DEVELOPMENT OF A COMPREHENSIVE SOFTWARE SOLUTION FOR PROCESSING HIGH-SULFUR, COPPER-POOR CONCENTRATES IN THE COPPER SMELTING INDUSTRY

The depletion of high-grade copper ores and the increasing prevalence of lowgrade, high-sulfur copper concentrates present significant challenges to the copper smelting industry. Traditional smelting processes struggle to maintain economic viability and comply with environmental regulations when processing these complex ores. This paper details the development of a comprehensive software solution designed to simulate the smelting process for high-sulfur, copper-poor concentrates. The software employs a detailed mathematical model to predict the yields and compositions of products, including valuable metals, during the smelting process. It integrates multiple modules, such as ore input, smelting simulation, and results presentation, providing a userfriendly platform for optimizing smelting operations. Critical parameters like ore composition, smelting temperature, and flux addition are incorporated into the model, enabling accurate predictions of matte and slag outputs. By analyzing these outputs, the software aids in optimizing metal recovery and reducing losses, ultimately enhancing the efficiency and sustainability of copper production. This tool is particularly relevant for large sulfide copper ore deposits, such as those in Kazakhstan, which have high sulfur content and low copper levels. The software's ability to simulate different processing scenarios provides valuable insights for industrial applications, supporting the development of more efficient and eco-friendly smelting technologies. The comprehensive software solution not only addresses the technical challenges of processing high-sulfur, low-copper ores but also contributes to the industry's efforts to reduce environmental impact and improve resource management. This innovation represents a significant step forward in the optimization of copper smelting operations, promoting sustainability and efficiency in the face of declining ore quality.

1. Guo Z. Innovative methodology for comprehensive and harmless utilization if waste copper slag via selective reduction-magnetic separation process / Z. Guo, J. Pan, D. Zhu, F. Zhang // Journal of Cleaner Production. – 2018. – Vol. 187. – P. 910-922. https://doi.org/10.1016/j.jclepro.2018.03.264.

2. Moskalyk P.R. Review of copper pyrometallurgical practice: today and tomorrow / P.R. Moskalyk, A.M. Alfantazi // Minerals Engineering. – 2003. – Vol. 16, Iss. 9. – P. 893-919. https://doi.org/10.1016/j.mineng.2003.08.002.

3. Bodujen A.Ja. Vlijanie povyshenija kachestva mednyh koncentratov na jeffektivnost' ih pererabotki (The effect of improving the quality of copper concentrates on the efficiency of their processing) / A.Ja. Bodujen, B.S. Ivanov, G.V. Konovalov // Zapiski Gornogo instituta. – 2011. – Vol. 192. – P. 46-48.

4. Danilova N.V. Raschet material'nyh potokov pirometallurgicheskogo cikla pererabotki mednogo sul'fidnogo syr'ja (Calculation of material flows of the pyrometallurgical cycle of processing copper sulfide raw materials) / N.V. Danilova // Zapiski Gornogo instituta. – 2010. – Vol. 186. – P. 176-180.

5. Pirometallurgicheskaja tehnologija pererabotki bednyh po medi vysokosernistyh koncentratov (Pyrometallurgical technology of processing of poor by copper high-sulfur concentrates) / S.M. Kozhahmetov et al // Metallurg. – 2019. – № 9. – P. 90-96.

6. Innovative methodology for separating copper and iron from Fe-Cu alloy residues by selective oxidation smelting / Y.-x. Zheng et al // Journal of Cleaner Production. – 2019. – Vol. 231. – P. 110-120. https://doi.org/10.1016/j.jclepo.2019.05.215.

7. Bellemans I. Metal losses in pyrometallurgical operations – A review. / I. Bellemans, E. De Wilde, N. Moelans, K. Verbeken // Advances in Colloid and Interface Science. – 2018. – Vol. 255. – P. 47-63. https://doi.org/10.1016/j.cis.2017.08.001.

8. Reduction of copper smelting slag using waste cooking oil / S. Zhou et al // Journal of Cleaner Production. – 2019. – Vol. 236. https://doi.org/10.1016/j.jclepo.2019.117668.

9. Roshhin V.E. Kompleksnaja pererabotka medeplavil'nyh shlakov dlja poluchenija vostrebovannyh produktov (Integrated processing of copper-smelting slag for manufacture of needed products) / V.E. Roshhin, A.D. Povolockij // Jelektrometallurgija. – 2019. – № 4. – P. 25-34. https://doi.org/10.31044/1684-5781-2019-0-4-25-34.

10. Anikeev A.N. Tverdofaznoe i zhidkofaznoe vosstanovlenie shlakov (Solid-phase and liquidphase reduction of slag). / A.N. Anikeev, V.V. Seduhin, D.V. Sergeev, I.V. Chumanov // Jelektrometallurgija. – 2019. – № 4. – P. 35-38. https://doi.org/10.31044/1684–5781-2019-0-4-35-38.

11. Reduction of Chilean copper slags: a case of waste management project / Gonzalea C. et al // Scandinavian Journal of Metallurgy. – 2005. – Vol. 34, Iss. 2. – P. 143-149. https://doi.org/10.1111/j.1600-0692.2005.00740.x.

12. Komkov A.A. Raspredelenie primesej pri plavke mednogo sul'fidnogo syr'ja v pechi Vanjukova (Distribution of impurities during melting of copper sulfide raw materials in Vanyukov furnace) / A.A. Komkov, V.P. Bystrov, M.B. Rogachev // Cvetnye metally. – 2006. – № 5. – P. 17-24.

13. Obednenie otval'nyh shlakov Balhashskogo medeplavil'nogo zavoda (Depletion of waste slag of Balkhash copper smelter) / Kenzhaliev B.K. et al // Kompleksnoe ispol'zovanie mineral'nogo syr'ja. – 2018. – № 3. – P. 45-53. https://doi.org/10.31643/2018/6445.16.

14. Povyshenie tehnologicheskih pokazatelej pererabotki otval'nyh shlakov medeplavil'nogo proizvodstva na osnove ih medlennogo ohlazhdenija i ul'tratonkogo izmel'chenija (Improvement of technological indices of copper smelters slags processing on the basis of their slow cooling and ultrafine grinding) / S.V. Mamonov et al // Gornyj zhurnal. – 2018. – № 2. – P. 83-90. https://doi.org/10.21440/0536-1028-2018-2-83-90.

15. Roy S. Flotation of copper sulphide from copper smelter slag using multiple collectors and their mixtures / S. Roy, A. Datta, S. Rehani // International Journal of Mineral Processing. – 2015. – Vol. 143. – P. 43-49. https://doi.org/10.1016/j.minpro.2015.08.008.

16. Mamonov S. Increasing technology indexes of beneficiation of copper slag / S. Mamonov, V. Ashikhin // XXVIII Int. Mineral Processing Congress Proceedings. – 2016. – Paper ID 676.

17. Karimi N. Recovery of copper from slag of Khatoonabad flash smelting furnace by flotation method / N. Karimi, R. Vaghar, M.R.T. Mohammadi, A.S. Hashemi // Journal of the Institution of engineering (India): Ser. D. – 2013. – Vol. 94, Is. 1. – P. 43-50. https://doi.org/10.1007/s40033-013-0015-3.

18. Technology and mechanism research for crystal phase regulating flotation of copper-containing slag / H. Huang et al // XXVIII Int. Mineral Processing Congress Proceedings. – 2016. – Paper ID 853.

19. Comparative analysis of pyrometallurgical processing methods for Udokan deposit’ sulphide copper concentrates / L.B. Tsymbulov et al // Proceedings of Copper. Santiago, Chile. – 2013. – Vol. 3. – P. 119-137.

20. Coursol P. Energy consumption in copper sulphide smelting. Proceedings of Copper / P. Coursol, P.J. Mackey, C.M. Diaz // Hamburg, Germany. – 2010. – Vol. 2. – P. 649-666.