The Interfacial Adhesion Behaviors of Sedimentation Zone in Flash Smelting Based on DFT Calculation (Part II)—The Adhesion Mechanisms of Fe3O4 with FeS, Ni3S2 and Cu2S
摘要
In nickel flash smelting, the adhesion of Fe3O4 to low-nickel matte results in the physical entrapment loss of valuable metals in slag, posing a critical barrier to improving copper and nickel recovery rates. In this study, the interfacial adhesion behaviors between Fe3O4 and representative sulfides in low-nickel matte, including FeS, Ni3S2, and Cu2S, were systematically investigated using first-principles density functional theory (DFT) calculations to elucidate the underlying adhesion mechanisms. The calculated adsorption energies of the (111) crystal plane of Fe3O4 with FeS, Ni3S2, and Cu2S are −13.74, −5.91, and −13.19 eV, respectively, substantially higher than those associated with SO2 and other matte constituents. This indicates that interfacial adhesion dominates the separation process between slag and matte at the interface. Electronic structure analysis reveals there exists significant charge transfer and covalent bonding between FeS, Cu2S with Fe3O4, as evidenced by distinct hybridization peaks in the density of states (DOS) near −4.23 and −4.60 eV. In contrast, Ni3S2 exhibits weaker interfacial polarization and lower binding strength. Based on these findings, strategies such as reducing the Fe/SiO2 ratio, raising the smelting temperature, and minimizing oxygen partial pressure and Fe3O4 content are proposed to enhance fluidity and interfacial tension between low-nickel matte and slag, which accordingly mitigate the adhesion effect between the Fe3O4 and low nickel matte, thereby offering theoretical guidance for improving the recovery efficiency of valuable metals during matte smelting.