Impurities at HBM&S' Flin Flon copper smelter

"With respect to impurities, HBM&S' copper smelter, located in Flin Ron, Manitoba, is in an unusual position. In addition to the usual concerns, the fact that copper and zinc production at Flin Ron is closely integrated results in the unique situation where feed to the copper smelter typically contains 7% to 8% zinc. This paper discusses the ramifications to copper smelter operations resulting from the marriage of HBM&S' metallurgical plants. Distributions of impurities (specifically Zn, Pb, Ni, As, Bi, Sb, and Cd) are presented and operating practices designed to reduce the impact of impurities on anode copper quality are detailed.IntroductionHudson Bay Mining & Smelting Co. Ltd. (HBM&s), has been operating its metallurgical complex located in Flin Flon, Manitoba, since 1930. The smelter and zinc plant were originally separate entities with respect to production. The smelting operation consisted of traditional multiple-hearth roasters, a reverberatory furnace and Peirce-Smith converters. The zinc plant also utilized multiple hearth roasters and then followed with sulphuric acid leaching, purification and electrowinning. The zinc plant also recovered cadmium from a separate purification/electrowinning circuit.The two plants operated essentially independently of each other until rising zinc levels in the copper concentrate and large stockpiles of zinc-rich leach residues prompted the construction of the fuming plant in 1949. The smelter used pulverized coal to reduce zinc oxide present in the reverb slag and then captured the resulting zinc bearing fume in the fuming plant baghouse. The fume was sent to a separate ""oxide roaster"" in the zinc plant where it was first roasted to remove halogens and then leached to recover the contained zinc. This oxide fume became a major source of feed to the zinc plant accounting for roughly one quarter of the total zinc production. Furthermore, through the smelter's treatment of sulphide leach residue, both copper and zinc recoveries were improved for the over-all complex."