxidation products generated during flash smelting. Studies in Nickel and Cobalt Production Processes: Research papers. Leningrad : Gipronikel, 1986. pp. 71–75.