Zhang Leru

Abstract:

The paper mainly introduces the engineering and operation of the two Kivcet Pb smelters in China. Kivcet process is a flash smelting process developed by VNIItsvetmet, characterized by high raw material flexibility, low energy consumption, high comprehensive recovery of resources as well as an environmental friendly solution. The China Jiangxi Copper Corp. and Zhuzhou Smelter Group (hereinafter referred to as JCC and ZSG respectively) both applied this process to build Pb smelters which were put into operation in March 2012 and January 2013 respectively. Presently, the two Kivcet furnaces are operating well. Hukou Pb & Zn Complex, invested by JCC, has a capacity of 100ktpa Pb and 100ktpa Zn. Its Pb smelting operation uses Kivcet furnace to treat the Pb concentrate blended with 100ktpa leaching residues from the Zn operation, accounting for 40% of the charge. Pb grade in charge is 29%.The other Kivcet Pb Smelting Plant, invested by Zhuzhou Smelter Group, has a designed capacity of 120ktpa lead bullion, which treats 120ktpa of leaching residues and sulfide filter cakes produced from the Zn atmosphere pressure leaching operation, accounting for 40% of the charge. The Pb grade in charge is 34%. The two Kivcet furnaces were successfully put into operation in one trial run in March 2012 and January 2013 respectively. The technical performance indexes and production capacity of both Kivcet furnaces reached or exceeded the design criteria within one year, and some indexes are extremely outstanding, e.g. unit oxygen consumption per ton of charge is 170m3 which is 30 to 50 m3 less than designed value (design criteria 200 m3/t); unit power consumption per ton of charge in EF is 110kVa, which 63% of designed value (design criteria 175kVa/t); and availability of both Kivcet furnaces are above 95%. Kivcet process is an environmental friendly and energy-saving process for Pb metallurgy which is particularly suitable for treating Zn leaching residues. Compared to the conventional roasting method for leaching residue treatment, the Kivcet furnace saves 50% energy, avoids the emission of low SO2 off gas into air, and increases the comprehensive resources recovery of Cu, Ag, Au and S. The Cu recovery is up to 80%, while Ag recovery can be increased to 96% which is 20% higher than conventional Pb smelter, and S recovery can reach up to 97% or higher. The Kivcet Pb Smelting Process has great advantages especially in Pb and Zn complex operations.