Treatment of as-Containing Flue Dust of Copper Flash Smelter

"Smelting of copper concentrates in the flash smelter generates a flue dust stream that contains a substantial amount of copper and accumulates more than half of the arsenic input to the smelter. In view of its high copper content flue dust recirculation to the flash smelter is common practice. Globally traded copper concentrates are affected by ever increasing arsenic contents and cause an increasing circulating arsenic load in flash smelter operation. Control of the arsenic level in the smelter slag becomes a challenge. This interaction of arsenic loaded copper feedstock, need for flue dust recirculation and slag quality control call for possibilities to reduce the arsenic load of the recirculated flue dust stream.The technology of partial roasting is known from pre-treatment of copper concentrates before smelting, and gold concentrates before cyanide leaching, to remove the harmful element arsenic. The partial roasting technology can be adapted for use in the purification of the flue dust. A major challenge for flue dust treatment is its extremely fine particle size compared to usual concentrates. For this reason Outotec developed a new process, which allows handling of such fine flue dust. This process solution provides an efficient possibility to reduce the arsenic burden in copper smelter operations.The suggested process aims at reducing the arsenic load to the smelter by treating the flue dust prior to recirculation to the smelter. The presented results are based on test work in the Outotec R&D-centre in Frankfurt. It is possible to remove 80-85% of the contained arsenic and to collect it in an arsenic trioxide residue with a concentration above 90%. The final off gas contains SO2 from decomposition of sulphates that are contained in the flue dust. The off gas stream is relatively small. We assume that it is possible to combine the off gas stream with other smelter process gas streams and to treat it in an existing sulphuric acid plant. Coal is used as fuel and as reductant to reduce pentavalent arsenate to trivalent arsenite. Arsenite can be kept in gas form at temperatures above 450°C. This permits separation of a calcine stream with arsenic levels of 0.2 – 0.3%, which is recirculated to the furnace.Outotec has a wide range of roasting testing facilities from lab-scale to pilot-scale. Outotec has both capability to modify and adapt technology to specific ore or concentrate requirements, but also the necessary infrastructure in its research centers in Frankfurt and Pori to do appropriate validation tests in lab and pilot scale size plants."