Plant Trial Evaluation of Concentric Versus Single-Pipe Sonic Tuyeres in Continuous Copper Converting
摘要
After close to 30 years developing and promoting sonic injectionSonic Injection for the nonferrous metalsMetal industry, I am finally witnessing a growing momentum of interest for the technologyTechnology when an ever increasing number of engineers and managers from copperCopper and nickelNickel smeltersSmelter reach out to me with renewed enquiries. Moreover, technologyTechnology suppliers and engineeringEngineering firms are also voicing their interest in collaborative development and implementation of sonic tuyeres for their clients. Although I am delighted that my long-held belief in the benefits of the technologyTechnology and my persistent efforts to promote it seem to be bearing fruit, I remain well aware that the road to global acceptance of sonic injectionSonic Injection is still an arduous one. Nevertheless, this growing momentum of interest is making me more motivated than ever! And in this spirit, I believe that the 12th International CopperCopper conference could not be a more suitable time and place to demonstrate that sonic injectionSonic Injection offers a much wider portfolio of technologiesTechnology than just the high oxygen shrouded tuyere. In fact, depending on the process where the sonic tuyeres will be implemented—whether in copper smeltingCopper Smelting, copperCopper or nickelNickel converting, or copperCopper refiningRefining—a large range of options are available by selecting the type of sonic tuyere or lance, e.g., concentric or single-pipe, and by varying the type of reactive and shrouding gases. In this paper, I am first briefly describing the characteristics of the concentric and single-pipe sonic tuyeres. Next, to offer a practical illustration of two such sonic tuyere alternatives, I present key results of a plant trialPlant Trial in continuous copper convertingContinuous copper converting where a concentric sonic tuyere and a single-pipe sonic tuyere were tested and evaluated simultaneously. I describe their characteristics and briefly discuss their respective performancePerformance. Then, to conclude, I share some important lessons learned during the plant trial that should be valuable for engineers and managers of copperCopper and nickelNickel smeltersSmelter wishing to test or implement sonic injection. Such lessons are critical and particularly valuable when considering that retrofitting sonic tuyeres is a lower capital expenditure solution in smelterSmelter modernizationModernization, whether the goals are to improve operators’ safetySafety and work hygiene with punchless blowing, to intensify processes to increase production or lower off-gas volumes, or to increase vessel campaign life.