Why is lead ore processing plant supplier Better?

Lead Processing: Mining, Concentrating, and Refining

Upon completion of the reduction process, the furnace is tapped, and lead is extracted to flow into drossing kettles or molds. At this stage, the resultant semi-finished product, which contains 95 to 99 percent lead along with dissolved metallic and nonmetallic impurities, is referred to as base bullion. This bullion is maintained at a temperature just above its melting point of approximately 330 °C (626 °F). At this temperature, the solubility of copper in lead is notably low, allowing the copper content to segregate and form a scum, or dross, on the surface of the bath within the drossing kettle. Following the skimming of this dross, additional copper and other impurities are removed by stirring sulfur and lead pyrite into the bath or by utilizing submerged air lances for agitation. The remaining base bullion is then refined to yield lead of commercial quality.

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The subsequent roasting process transforms the remaining materials into a brittle substance known as sinter, which contains oxides of lead, zinc, iron, and silicon, together with lime, metallic lead, and residual sulfur. As the material is discharged from the moving grate, it is broken down into lumps ready for further processing. These pre-fluxed, lumpy sinter materials are then loaded into a top-heated blast furnace along with coke fuel. A blast of air introduced at the bottom assists in the combustion of the coke, creating a temperature of approximately 1,200 °C (2,200 °F) and generating carbon monoxide. This gas then reacts with the metallic oxides, leading to the production of carbon dioxide and molten metal, while nonmetallic wastes combine with the fluxing materials to form slag.

Direct Smelting: An Alternative Process

The emergence of direct smelting processes was noted during the late 20th century, replacing traditional indirect smelting methods. These newer techniques are executed in smaller, more efficient reactors that do not necessitate sintering feed materials or the use of metallurgical coke, resulting in lower volumes of gas and dust. Generally, direct smelting falls into two categories: submerged smelting, where reactions occur in a liquid medium, and suspension smelting, involving interactions between gases and solids.

The KIVCET process, using an innovative oxygen electric smelting approach, comprises a tri-partite furnace structure allowing fuel-less flash smelting. The environmental impact of direct processes such as KIVCET is minimized, demonstrated by reduced flue dust, although the reliance on electricity rather than fossil fuels can complicate certain recovery processes.

The Queneau-Schuhmann-Lurgi (QSL) process effectively processes various grades of lead concentrates, utilizing oxygen and natural gas for efficient reactions, achieving minimized dust emissions during the treatment of unroasted charges.

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Lead Recycling Solutions

The advanced processes employed in lead recycling involve fully automated systems for crushing and sorting used lead-acid batteries, which are capable of effectively segregating diverse materials post-crushing. Such systems not only achieve high production efficiency and safety but also boast excellent environmental protection outcomes through close circulation of acid and centralized emission treatment.

The oxygen-enriched side-blown furnace is particularly notable for its ability to handle various lead-containing materials, including lead paste and slag, facilitating quick and thorough smelting reactions. With stringent management of sulfur dioxide emissions, it meets international environmental standards and bolsters economic performance through the recovery of sulfuric acid as a by-product.

The implementation of an electro-refining system further ensures high-purity lead recovery, achieving purity levels exceeding 99.99%. For a comprehensive understanding of the recycling processes, readers are encouraged to explore more about pb paste refining as part of their research.