This application addresses an integrated smart system to control the variables involved in the process for melting mineral concentrates. Specifically, it addresses an integrated smart system that allows the whole melting process operation to be controlled, measuring the mineralogical quality and quantity of the concentrate that is injected into the melting furnace, as well as variables such as the temperature, the level of the liquid phases and the percentage of copper within the furnace. In this manner, by reading said variables, it acts autonomously on manipulated variables, considering uncertainties, allowing a stable temperature to be maintained in the reactor, allowing products to be obtained at the required quality and controlling the liquid phases therein, among other controlled variables, to achieve efficient melting.

A direct current plasma arc furnace includes a tank having a crucible delimiting a chamber to receive material to be melted and/or treated; refractory walls surrounding the crucible outer surface; a metallic frame covering the refractory walls; and a heating system for heating the received material. The heating system includes two electrodes acting as cathode and anode, respectively, wherein the first electrode is a movable electrode to project vertically into the chamber. The crucible is part of an anode system also having the second electrode and at least one part connecting the crucible and second electrode. The crucible receives and holds material to be melted and/or treated and provides electric conduction for the flow of current to heat the material, such that the voltage potential difference between the cathode and any point of the crucible surface defined to be in contact with the material is the same.

The present invention provides a manufacturing method of crude copper from low-grade copper sludge, one embodiment of the present invention comprises the steps of: (1) calcining a low-grade copper sludge (step 1); (2) producing a mixture by adding at least one selected from a group consisting of binder, flux and combinations thereof to the calcined low-grade copper sludge (step 2); (3) producing a briquette by compression molding the mixture (step 3); (4) melting and reducing by charging the briquette into a submerged arc furnace with adding flux (step 4); and (5) separating crude copper and slag produced by melting and reducing (step 5).

A method for recycling a material may include carrying out a first pass operation. The first pass operation may include preparing an E-waste material and a solid oxide material. The E-waste material may include Fe and Si. The first pass operation may include blending the E-waste material with fluxing agents. The first pass operation may include feeding a furnace with the blended E-waste material and the solid oxide material. The method may include smelting the blended E-waste material and the solid oxide material from the first pass operation to obtain a slag. The slag may include iron oxide and a molten metal. The molten metal may include copper.

Provided is a method for transporting reductant such as coke into a metallurgical furnace containing a bottom layer containing molten metal and a top layer on top of the bottom layer containing molten metal. The method comprises a first providing step for providing reductant, a second providing step for providing metal, a forming step for forming carriers containing reductant and metal of reductant provided in the first providing step and metal provided in the second providing step, and a feeding step for feeding carriers formed in the forming step into the metallurgical furnace. Also provided is a carrier and a production method for producing carriers.

In the disclosure, a method for recycling a material is disclosed, the method including: carrying out a first pass operation, wherein the first pass operation includes preparing an E-waste material and a solid oxide material, wherein the E-waste material includes Fe and Si, blending the E-waste material with fluxing agents, feeding a furnace with the blended E-waste material and the solid oxide material, and carrying out smelting the blended E-waste material and the solid oxide material to obtain a slag including iron oxide and a molten metal including copper. A system for recycling an E-waste material including Fe and Si is also disclosed, where the system includes an E-waste material blending unit where the E-waste material blending unit is configured to prepare the E-waste material, fluxing agents and a copper oxide material, and a furnace configured to carry out gasification and smelting the E-waste material and the copper oxide material to obtain a slag including iron oxide and a molten metal including copper.

Provided is a method for transporting reductant such as coke into a metallurgical furnace containing a bottom layer containing molten metal and a top layer on top of the bottom layer containing molten metal. The method comprises a first providing step for providing reductant, a second providing step for providing metal, a forming step for forming carriers containing reductant and metal of reductant provided in the first providing step and metal provided in the second providing step, and a feeding step for feeding carriers formed in the forming step into the metallurgical furnace. Also provided is a carrier and a production method for producing carriers.

The present invention provides a manufacturing method of crude copper from low-grade copper sludge, one embodiment of the present invention comprises the steps of: (1) calcining a low-grade copper sludge (step 1); (2) producing a mixture by adding at least one selected from a group consisting of binder, flux and combinations thereof to the calcined low-grade copper sludge (step 2); (3) producing a briquette by compression molding the mixture (step 3); (4) melting and reducing by charging the briquette into a submerged arc furnace with adding flux (step 4); and (5) separating crude copper and slag produced by melting and reducing (step 5).

The invention relates to a method and to an arrangement for refining copper concentrate. The arrangement includes a suspension smelting furnace comprising a reaction shaft, and a settler. The reaction shaft is provided with a concentrate burner for feeding copper concentrate such as copper sulfide concentrate and/or copper matte and additionally at least reaction gas into the reaction shaft to obtain a blister layer containing blister and a first slag layer containing slag on top of the blister layer in the settler, and a slag cleaning furnace. The arrangement includes a feeder configured for feeding blister from the blister layer in the settler and for feeding slag from the first slag layer in the settler into the slag cleaning furnace.