大规模生产FRHC铜和阳极铜的成本优化

废杂铜是一种有价资源,它应用于精矿铜冶炼、再生铜和铜加工行业。根据废杂铜质量,可以直接用它生产不同类型的半成品,如:阳极铜、铜棒或作为精矿铜冶炼过程中的冷却材料。尤其是高品质的废杂铜可用作倾斜式和固定式反射炉的炉料,后者广泛用于回收废杂铜。这种炉子采用单一物料进行熔炼、精炼和浇铸生产阳极铜,或是生产用于制作铜棒的FRHC铜(火法精炼高导电性铜)。精矿铜冶炼的特点是冶炼厂的年生产能力越来越高,单位生产成本越来越低。对比精矿铜冶炼的最新发展,FRHC铜棒和新的再生铜厂的生产中看不到这种趋势。然而,单位生产成本低对于废杂铜的回收极为重要,因为要比精矿冶炼厂生产阴极铜拥有成本优势。大部分用于生产FRHC铜棒的炉子年生产能力仍然很小,每天的生产能力仅为50～80t。本文提出为什么再生铜行业尤其是生产FRHC铜棒的炉子没有明显大型化的趋势。不同炉型的单位生产成本和单位投资成本之间的差异表明,大型炉子和可选择性的炉子有助于生产成本的优化。由于这些小型炉子大多建于发展中国家,对发展中国家能源成本和劳动力成本增加的影响也进行了讨论。

Large scale FRHC and anode copper production for optimized production costs

Copper scrap is a valuable resource,which is used in the primary,secondary and copper processing industry.Depending on its quality the scrap is directly used for the production of different types of semi-finished copper products like copper anodes and copper rod or it acts as cooling material for the processes in the primary industry. Especially copper scrap of good quality is used as an input material for tilting and stationary rever-beratory furnaces,which are widely-used for copper scrap recycling.These furnaces allow melting,refining and casting of the copper with one single aggregate for the production of copper anodes or FRHC(Fire Refined High Conductivity) copper for the rod production. Compared to the latest development in the primary copper industry,which is characterized by a trend towards primary smelters with a growing annual capacity to generate low specific production costs,this trend cannot be seen for the production of FRHC copper rod and some of the new secondary smelters.However,low specific production costs are vital for the scrap recycling in order to generate a cost advantage over the cathodes from the primary industry.Still most furnace systems used in the FHRC copper rod production have small annual capacities between 50 and 80t per day. This paper questions why there is no clear trend for larger furnaces in secondary industry and especially for systems for FRHC copper rod production.On the basis of the difference in specific production costs and specific investment costs for different furnace types it is shown,that larger furnaces and alternative furnace concepts help to optimize the production costs.The effects of rising energy and labor costs even in the developing countries, where most of these smaller furnace systems can be found,are further discussed to show a possible scenario for the future.