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1 Electric furnace smelting of copper-nickel sulfide concentrate 1.1 Roasting………………………………………(463) 1.2 Pelletizing………………………………………(471) 1.3 Electric furnace smelting…………………………………(477) 2 Flash furnace smelting of copper-nickel sulfide concentrate 2.1 Deep drying and batching of furnace charge……………………...(507) 2.2 Flash furnace smelting………………………………..(518) 2.3 Depuration of flash furnace slag……………………………..(542) 3 Blast furnace smelting of nickel 3.1 Raw materials, fluxes, and fuels………………………..(546) 3.2 Preparation of materials………………………………………..(547) 3.3 Smelting………………………………………..(554) 4 Converter melting 4.1 Melting low-nickel matte………………………………..(561) 4.2 Melting high-nickel matte………………………………...（573）4.3 Depuration of converter slag………………………………..(576) 5 Beneficiation and treatment of high-nickel matte 5.1 Beneficiation of high-nickel matte………………………….（586）5.2 Melting secondary nickel concentrate to produce nickel sulfide anodes………….（600）5.3 Roasting secondary nickel concentrate to produce nickel oxide………….（606）5.4 Treatment of secondary copper concentrate………………………….（614）6 Electrolytic refining of nickel 6.1 Electrolysis using nickel sulfide anodes………………………….（624）6.2 Electrolytic refining of metallic nickel anodes…………………….（633）6.3 Purification of the anode electrolyte………………………….（636）6.4 Reduction smelting of nickel oxide in an electric furnace to produce crude nickel anodes ………………………………………….（647）7 Wet processing of high-nickel matte 7.1 Selective leaching with sulfuric acid…………………………..（649）7.2 Purification of the leachate………………………………..（655）7.3 Electrodeposition of nickel……………………………..（657）8 Recovery of cobalt from cobalt-containing residues purified from nickel electrolytes 8.1 Production of electrolytic cobalt by electrodeposition………………..（661）8.2 Production of electrolytic cobalt by electrolytic refining…………………..（675）8.3 Production of refined cobalt oxide………………………….（688）9 Pyrometallurgical processing of nickel oxide 9.1 Ores………………………………………...（694）9.2 Process parameters………………………………….（696）9.3 Melting temperatures of slag and metal, as well as their discharge temperatures ………………………………………….（697）9.4 Examples of pyrometallurgical treatment of nickel oxide ores…………………..（698）10 Wet processing of nickel oxide ores (ammonia leaching process) 10.1 Reductive roasting…………………………………（714）10.2 Leaching and washing of roasted slag…………………………（723）10.3 Ammonia recovery……………………………………（742）10.4 Production of nickel powder by hydrogen reduction…………………………（754）10.5 Treatment of the effluent from hydrogen reduction…………………………（759）10.6 Production of cobalt powder by hydrogen reduction…………………………（764）10.7 Liquid ammonia storage tanks……………………………………（769）11 Recovery of nickel from other nickel-containing materials 11.1 Production of electrolytic nickel from crude nickel sulfate………………….（773）11.2 Production of electrolytic nickel from nickel-iron-phosphorus alloys……………………（775）11.3 Production of electrolytic nickel from nickel-chromium alloy waste……………（781）11.4 Production of cobalt-nickel products from waste Permalloy ………………………………………..（783）11.5 Production of cobalt-nickel products from cobalt-containing magnetic steels ………………………………………..（788）12 Metallurgical calculations in nickel metallurgy 12.1 Metallurgical calculations for fluidized roasting of copper-nickel sulfide concentrate ………………………………………..（791）12.2 Metallurgical calculations for electric furnace smelting of nickel sulfide ores…………...（794）12.3 Metallurgical calculations for flash furnace smelting……………………（801）12.4 Calculations related to electrolytic refining of nickel and purification of anode electrolytes…...（829）12.5 Metallurgical calculations for ammonia leaching and washing of nickel oxide ore roasted slag……（833）12.6 Metallurgical calculations for ammonia recovery…………………………（844）12.7 Metallurgical calculations for production of nickel powder by hydrogen reduction……………...（851）12.8 Metallurgical calculations for production of cobalt powder by hydrogen reduction……………...（862）
Design Manual for the Smelting of Heavy Non-ferrous Metals – Copper-Nickel Volume (Nickel Section)
1. Ore Storage and Blending
1.1 Ore Storage………………………………………...（4）
1.2 Blending………………………………………..（11）
2. Crushing and Grinding of Fluxes
2.1 Selection and Calculation of Crushing and Screening Processes………….....（20）
2.2 Selection and Calculation of Grinding and Classification Processes……..……...（27）
2.3 Selection of Main Equipment……………………….....（28）
2.4 Reference Diagrams for Workshop Layout…………………….……（35）
3. Drying of Concentrate
3.1 Drying Using Cylindrical Dryers…………………………（39）
3.2 Fluidized Bed Drying…………………………………（47）
4. Fluidized Bed Roasting of Copper Concentrate
4.1 Oxidative Roasting of Copper Concentrate………………………….（55）
4.2 Sulfurization Roasting of Copper Concentrate…………………….....（61）
4.3 Selection of Main Equipment………………………….....（64）
4.4 Reference Diagrams for Workshop Layout……………………….…（68）
5. Smelting
5.1 Smelting in Reflecting Furnaces………………………………..（71）
5.2 Smelting in Hermetic Blast Furnaces……………………….….（96）
5.3 Smelting in Electric Furnaces………………………………..….（119）
5.4 Flash Smelting…………………………………..（146）
5.5 Silver-Copper Smelting Process………………………………..（178）
5.6 Noranda Copper Smelting Process……………………………..（189）
5.7 Vannucchi Copper Smelting Process…………………………..（200）
5.8 Depuration of Flash Furnace Slag Using Electric Furnaces…..（209）
5.9 Slag Disposal Facilities…………………………………..（217）
6. Converting
6.1 Converting in Converters………………………………….（222）
6.2 Converting in Continuous Furnaces……………………………….（245）
6.3 Beneficiation of Converter Slag……………………………….（250）
7. Refining
7.1 Pyrometallurgical Refining………………………………….（266）
7.2 Electrolytic Refining of Copper………………………………（289）
7.3 Purification of Copper Electrolyte and Production of Sulfates……………（317）
8. Hydrometallurgical Copper Processing
8.1 Leaching-Extraction-Electrodeposition Process for Low-Grade Copper Ores………………………………….…..（343）
8.2 Acidification Roasting of Copper Sulfide Concentrate – Atmospheric Pressure – Acid Leaching – Electrodeposition Process………………………………………（357）
9. Electrowinning for Copper Production
9.1 Mineral Sources, Reducing Agents, Chlorinating Agents, and Fuels………….（365）
9.2 Preparation of Raw Materials………………………………….（367）
9.3 Preparation of Reducing Agents……………………………….（369）
9.4 Electrowinning……………………………………….（370）
9.5 Selection of Main Equipment…………………………….（376）
9.6 Flotation……………………………………….（380）
9.7 Smelting of Copper Concentrate……………………………….（381）
9.8 Reference Diagrams for Workshop Layout………………………….（382）
10. Production of Recycled Copper
10.1 Raw Materials for Recycled Copper Production…………………………...（383）
10.2 Processes for Recycled Copper Production………………………（386）
10.3 Smelting in Blast Furnaces………………………………（388）
10.4 Converting of Brass………………………………….（394）
10.5 Pyrometallurgical Refining in Reflecting Furnaces………………………….（397）
11. Metallurgical Calculations
11.1 Metallurgical Calculations for Drying Copper Concentrate Using Cylindrical Dryers…………….（405）
11.2 Metallurgical Calculations for Fluidized Bed Drying of Copper Concentrate……………….（407）
11.3 Metallurgical Calculations for Smelting in Reflecting Furnaces……………………（413）
11.4 Metallurgical Calculations for Smelting in Hermetic Blast Furnaces………………（422）
11.5 Metallurgical Calculations for Flash Smelting…………………….（429）
11.6 Metallurgical Calculations for Converting in Converters………………………（439）
11.7 Metallurgical Calculations for Pyrometallurgical Refining of Rough Copper………………（443）
11.8 Metallurgical Calculations for Electrolytic Refining of Copper…………………….（452）
11.9 Metallurgical Calculations for Purification of Electrolyte and Production of Sulfates…….（454）
11.10 Metallurgical Calculations for Hydrometallurgical Processing of Low-Grade Copper Ores………………………………………（456）
1. Ore Storage and Blending
1.1 Ore Storage………………………………………...（4）
1.2 Blending………………………………………..（11）
2. Crushing and Grinding of Fluxes
2.1 Selection and Calculation of Crushing and Screening Processes………….....（20）
2.2 Selection and Calculation of Grinding and Classification Processes……..……...（27）
2.3 Selection of Main Equipment……………………….....（28）
2.4 Reference Diagrams for Workshop Layout…………………….……（35）
3. Drying of Concentrate
3.1 Drying Using Cylindrical Dryers…………………………（39）
3.2 Fluidized Bed Drying…………………………………（47）
4. Fluidized Bed Roasting of Copper Concentrate
4.1 Oxidative Roasting of Copper Concentrate………………………….（55）
4.2 Sulfurization Roasting of Copper Concentrate…………………….....（61）
4.3 Selection of Main Equipment………………………….....（64）
4.4 Reference Diagrams for Workshop Layout……………………….…（68）
5. Smelting
5.1 Smelting in Reflecting Furnaces………………………………..（71）
5.2 Smelting in Hermetic Blast Furnaces……………………….….（96）
5.3 Smelting in Electric Furnaces………………………………..….（119）
5.4 Flash Smelting…………………………………..（146）
5.5 Silver-Copper Smelting Process………………………………..（178）
5.6 Noranda Copper Smelting Process……………………………..（189）
5.7 Vannucchi Copper Smelting Process…………………………..（200）
5.8 Depuration of Flash Furnace Slag Using Electric Furnaces…..（209）
5.9 Slag Disposal Facilities…………………………………..（217）
6. Converting
6.1 Converting in Converters………………………………….（222）
6.2 Converting in Continuous Furnaces……………………………….（245）
6.3 Beneficiation of Converter Slag……………………………….（250）
7. Refining
7.1 Pyrometallurgical Refining………………………………….（266）
7.2 Electrolytic Refining of Copper………………………………（289）
7.3 Purification of Copper Electrolyte and Production of Sulfates……………（317）
8. Hydrometallurgical Copper Processing
8.1 Leaching-Extraction-Electrodeposition Process for Low-Grade Copper Ores………………………………….…..（343）
8.2 Acidification Roasting of Copper Sulfide Concentrate – Atmospheric Pressure – Acid Leaching – Electrodeposition Process………………………………………（357）
9. Electrowinning for Copper Production
9.1 Mineral Sources, Reducing Agents, Chlorinating Agents, and Fuels………….（365）
9.2 Preparation of Raw Materials………………………………….（367）
9.3 Preparation of Reducing Agents……………………………….（369）
9.4 Electrowinning……………………………………….（370）
9.5 Selection of Main Equipment…………………………….（376）
9.6 Flotation……………………………………….（380）
9.7 Smelting of Copper Concentrate……………………………….（381）
9.8 Reference Diagrams for Workshop Layout………………………….（382）
10. Production of Recycled Copper
10.1 Raw Materials for Recycled Copper Production…………………………...（383）
10.2 Processes for Recycled Copper Production………………………（386）
10.3 Smelting in Blast Furnaces………………………………（388）
10.4 Converting of Brass………………………………….（394）
10.5 Pyrometallurgical Refining in Reflecting Furnaces………………………….（397）
11. Metallurgical Calculations
11.1 Metallurgical Calculations for Drying Copper Concentrate Using Cylindrical Dryers…………….（405）
11.2 Metallurgical Calculations for Fluidized Bed Drying of Copper Concentrate……………….（407）
11.3 Metallurgical Calculations for Smelting in Reflecting Furnaces……………………（413）
11.4 Metallurgical Calculations for Smelting in Hermetic Blast Furnaces………………（422）
11.5 Metallurgical Calculations for Flash Smelting…………………….（429）
11.6 Metallurgical Calculations for Converting in Converters………………………（439）
11.7 Metallurgical Calculations for Pyrometallurgical Refining of Rough Copper………………（443）
11.8 Metallurgical Calculations for Electrolytic Refining of Copper…………………….（452）
11.9 Metallurgical Calculations for Purification of Electrolyte and Production of Sulfates…….（454）
11.10 Metallurgical Calculations for Hydrometallurgical Processing of Low-Grade Copper Ores………………………………………（456）