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Tutorial 2

The document contains 10 questions regarding chemical engineering processes related to minerals processing and copper smelting. Question 1 asks the reader to calculate product weights from a limestone-coke kiln reaction. Question 2 asks how to design a furnace process to produce a 55% copper matte concentrate from a 24% copper feed. It asks for pre-treatment steps, reactions, and operating parameters. Question 10 presents compositional information about a fluidized bed roaster process and asks four specific questions about feed composition, calcine product composition, theoretical air requirements, and excess air requirements.

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Arnold Mugadza
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182 views2 pages

Tutorial 2

The document contains 10 questions regarding chemical engineering processes related to minerals processing and copper smelting. Question 1 asks the reader to calculate product weights from a limestone-coke kiln reaction. Question 2 asks how to design a furnace process to produce a 55% copper matte concentrate from a 24% copper feed. It asks for pre-treatment steps, reactions, and operating parameters. Question 10 presents compositional information about a fluidized bed roaster process and asks four specific questions about feed composition, calcine product composition, theoretical air requirements, and excess air requirements.

Uploaded by

Arnold Mugadza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING


TCE 5107 – ADVANCED MINERALS ENGINEERING 1A
TUTORIAL 02

Qn. 1.
Limestone mixed with coke is being burnt in a kiln. An average analysis of the limestone is
CaCO3 84.5%, MgCO3 11.5% and the rest are inerts. The coke contains 76% C, 21% ash and 3%
moisture. The calcinations of CaCO 3 and MgCO3 are 95% and 90% complete respectively. The C
in coke is completely burnt to carbon dioxide. The kiln is fed with 1 kg of coke per 5kg of
limestone. Calculate the weight percent of each product leaving the kiln. Assume that the
moisture in the feed is completely vaporized.

Qn.2.
A flotation concentrate (24% Cu) is to be smelted in a furnace to give a copper matte with 55%
Cu. Describe how you as the process engineer can achieve this product (i.e.55% Cu matte) using
a smelting furnace of your choice. Include pre-treatment of concentrate, reactions and any
important operating parameters.

Qn.3.
What are the advantages and disadvantages of each of these furnaces?

(i) Flash furnaces


(ii) Submerged tuyere furnaces
(iii) Top lance furnaces

Qn.4
In copper converting “blister copper” is the main product. Why is it called blister copper?

Qn.5
What are the advantages and disadvantages of the Pierce-Smith converter?

Qn.6
What is the purpose of silica in the slag forming stage of copper converting?

Qn.7
Describe the copper converting process in detail.
Qn.8
Describe in detail how you would remove S and O2 from liquid blister copper.

Qn.9
What is galvanising?

Qn.10
A fluidised bed roaster, designed to treat 1000 tons/day of concentrates is currently working
at 7.5 % below capacity, and is used roast wet concentrates with the following composition;

Composition of concentrates: ZnS = 58 %; PbS = 24%; Cu2S = 11%


Ambient air is used during fluidisation; the calcine which is discharged at 1400 K has the
following compositions;
Composition of calcine : ZnS, ZnO, PbO, Cu2O

The analysis of the flue gases show that the gases are made up of 15 % SO 2which accounts for
97 % of the sulphur originally contained in the concentrates.

(i) What is the composition of the wet feed [3]


(ii) What is the composition of the calcine [4]
(iii) How much air is air is theoretically required [3]
(iv) How much excess air is required [3]

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