Process for continuous smelting and converting of copper concentrates

Apparatus for continuously smelting and converting copper concentrates to copper matte, comprising:

• a. a generally horizontally disposed reactor consisting of a single vessel having a single zone where both the smelting and the converting occur together, a settling zone contiguous with said smelting and converting zone and a slag zone contiguous with said settling zone;
• b. said reactor having a charging port for feeding the concentrates and flux at one end, a discharge port for the slag at the other end and at least one matte discharge port in between;
• c. heating means for inducing and maintaining molten bath conditions in said reactor including at least one fuel-fired burner located at at least one end of said single vessel;
• d. mixing means provided in the single smelting and converting zone of said reactor and located between the charging port and the matte discharge port, said mixing means comprising a plurality of jets of an oxidizing gas injected below the surface of the molten bath, said jets being positioned more than 6 feet out from the charging port at said one end in said single smelting and converting zone and having sufficient force to create a turbulent and dynamic state within and above the bath of said single zone during the smelting and converting whereby liquid sulfide is forced through and above the upper slag layer;
• e. first control means for controlling the rate of introduction of the copper concentrates and flux through the charging port;
• f. second control means adapted to control the injection of the oxidizing gas and the introduction of the copper concentrates and flux in a predetermined relationship, such that copper matte is continuously produced;
• and
• g. exhaust means for removing off-gases from the reactor provided substantially outside of said single smelting and converting zone.

Apparatus for continuous smelting and converting of copper containing concentrates comprising:

• a. a generally horizontally disposed reactor consisting of a single vessel having a single zone where both the smelting and the converting occur together, a settling zone contiguous with said smelting and converting zone and a slag zone contiguous with said settling zone;
• b. said reactor having a charging port for feeding the concentrates and flux at one end, a discharge port for the slag at the other end and at least one product discharge port in between;
• c. heating means for inducing and maintaining molten bath conditions in said reactor including at least one fuel-fired burner located at at least one end of said single vessel;
• d. mixing means provided in the single smelting and converting zone of said reactor and located between the charging port and the product discharge port, said mixing means comprising a plurality of jets of an oxidizing gas injected below the surface of the molten bath, said jets being positioned more than 6 feet out from the charging port at said one end in said single smelting and converting zone and having sufficient force to create a turbulent and dynamic state within and above the bath of said single zone during the smelting and converting whereby liquid sulfide is forced through and above the upper slag layer;
• e. control means for controlling the introduction of the concentrates and flux through said charging port in balanced relationship to the introduction of oxidizing gas into the reactor;
• and
• f. exhaust means for removing off-gases from the reactor provided in said reactor substantially outside of said single smelting and converting zone.