REFRACTORY MATERIALS FOR COPPER METALLURGY

1. REFRACTORY MATERIALS FOR COPPER METALLURGY Dr inż. Józef Wojsa Gliwice, February 2008

2. 1. The main user in Cu industry 2. Characteristics of refractories 3. Results of application 4. Current trends in development of refractories for Cu metallurgy 5. Summary

4. Tab. 1. Current position of KGHM in the world Annual production in 2006 Electrolytic Copper 556.6 ·103 tSilver 1.226·103 tGold 1700 kg Lead 21 ·103 tSulphuric acid 674.6 ·103 t Nickel sulphate 2.1 ·103 tTechnical selenium 87 t

5. I. Based on shaft furnace copper smelting technology

6. II. Flash furnace one stage technology

7. Tab. 2. Selected brands of refractories for copper metallurgy

8. 25 20 15 specyfic consumption [kg/t Cu] 10 5 0 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 years Fig. 1. Refractories for copper industry

9. Current trends in the development of refractories for Cu industry • controlled microstructure of basic fired materials and castables • improvement of TSR and corrosion resistance of refractories • chrome-free basic refractories

10. Fig. 2. Pore diameter distribution in MC refractory materials

11. Fig. 3. Pore diameter distribution in the high alumina castables

12. Fig. 4. Pore diameter distribution in the high alumina castables

13. 400 γWOF = 48 J/m2 Wo/WRm = 2,9 300 Force, N 200 100 0 200 400 600 800 Deformation, µm Fig. 5. Fired andalusite brick

14. 400 300 γWOF = 45 J/m2 Wo/WRm = 3,1 Force, N 200 100 0 200 400 600 800 Deformation, µm Fig. 6. Andalusite castable after firing

15. 400 300 200 Force, N 100 0 200 400 600 800 Deformation, µm Fig. 7. Andalusite castable + fibres after firing γWOF = 102 J/m2 Wo/WRm = 6,2 γWOF = 102 J/m2 Wo/WRm = 6,2

16. Summary • Copper metallurgy is very important user of refractories in Poland, what results not only from annual sales, but also from its significant role in domestic and world economy. • More than 96% of basic refractory materials are supplied by the Polish producer, e.i. ZM”R” SA. • Unfortunately, increasing quality and durability of refractories is joined with decreasing demand that has been ilustrated by the changes of specific consumption of basic refractories in the period 1990-2006. • Present position of ZM”R” SA on the market of refractories for copper metallurgy is also a result of active R and D policy as well as efficient cooperation with the Institute of Refractory Materials and the Academy of Mining and Metallurgy.