Evaluación de procesos de la tecnología de fusión SKS, comparándola con las utilizadas en Chile y evaluando su potencial de proceso
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Fecha
2018
Profesor/a Guía
Facultad/escuela
Idioma
es
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Título del volumen
Editor
Universidad Andrés Bello
Nombre de Curso
Licencia CC
Licencia CC
Resumen
El proceso de fusión consiste en llevar el concentrado a hornos que funcionan a 1200 ºC aproximadamente. Tradicionalmente, se utilizan en Chile dos tipos de horno, los cuales corresponden al FLASH y el Convertidor Teniente (CT). En China, se está utilizando para la producción de cobre una nueva tecnología, la cual utiliza soplado inferior. Este reactor es comunmente conocido como SKS/BBS.
La actual tesis, se confecciona por medio de una investigación bibliográfica y elaboración de un balance de masa y energía, para realizar una evaluación de procesos de la tecnología de fusión SKS, comparándola con las utilizadas en Chile y evaluando su potencial de proceso. Dentro del análisis expuesto por diferentes autores, es posible vislumbrar grandes razones respecto a la diferencia entre la nueva tecnología de fusión en baño y las utilizadas en Chile, destacando entre ellas, el soplado inferior de aire con régimen de chorro utilizado en el SKS, el cual produce que se obtengan burbujas mas pequeñas en el baño, reduce total o parcialmente el bloqueo e infiltración del baño en la punta de la tobera y reduce las salpicaduras al tener un baño mucho más tranquilo, mientras que el convertidor teniente insufla aire de forma lateral y se comporta de manera contraria al SKS. Así mismo, la nueva tecnología china utiliza “lanzas de oxígeno” o “inyectores Savard-Lee”, lo que permite el uso de un mayor enriquecimiento de oxígeno.
Para realizar el balance de masa y energía del reactor Flash, SKS y Convertidor Teniente, se utilizaron concentrados típicos chilenos, los cuales son representativos a los utilizados en la industria. Con los datos obtenidos, se realizaron comparaciones como la variación de energía utilizada en cada proceso, donde se observó que el mayor aumento de energía generado por las reacciones de oxidación, ocurrían en el convertidor teniente seguido por el SKS, dejando atrás el horno de fusión flash, puesto que ambos obtienen grados de eje diferentes, 70%-75% y 62% respectivamente. Así mismo, en la fase gaseosa, el CT tiene un mayor consumo energético respecto a los demás reactores, lo cual se relaciona al bajo enriquecimiento de oxígeno y, por ende, un mayor volumen de nitrógeno, lo que provoca gran cantidad de gases.
Por otra parte, al variar la ley de eje y enriquecimiento de oxígeno, el CT es el resultó ser el menos estable, puesto que su volumen varió un 24%. El HFF, varió un 17% y el SKS tuvo la mejor estabilidad en el volumen de gases con una variación del 11%, con respecto a la ley y enriquecimiento más bajos en los parámetros de simulación. Así mismo, también se observó que, al aumentar la ley de eje, también aumentará la cantidad de carga fría que necesitan los reactores de fusión para lograr el balance térmico, debido principalmante a que la ley de eje esta directamente relacionada con la generación de energía de las reacciones de oxidación, siendo el SKS el que acepta mas carga fría, ya que además es el que acepta un mayor enriquecimiento de oxígeno.
Finalmente, se analizó el comportamiento del volumen de gases, variando la razón S/Cu, para lo cual se realizó una simulación en el balance con los criterios operacionales propios de cada reactor, pero se fijó una ley de mata de 62% para todos los reactores. De lo anterior, se concluyó que un aumento en la porción de azufre en el flujo de alimentación, aporta mucho más al volumen de gases del horno de fusión instantánea, que en los reactores en baño.
A modo de conclusión, el reactor SKS resultó ser el proceso con mejor rendimiento operacional al operar con altos niveles de enriquecimiento, según las ventajas descritas y evaluadas en este documento.
The fusion process consists in melting concentrates in kilns that operate at approximately 1200 ºC. Traditionally, two types of furnaces are used in Chile, which correspond to FLASH and the Teniente Converter (CT). In China, a new technology is currently in use for copper production, which uses bottom blowing. This reactor is commonly known as SKS/BBS. This thesis is composed of literature review and a mass and energy balance, to make an assessment evaluation of the processes of the fusion technology SKS, to make a with technologies currently employed in Chile and and evaluate its potential use in our country Among the analysis reported by various authors, it is possible to observe several advantages of the new SKS/BBS technology with respect to others used in Chile, such as lower blowing of the air through a jet, which produces smaller bubbles in the bath. It also reduces partially or totally the blockage and the infiltration of the bath in the tip of the nozzle and reduces the splashes as the bath is much calmer, whereas, the Teniente converter blows air sidewise and behaves in an opposite way comparedto the SKS. Likewise, the new Chinese technology uses "oxygen lances" or "Savard-Lee injectors", which allow the use of a higher oxygen enrichment, causing better results inside the kiln, as well as in the results of the balance. To calculate the mass and energy balance of the Flash reactor, SKS and Teniente Converter, typical Chilean concentrates characterization was used, which are representative as these are the same used by the industry. With the data obtained, comparisons were carried out such as, the variation of energy employed in each process, where it was observed that the higher increase in energy generated by the oxidation reactions occurred in Teniente Converter, followed by SKS leaving behind the flash melting furnace, since both obtain different matte percentage, 70% -75% and 62% respectively. Likewise, in the gaseous phase, the CT has a higher energy consumption, which is related to the lower oxygen enrichment and, therefore, a greater volume of nitrogen, which causes a large amount of gases. On the other hand, when the matte percentaje and the oxygen enrichment is modified, the CT is the least stable, since its volume varied by 24%. The HFF, varied a 17% and the SKS had the best stability in the volume of gases with a variation of 11%, with respect to the matte percentaje and the lowest enrichment in the simulation parameters. Likewise, it was also observed that by increasing the axis law, the amount of cold load required by the fusion reactors will also increase to achieve thermal balance, mainly because the axis law is directly related to the generation of energy from the oxidation reactions, being the SKS the one that accepts more cold load, since in addition it is the one that accepts a greater enrichment of oxygen. Finally, the behavior of the volume of gases was analyzed, varying the S / Cu ratio, for which a balance simulation was performed with the operational criteria of each reactor, but it was set at a matte percentaje of 62% for all the reactors. it was concluded that an increase in the sulfur amount in the feed flow, contributes much more to the volume of gases from the instant melting furnace, than in the bath reactors . To conclude, the SKS reactor is the process with the best operational performance, as it operates with high levels of oxygen enrichment, according to the advantages described and evaluated in this document.
The fusion process consists in melting concentrates in kilns that operate at approximately 1200 ºC. Traditionally, two types of furnaces are used in Chile, which correspond to FLASH and the Teniente Converter (CT). In China, a new technology is currently in use for copper production, which uses bottom blowing. This reactor is commonly known as SKS/BBS. This thesis is composed of literature review and a mass and energy balance, to make an assessment evaluation of the processes of the fusion technology SKS, to make a with technologies currently employed in Chile and and evaluate its potential use in our country Among the analysis reported by various authors, it is possible to observe several advantages of the new SKS/BBS technology with respect to others used in Chile, such as lower blowing of the air through a jet, which produces smaller bubbles in the bath. It also reduces partially or totally the blockage and the infiltration of the bath in the tip of the nozzle and reduces the splashes as the bath is much calmer, whereas, the Teniente converter blows air sidewise and behaves in an opposite way comparedto the SKS. Likewise, the new Chinese technology uses "oxygen lances" or "Savard-Lee injectors", which allow the use of a higher oxygen enrichment, causing better results inside the kiln, as well as in the results of the balance. To calculate the mass and energy balance of the Flash reactor, SKS and Teniente Converter, typical Chilean concentrates characterization was used, which are representative as these are the same used by the industry. With the data obtained, comparisons were carried out such as, the variation of energy employed in each process, where it was observed that the higher increase in energy generated by the oxidation reactions occurred in Teniente Converter, followed by SKS leaving behind the flash melting furnace, since both obtain different matte percentage, 70% -75% and 62% respectively. Likewise, in the gaseous phase, the CT has a higher energy consumption, which is related to the lower oxygen enrichment and, therefore, a greater volume of nitrogen, which causes a large amount of gases. On the other hand, when the matte percentaje and the oxygen enrichment is modified, the CT is the least stable, since its volume varied by 24%. The HFF, varied a 17% and the SKS had the best stability in the volume of gases with a variation of 11%, with respect to the matte percentaje and the lowest enrichment in the simulation parameters. Likewise, it was also observed that by increasing the axis law, the amount of cold load required by the fusion reactors will also increase to achieve thermal balance, mainly because the axis law is directly related to the generation of energy from the oxidation reactions, being the SKS the one that accepts more cold load, since in addition it is the one that accepts a greater enrichment of oxygen. Finally, the behavior of the volume of gases was analyzed, varying the S / Cu ratio, for which a balance simulation was performed with the operational criteria of each reactor, but it was set at a matte percentaje of 62% for all the reactors. it was concluded that an increase in the sulfur amount in the feed flow, contributes much more to the volume of gases from the instant melting furnace, than in the bath reactors . To conclude, the SKS reactor is the process with the best operational performance, as it operates with high levels of oxygen enrichment, according to the advantages described and evaluated in this document.
Notas
Tesis (Ingeniero Civil en Metalurgia)
Palabras clave
Fundición de Cobre, Métodos de Producción, Hornos para Fundición