Furnaces roasting

Rdstofen, m. roasting furnace, roasting kiln, calciner, roaster. 

Dynamic reactions like processes in blast furnaces, roasting processes or the solidification of liquid alloys can be simulated using the REACTOR MODEL... 

Roast. The heating of soflds, frequently to promote a reaction with a gaseous constituent in the furnace atmosphere. 

Fuming is also an alternative to roasting in the processing of low grade concentrates (5—25 wt % tin). This procedure yields a tin oxide dust, free of iron, which is again fed back to a conventional smelting furnace. 

The ore is ordinarily ground to pass through a ca 1.2-mm (14-mesh) screen, mixed with 8—10 wt % NaCl and other reactants that may be needed, and roasted under oxidising conditions in a multiple-hearth furnace or rotary kiln at 800—850°C for 1—2 h. Temperature control is critical because conversion of vanadium to vanadates slows markedly at ca 800°C, and the formation of Hquid phases at ca 850°C interferes with access of air to the mineral particles. During roasting, a reaction of sodium chloride with hydrous siUcates, which often are present in the ore feed, yields HCl gas. This is scmbbed from the roaster off-gas and neutralized for pollution control, or used in acid-leaching processes at the mill site. 

Multiple-hearth roasting offers ease of operation, abiUty to handle a wide variety of ores or blends, and Httle downtime. On the other hand, these furnaces are no longer being built because of their high capital and labor costs, relatively low sulfur dioxide off-gas, need for added fuel, and marginal opportunity for waste-heat recovery. 

St. Joe Minerals Corporation uses a fluid-bed roaster to finish the roasting at 950°C of material that has been deleaded in a modified multiple-hearth furnace operated with insufficient oxidation (34). First, sulfur is reduced from 31 to 22% and lead from 0.5 to 0.013%. Somewhat aggregated, the product is hammer-milled before final roasting. Half of the calcined product is bed overflow and special hot cyclones before the boiler remove the other half total sulfur is ca 1.5%. Boiler and precipitator dusts are higher in sulfur, lead, etc, and are separated. 

Ammonium chloride is used as a flux ia the melting furnace because the large surface of the cathodes favors the formation of dross, ie, oxide-coated globules of ziac. The dross is separated by Hquation or air-swept milling iato metal and oxide fractions. In the latter, the oxide fraction is swept out of the mill and can be returned to roasting for the elimination of chloride. Metallic ziac is recycled. Overall melting efficiency is 96—98%. 

The ziac concentrate is first roasted ia a fluid-bed roaster to convert the ziac sulfide to the oxide and a small amount of sulfate. Normally, roasting is carried out with an excess of oxygen below 1000°C so that comparatively Htfle cadmium is eliminated from the calciaed material ia this operation (3). Siace the advent of the Imperial Smelting Ziac Furnace, the preliminary roasting processes for ziac and ziac-lead concentrates result ia cadmium recovery as precipitates from solution or as cadmium—lead fume, respectively, as shown ia Figure 1. 

The chemical-grade ore, containing about 30% chromium, is dried, cmshed, and ground in ball mills until at least 90% of its particles are less than 75 ]lni. It is then mixed with an excess of soda ash and, optionally, with lime and leached residue from a previous roasting operation. In American and European practice, a variety of kiln mixes have been used. Some older mixes contain up to 57 parts of lime per 100 parts of ore. However, in the 1990s manufacturers use no more than 10 parts of lime per 100 parts of the ore, and some use no lime at all (77). The roasting may be performed in one, two, or three stages, and there maybe as much as three parts of leached residue per part of ore. These adaptations are responses to the variations in kiln roast and the capabihties of the furnaces used. 

After thorough mixing, the mixture is roasted in a mechanical furnace, usually a rotary kiln. An oxidizing atmosphere is essential, and the basic reaction of a theoretical chromite is... 

It is prepared by pasting potassium or sodium dichromate with three times its weight of boric acid, roasting the mixture at 500°C in a muffle furnace in an oxidizing atmosphere, then hydrolyzing the melt with water and superheated steam. The product is then dried and ground. 

Roasting . Roasting has been largely abandoned ia modem copper smelters, ia which this function is combiaed with the smelting furnace. In older systems, the multiple-hearth roaster is a brick-lined tower having horizontal brick hearths. The concentrate is iatroduced at the top hearth, where rotating arms with rabble blades turn it over and move it to holes ia the hearth. The concentrate is transferred successively to lower hearths and finally... 

FIG. 23-43 Reactors for solids, (a) Temperature profiles in a rotary cement lain, (h) A multiple hearth reactor, (c) Vertical lain for lime burning, 55 ton/d. (d) Five-stage fluidized bed lime burner, 4 by 14 m, 100 ton/d. (e) A fluidized bed for roasting iron sulfides. (/) Conditions in a vertical moving bed (blast furnace) for reduction of iron oxides, (g) A mechanical salt cake furnace. To convert ton/d to kg/h, multiply by 907. 

In the blast furnace reduction slag-making materials are also added together with a small amount of iron, the function of which is to reduce any sulphide which remains, to the product of the roasting operation to produce a sinter. The sinter is then reduced with coke in a vertical shaft blast furnace in which air is blown tluough tuyeres at the bottom of tire shaft. The temperature in the heartlr where metal is produced must be controlled to avoid the vaporization of any zinc oxide in the sinter. The products of tlris process are normally quite complex, and can be separated into four phases. Typical compositions of these are shown in Table 13.1. 

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