PS Converter-Metallurgical Furnace-Changsha Metalcess Intelligent Equipment Co., Ltd.-Metallurgical Equipment Design and Manufacturing, Process Technology Package Delivery, and Automation Integration

PS Converter

The PS converter (also known as the horizontal blowing converter or P-S converter) is a core equipment used in the smelting of non-ferrous metals, especially widely applied in the processes of converting copper matte (baked copper), nickel matte, and black copper. It is the most mature and widely adopted smelting technology in the copper metallurgy industry. The production capacity of the PS converter Metalcess manufactured can range from 10 to 100 tons, and it can adapt to various smelting scales. It is an important equipment for the pyrometallurgical smelting of sulfide copper ores, the recovery of scrap copper, and the recovery of copper containing precious metals. The main product is secondary crude copper (with a copper content of 92-98.5%).

General introduction fo PS Converter

Definition of converting In metallurgy

Converting usually refers to the oxidation reaction carried out by blowing gases (such as oxygen or air) into the molten material, in order to remove impurities (such as sulfur, iron, carbon, etc.). A typical example is the converting process for copper matte or the oxygen top-blown process (BOS) for steel.

Working Principle of PS Converter

Working Principle of PS Converter

The PS converter for treating copper matte or nickel mattr operates in batch manner, divided into two stages:

Slag-making stage:The liquid copper slag (containing Cu 48-70%) produced by the smelting furnace is transported to the converter by crane or chute. The FeS in the oxidized copper slag is oxidized to FeO and reacts with the quartz flux (SiO₂) to form slag. After the wind stops, the converter body is tilted to discharge the slag, and the feeding process is repeated until the copper slag accumulates to approximately 200 tons.
Copper-making stage:The oxidized remaining Cu₂S generates crude copper (containing Cu ≥ 98.5%), which is poured from the furnace mouth into the steel ladle and transported to the anode furnace for refining.

The PS converter process the black copper produced after the blast furnace smelting of copper scrap or PCB (waste circuit boards), mainly oxidizing the impurities and removing them. After the impurities in the black copper are turned into oxides, they are either removed by volatilization into the gas phase or combined with the quartz flux added to the converter to form slag. Iron, zinc, and tin are relatively easy to remove. Antimony, nickel, and cobalt are more difficult to remove from the black copper.

After smelting, secondary crude copper, converter slag, furnace gas, and dust can be produced. The secondary crude copper (Cu: 92-98.5%) is sent to the anode furnace for refining.

Advantages of PS Converter

Advantages of PS Converter

Proven and reliable: The process is stable, with a low sulfur content in the crude copper (≤0.05%), making it suitable for processing waste scrap copper containing precious metals.

Self-heating reaction: During the smelting process, it releases heat and no additional fuel is required, resulting in lower energy consumption.

Flexible adaptation: It can be compatible with different specifications (10-100 ton loading capacity), and is suitable for various smelting scales.

Application Field of PS Converter

Application Field of PS Converter

Copper smelting: The core application is the converting of copper matte to crude copper (this is the mainstream process for global copper production).
Treatment of lead-zinc sulfide ores and separation of gold and silver (using as a silver furnace).
Converting of nickel matte for the production of high-purity nickel.
Matte smelting of copper concentrate and refining of crude copper.
Converting of black copper produced by the blast furnace smelting of copper scrap and and electronic waste containing precious metals (PCB recycling).