Tsarin Samar da Ma'adinan Tagulla da Sarrafawa
Tagulla (Cu) yana ɗaya daga cikin muhimman ƙarfe a rayuwar zamani. Lantarkinsa na lantarki da na zafi, juriya ga tsatsa, da kuma sauƙin daidaitawa sun sanya jan ƙarfe ya zama muhimmin abu ga kebul na lantarki, kayan lantarki, bututu, har ma da makamashi mai sabuntawa kayan masana'antu kamar su allunan hasken rana da injinan iska. Duk da haka, kafin ya zama samfuri na ƙarshe, jan ƙarfe dole ne ya yi dogayen tsari, tun daga haƙar ma'adinai da sarrafa ma'adinai zuwa tsaftacewa da ƙera shi zuwa cathodes ko wasu nau'ikan kasuwanci. Wannan labarin ya tattauna tsarin gabaɗaya na samar da ma'adinan tagulla da sarrafawa, tare da manufofi da ƙa'idodin aiki a kowane mataki.
1. Binciken Ma'adinan Tagulla da Haƙar Ma'adinai
Mataki na farko yana farawa da bincike don nemo ma'ajiyar jan ƙarfe mai amfani a fannin tattalin arziki. Ayyukan bincike sun haɗa da taswirar ƙasa, binciken ƙasa da na ƙasa, da haƙa rami don tantance matsayi, rarraba ma'adinai, da adadin ajiyar. Da zarar an sami nazarin yuwuwar aiki da izini, ana yin haƙar ma'adinai ta amfani da manyan hanyoyi guda biyu:
1. Haƙar ma'adinai a buɗe: ana amfani da shi don ma'adinan tagulla kusa da saman, kamar jan ƙarfe na porphyry. Wannan hanyar ta mamaye samar da jan ƙarfe a duniya saboda tana da yawa duk da cewa ma'adinan yana da ƙarancin yawa.
2. Haƙar ma'adinai a ƙarƙashin ƙasa: ana amfani da shi idan ma'adinan sun fi zurfi ko kuma yanayin ƙasa ba ya ba da damar haƙar ma'adinai a buɗe.
Ma'adinan da aka haƙa galibi yana ɗauke da ma'adanai na jan ƙarfe kamar chalcopyrite (CuFeS₂), bornite (Cu₅FeS₄), chalcocite (Cu₂S), da ma'adanai na oxide kamar malachite (Cu₂CO₃(OH)₂) da azurite. Baya ga jan ƙarfe, ma'adinan galibi yana ɗauke da ƙazanta ko ma'adanai masu alaƙa kamar ƙarfe, sulfur, silica, zinariya, azurfa, da molybdenum.
2. Niƙawa da Niƙawa
Ma'adinan da aka haƙa yana da girma don haka yana buƙatar a niƙa shi don raba ma'adinan jan ƙarfe daga gangue. Wannan tsari ya ƙunshi matakai biyu:
– Murkushewa: amfani da na'urar murkushe muƙamuƙi, na'urar murkushe mazugi, ko na'urar murkushe mazugi don rage girman ma'adinan zuwa santimita da yawa.
– Niƙa: ta amfani da injin niƙa ƙwallo ko injin niƙa SAG don samar da ƙananan ƙwayoyin cuta, yawanci har zuwa dubun-dubatar micrometers a girma.
Babban manufar wannan matakin shine a 'yantar da ma'adanai na jan ƙarfe daga ma'aunin duwatsu. Matakin 'yanci yana da matuƙar muhimmanci ga nasarar ayyukan rabuwa daga baya.
3. Tattara Ma'adinai: Tafkewar ruwa (Ga Ma'adanai na Sulfide)
Ga ma'adinan tagulla na sulfide, hanyar da aka fi amfani da ita ita ce flotation na kumfa. A cikin wannan tsari, ana haɗa ƙaramin slurry na ma'adinai da ruwa da wasu sinadarai masu guba:
– Mai Tarawa: yana yin saman ma'adinan jan ƙarfe mai kama da ruwa ta yadda zai iya mannewa da kumfa mai sauƙi.
– Frother: yana samar da kumfa mai karko.
- Masu gyara (masu kunna, masu rage damuwa, masu daidaita pH): ƙara zaɓin rabuwa.
Iska tana shiga cikin tantanin da ke shawagi, wanda hakan ke sa ma'adanai na jan ƙarfe su manne da kumfa kuma su tashi sama kamar kumfa, inda ake tattara su a matsayin tarin jan ƙarfe. Sauran kayan da ba na jan ƙarfe ba ana zubar da su a matsayin wutsiya.
Yawan sinadarin da aka samu yawanci yana ɗauke da kusan kashi 20-35% na Cu, wanda ya fi ƙarfin ma'adinan farko wanda zai iya zama ƙasa da kashi 0,4-1% na Cu a wasu ma'adanai na porphyry.
4. Sarrafa Hydrometallurgical (Ga Ma'adanai na Oxide)
Ba a sarrafa ma'adinan jan ƙarfe mai ƙarfi ta hanyar amfani da sulfide flotation yadda ya kamata. Saboda haka, hanyoyin hydrometallurgical kamar:
1. Zubar da ruwa: Ana tara ma'adinai ko kayan da aka niƙa (tarin zubar ruwa) sannan a zuba sulfuric acid (H₂SO₄). Tagulla yana narkewa cikin ions na Cu²⁺ a cikin ruwan zubar ruwa mai ciki.
2. Cirewar sinadaran da ke narkewa (SX): rabawa da tsarkake Cu²⁺ daga ruwan da ke fita daga leaks ta amfani da sinadaran da ke narkewa ta hanyar halitta.
3. Electrowinning (EW): saka tagulla tsantsa a kan cathode ta hanyar wutar lantarki, yana samar da cathode mai tsabta sosai.
Hanyar SX-EW ta shahara sosai saboda tana iya samar da cathodes kai tsaye ba tare da narkewa ba, musamman ga ma'adanai masu ƙarancin sinadarin oxide.
5. Narkewar Tagulla Mai Yawa
Ga yawan sinadarin sulfide, mataki na gaba shine pyrometallurgy. Ana busar da sinadarin sannan a narke a cikin tanderu (misali, na'urar narke mai walƙiya ko kuma tanderun reverberatory). A lokacin narkewar, rabuwar ta faru zuwa manyan matakai guda biyu:
– Matte: cakuda jan ƙarfe da baƙin ƙarfe sulfide, wanda ke ɗauke da kusan 45–70% Cu.
– Slag: yana ɗauke da oxides da silicates daga ƙazanta kamar silica, ƙarfe, da sauran ma'adanai.
Halayen sinadarai yayin narkewar narkarwa suma suna samar da iskar gas mai arzikin SO₂. A cikin cibiyoyin zamani, ana kama SO₂ kuma ana sarrafa shi zuwa sulfuric acid, yana rage hayaki da kuma samar da wani abu mai mahimmanci.
6. Canzawa zuwa Blister Copper
Sannan ana sarrafa matte ɗin da ke fitowa daga na'urar narkewa a cikin na'urar juyawa (misali, Pierce-Smith converter). Ana hura iska ko iskar oxygen don ya yi oxidize da ƙarfe sulfide da sulfur:
– Ana shafa ƙarfe a cikin iskar oxygen zuwa FeO sannan a shiga cikin slag.
– Ana haɗa sulfur zuwa SO₂.
Sakamakon ƙarshe shine jan ƙarfe mai launin shuɗi tare da tsarkin kusan kashi 98-99% na Cu. Ana kiransa "blister" saboda saman sa yakan bayyana a cikin ramuka saboda fitowar iskar gas yayin aikin.
7. Tacewa: Tace Wuta da Tace Wutar Lantarki
Duk da cewa sinadarin jan ƙarfe a cikin blister ɗin yana da yawa, har yanzu akwai ƙazanta kamar Fe, S, Ni, As, Sb, da abubuwa masu mahimmanci (Au, Ag, Pt, Pd) waɗanda ke buƙatar a cire su. Ana yin tsaftacewa ta matakai biyu gabaɗaya:
1. Gyaran Wuta: gyaran farko a cikin tanda don rage iskar oxygen da wasu ƙazanta, yana samar da anode mai siffar faranti mai kama da jan ƙarfe.
2. Gyaran Wutar Lantarki: ana narkar da anode ta hanyar lantarki a cikin maganin jan karfe sulfate. Tsarkakken jan karfe yana kwarara akan cathode a matsayin jan karfe cathode tare da tsarkin kashi 99,99%.
Datti kamar zinariya da azurfa ba sa narkewa kuma za su zube kamar ƙura mai anode, wanda daga nan ake sarrafa shi don dawo da ƙarfe masu daraja. Shi ya sa masana'antar jan ƙarfe galibi ke samar da zinare da azurfa a matsayin samfuran da suka rage.
8. Bugawa da Kaya na Ƙarshe
Ana iya sayar da cathodes na tagulla kai tsaye a matsayin kayayyaki na ƙasashen duniya (misali LME Grade A) ko kuma a sarrafa su zuwa wasu siffofi:
- Sanda mai waya don kebul na lantarki,
- bututun jan ƙarfe don famfo da HVAC,
– zanen gado/faranti na masana'antar masana'antu,
– ƙarfe kamar tagulla (Cu-Zn) da tagulla (Cu-Sn).
Wannan matakin ƙera galibi ana yin sa ne a cikin injin naɗawa, ko naɗawa, ko kuma injin zana waya, ya danganta da samfurin da ake so.
9. Gudanar da Muhalli da Sharar Gida
Tsarin sarrafa ma'adinan jan ƙarfe yana samar da fitar da hayaki mai guba, tarkace, da iskar gas. Saboda haka, fannonin muhalli suna da mahimmanci:
– Ana adana wukake a cikin madatsun ruwa tare da sa ido kan daidaito da ingancin ruwa.
– Sau da yawa ana sake yin amfani da ruwan da aka tace don rage yawan shan ruwan sabo.
– Ana kama SO₂ daga na'urar narkar da ruwa don samar da sinadarin sulfuric acid.
– Ana yin gyaran ƙasa bayan an kammala haƙar ma'adinai.
Ka'idojin muhalli na zamani suna buƙatar rage fitar da ƙura, amfani da makamashi mai inganci, da kuma kula da sinadarai kamar sulfuric acid cikin aminci.
Kammalawa
Tsarin samar da jan ƙarfe daga ma'adinai ya ƙunshi wani tsari mai rikitarwa na fasaha: farawa da haƙar ma'adinai, niƙawa da niƙa, rabuwar ma'adinai ta hanyar flotation ko leaching, sannan tsaftacewa ta hanyar narkewa ko SX-EW, don samar da cathodes na jan ƙarfe masu inganci. Zaɓin hanyar aiwatarwa ya dogara sosai akan nau'in ma'adinai (sulfide ko oxide), yawan jan ƙarfe, da kuma la'akari da tattalin arziki da muhalli. Tare da ƙaruwar buƙatar wutar lantarki a duniya, motocin lantarki, da makamashi mai sabuntawa, samar da jan ƙarfe mai inganci da dorewa shine mabuɗin ci gaban masana'antar a nan gaba.
