Nickel matte smelting furnace
Abstract: Nickel matte smelting furnace is designed and installed for small scale smelting of nickel ore and matte. This paper describes the design and construction process of the furnace and the features of the furnace. The process of smelting and refining nickel in the furnace is discussed.
1 Introduction
Nickel is an important elemental in today’s industry. Although it is an expensive metal, its versatile properties have made it increasingly popular in the production of various alloys, electrical and electronic components and many other industries. In order to extract nickel from its ore, smelting and refining need to be applied. There are many types of furnaces of different sizes, shapes, and capabilities that can be used for smelting and refining nickel ore and matte. Among the many types of furnaces, the most widely used is the nickel matte smelting furnace.
2 Design and construction of the furnace
The nickel matte smelting furnace is constructed based on the principles of heat transfer, combustion, and convection to achieve the desired temperature inside the furnace. The furnace consists of several components including the refractory lining, burner, fan, air distributor, and exhaust. The furnace is equipped with a bell-less top to ensure homogeneous mixing of air with the fuel during combustion. The air distributor ensures a uniform distribution of air into the furnace and helps to achieve the desired temperature required for smelting.
To further improve the efficiency of the furnace, several refractory bricks are placed on the furnace walls to reduce heat loss and to absorb heat radiated from the burning fuel. The burner is usually a multi-jet propane burner that can be used to heat the furnace up to 2000°C. In addition, the furnace is equipped with a fan that circulates air and aids in the quick cooling of the furnace. Finally, an exhaust is used to remove byproducts from the furnace.
3 Smelting and refining process
The smelting and refining process in the nickel matte smelting furnace consists of five main steps. First, the furnace is heated up to the desired temperature. Nickel ore and matte are then added into the furnace and heated for several hours. This process is known as smelting. During smelting, the nickel ore and matte react with the oxygen to form nickel oxide. The generated gas is then removed from the furnace by the exhaust.
Next, the hot furnace is cooled down to allow the newly formed nickel oxide to settle. Once the nickel oxide is separated from the melted matte, it is ready to be refined. The refining process involves further heating up the furnace and passing electric current through the molten nickel oxide. This process helps to remove the impurities and generate a high-grade nickel product. Finally, the matte and nickel products are removed from the furnace and ready for further processing or use.
4 Advantages and disadvantages
The nickel matte smelting furnace provides several advantages for metal smelting and refining. The furnace is relatively easy to use and provides complete control over the smelting and refining process. In addition, the furnace is space-efficient and relatively low cost compared to other large-scale furnaces. Another advantage of the furnace is its efficient fuel usage. Due to the small size of the furnace, it does not require large amounts of fuel to reach the desired temperature for smelting and refining.
However, there are still several disadvantages associated with the nickel matte smelting furnace. The furnace is limited by its small-scale smelting capability and hence is not suitable for large-scale production of metal products. In addition, since the furnace is operated manually, it is prone to human error which can result in erroneous results. Moreover, improper operation of the furnace can lead to by-products such as sulfur dioxide and other toxic fumes that can have an adverse environmental impact.
5 Conclusion
The nickel matte smelting furnace is a suitable choice for small-scale smelting and refining of nickel ore and matte. The furnace is easy to use and provides excellent fuel efficiency, making it ideal for use by small businesses. Despite its drawbacks, the smelting and refining process employed in the furnace is reliable and precise. Therefore, the nickel matte smelting furnace is an ideal option for small-scale metal smelting and refining.
