Copper anode refining system and method

Abstract

A method and system for the copper anode refining is provided in which coherent jet technology is employed to heat the molten blister copper and/or melt scrap copper charges using a melting flame, oxidize the sulfur in the molten blister copper, and reduce the oxygen in the molten blister copper using top-blown coherent jet gas streams from one or more multi-functional, coherent jet lance assemblies. The present system and method employs a microprocessor-based controller operatively controlling the flow of an oxygen-containing gas, an inert gas, a reducing agent and a fuel to the coherent jet lance. The disclosed copper anode refining system and method greatly improves copper production while lowering oxidation /reduction cycle times and minimizing NO x emissions.

What is claimed is: 
     
         1 . A method for the anode refining of copper comprising the steps of:
 (i) charging molten blister copper to a furnace;   (ii) charging copper scrap to the molten blister copper in the furnace;   (iii) melting said copper scrap or heating the molten blister copper using a melting flame produced from a top blown, multi-functional coherent jet lance, said coherent jet lance coupled to an oxygen-containing gas source, and a fuel source;   (iv) oxidizing sulfur impurities in the molten blister copper in the furnace using a top-blown, coherent oxygen-containing gas stream ejected from the coherent jet lance, said coherent jet lance coupled to the oxygen-containing gas source and the fuel source; and   (v) reducing oxygen in the molten blister copper in the furnace using a top-blown, coherent reducing gas stream containing a reducing agent and an inert gas ejected from the coherent jet lance; said coherent jet lance coupled to the oxygen-containing gas source, the fuel source; a source of the reducing agent; and a source of the inert gas.   
     
     
         2 . The method of  claim 1  wherein the method of anode refining of copper is a continuous fire refining process and the method further comprises the steps of repeating steps (iii) through (v) for each additional charge of copper scrap or molten blister copper introduced to the furnace. 
     
     
         3 . The method of  claim 1  further comprising the step of directing one or more purge flows through the multi-functional coherent jet lance; after the oxidizing step and prior to the reducing step; after the melting or heating step and prior to the oxidizing step; during the charging steps; during the melting step; or after the reducing step. 
     
     
         4 . The method of  claim 1  wherein the oxidation step is conducted in two or more sub-steps in which the molten copper is contacted with a first coherent oxygen-containing gas stream having an oxygen concentration of at least 30 volume percent oxygen in a first step and the molten copper is subsequently contacted with a second coherent oxygen-containing gas stream having a lower concentration of oxygen than said first coherent oxygen-containing gas stream. 
     
     
         5 . The method of  claim 1 , wherein the reducing agent and fuel are natural gas and the inert gas is nitrogen. 
     
     
         6 . The method of  claim 1 , wherein the melting flame is substantially free of nitrogen gas. 
     
     
         7 . The method of  claim 1  further comprising the step of heating said molten copper during casting of the copper into anodes by contacting said molten copper with a melting flame produced by said coherent jet lance. 
     
     
         8 . The method of  claim 1  further comprising the step of skimming slag from the molten copper using a gas stream ejected from the coherent jet lance to direct the slag in the direction of a furnace mouth. 
     
     
         9 . The method of  claim 1  further comprising the step of suppressing the formation of NO x  in the furnace by injecting nitrogen gas into the furnace headspace using the coherent jet lance during the charging step. 
     
     
         10 . A copper anode refining system comprising:
 a copper metallurgical furnace having a refractory wall, the furnace adapted to contain a bath of molten copper having a top surface and said furnace defining a headspace above the top surface of the copper bath;   at least one multi-functional, coherent jet lance connected to sources of oxygen-containing gas, inert gas, reducing agent and fuel, said coherent jet lance mounted in said furnace refractory wall at a location above the top surface of the copper bath; and   a controller operatively controlling the flow of oxygen-containing gas, inert gas, reducing agent and fuel to the at least one coherent jet lance;   wherein a melting flame comprising the fuel and the oxygen-containing gas is produced from the at least one coherent jet lance to heat the molten copper or melt any scrap copper charges provided to the furnace; and   wherein a coherent oxygen-containing gas stream is produced from the coherent jet lance to oxidize sulfur in the copper bath; and   wherein a coherent reducing gas stream containing the reducing agent and the inert gas is produced from the coherent jet lance to reduce oxygen in the copper bath.   
     
     
         11 . The system of  claim 10  wherein the coherent jet lance is a removable, lightweight coherent jet lance that may be removed from the furnace during copper refining steps other than melting, oxidizing and reducing. 
     
     
         12 . The system of  claim 10  wherein the melting flame is substantially free of nitrogen gas. 
     
     
         13 . The system of  claim 10  wherein a top-blown nitrogen gas stream is introduced into the furnace headspace from the at least one coherent jet lance during charging of copper scrap into the furnace to suppress the formation of NO x  in the furnace. 
     
     
         14 . The system of  claim 10 , wherein the oxygen-containing gas is industrial grade purity oxygen, the reducing agent and fuel are natural gas, and the inert gas is nitrogen. 
     
     
         15 . A method for inhibiting the formation of NO x  during the refining of metals comprising the steps of:
 providing a charge of scrap metal to a molten metal bath in a furnace equipped with at least one top blown lance assembly and coupled to an oxygen-containing gas source, a fuel source, and a nitrogen gas source;   melting said scrap metal charge using a melting flame using the fuel and the oxygen containing gas;   oxidizing or reducing impurities in the melt using the oxygen-containing gas or reducing agents; and   intermittently injecting prescribed volume of nitrogen gas into the furnace headspace using the top blown lance assembly during or after the step of providing a charge of scrap metal to inhibit the formation of NO x  during the refining process.   
     
     
         16 . An improvement to the method for continuous refining of copper in an anode furnace, the improvement comprising the steps of:
 charging molten blister copper to the anode furnace and optionally charging copper scrap to the molten blister copper in the anode furnace;   oxidizing sulfur impurities in the molten blister copper in the anode furnace using a top-blown, coherent oxygen-containing gas stream ejected from a coherent jet lance mounted in a refractory wall of the anode furnace at a location above the top surface of the molten blister copper, said coherent jet lance coupled to the oxygen-containing gas source and the fuel source; and   reducing oxygen in the molten blister copper in the anode furnace using a top-blown, coherent reducing gas stream containing a reducing agent and an inert gas ejected from the coherent jet lance; said coherent jet lance coupled to the oxygen-containing gas source, the fuel source; a source of the reducing agent; and a source of the inert gas.