Thermodynamics of converting high-impurity copper matte

As long as the tendency of Chilean copper ores continues to feature high levels of impurities, the smelters will tend to produce high-impurity mattes. The most notable impurities include As, Sb, Ph and Zn. Producing high-quality copper with such materials is a major challenge to metallurgical engineers and operators. More investigations into process optimisations and/or alternatives are needed, using both theoretical knowledge and operational skill. Converting of matte in Chile depends on the matte grade using established technologies. Mattes up to 66 per cent Cu, such as those from Outokumpu Flash furnaces, are converted in two stages, while typical Teniente Converter mattes, ranging from 70-74 per cent Cu are converted in one blow, directly to copper. In this paper thermodynamic data are used to evaluate possible variations in the use of traditional technologies applied to smelt copper concentrates with high impurity levels. The results of this analysis help to predict the impurity distributions between matte-slag-gas during the slag blow, and between copper-slag-gas during the copper blow. For converting high-impurity white metal, the effectiveness of volatilisation in the slag blow is analysed. In the copper blow, the type and the amount of flux (SiO2, CaO and others) are altered with the aim of optimising impurity distribution to the slag and gas.