Extractive Metallurgy of Copper (eBook)

Front Cover 1
Extractive Metallurgy of Copper 4
Copyright Page 5
Table of Contents 6
Preface to the Third Edition 14
Preface to the Second Edition 16
Preface to the First Edition 18
Chapter 1. Synopsis 20
1.1 Introduction 20
1.2 Extraction of Copper from Sulphide Ores 23
1.3 Hydrometallurgical Extraction of Copper 34
1.4 Melting of Cathodes and Casting 37
1.5 Recycle of Copper and Copper-Alloy Scrap 38
1.6 Miscellaneous Copper Processes 40
1.7 Summary of Chapter 40
Suggested Reading 41
References 41
Chapter 2 Production Statistics 42
2.1 Location of Copper Deposits 42
2.2 Location of Extraction Facilities 43
2.3 Copper Minerals and Cut-Off Grades 52
2.4 Price of Copper 54
2.5 Summary of Chapter 55
Suggested Reading 55
References 55
Chapter 3 Concentration of Copper Ores 57
3.1 Concentration Flowsheet 57
3.2 Crushing and Grinding (Comminution) 61
3.3 Size Classification 61
3.4 Froth Flotation 71
3.5 Specific Flotation Procedures for Copper Ores 76
3.6 Flotation Cells, Residence Times 77
3.7 Sensors, Operation and Control 84
3.8 The Flotation Product 86
3.9 Other Flotation Separations 87
3.10 Summary of Chapter 89
Suggested Reading 90
References 90
Chapter 4. Matte Smelting 93
4.1 Reactions 95
4.2 Industrial Arrangements for Matte Smelting 98
4.3 Objectives and Control 98
4.4 Smelting Mechanisms 100
4.5 Atate 102
4.6 Slag 105
4.7 Creating Matte-Slag Immiscibility 109
4.8 Copper Distribution Between Matte and Slag 112
4.9 Choice of Matte Grade (% Cu in Matte) 114
4.10 Behaviour of Impurities During Smelting 115
4.11 Summary of Chapter 116
Suggested Reading 117
References 117
Chapter 5. Flash Smelting—Outokumpu Process 119
5.1 Outokumpu Flash Furnace 120
5.2 Operation—Startup and Shutdown 126
5.3 Steady State Operation 127
5.4 Control 127
5.5 Optimum Operating Conditions 131
5.6 Process Variations 134
5.7 Dust and Waste Heat Boiler Problems 135
5.8 Recent Developments 136
5.9 Future Developments 137
5.10 Summary of Chapter 138
Suggested Reading 138
References 139
Chapter 6. Flash Smelting—Inco Process 142
6.1 Process Description 142
6.2 Construction Details 143
6.3 Auxiliary Equipment 145
6.4 Operation 148
6.5 Advantages of Inco Flash Smelting 152
6.6 Summary of Chapter 153
Suggested Reading 153
References 154
Chapter 7. Reverberatory Furnace Matte Smelting 155
7.1 Reasons for Decline of Reverberatory Smelting 13 155
7.2 Description of the Process 159
7.3 Construction Details 161
7.4 Burners 162
7.5 Summary of Chapter 165
Suggested Reading 166
References 166
Chapter 8. Electric Furnace Matte Smelting 168
8.1 Advantages and Disadvantages 168
8.2 Description 171
8.3 Construction Details 172
8.4 Electrical System 173
8.5 Power Input, Productivity, Control 174
8.6 Energy Requirements and Costs 176
8.7 Summary of Chapter 176
Suggested Reading 177
References 177
Chapter 9. Noranda and Teniente Processes 179
9.1 Noranda Process 181
9.2 Reaction Mechanisms 181
9.3 Operation and Control 185
9.4 Production Rate Enhancement 187
9.5 Teniente Process 188
9.6 Process Description 192
9.7 Operation and Control 192
9.8 Dry Concentrate Injection Through Tuyeres 193
9.9 Other Developments 194
9.10 Summary of Chapter 195
Suggested Reading 196
References 196
Chapter 10. Emerging Matte Smelting Technologies—Isasmelt, Vanyukov and Contop Processes 198
10.1 Isasmelt Matte Smelting 198
10.2 Vanyukov Matte Smelting 203
10.3 Contop Matte Smelting 206
10.4 Summary of Chapter 210
Suggested Reading 210
References 211
Chapter 11. Converting of Cu Matte 213
11.1 Chemistry 215
11.2 Industrial Peirce-Smith Converting Operations 220
11.3 Oxygen Enrichment of Peirce-Smith Converter Blast 229
11.4 Maximizing Converter Productivity 230
11.5 Recent Developments in Converting—High Pressure Injection of Converter Blast 233
11.6 Alternatives to Peirce-Smith Converting 234
11.7 Summary of Chapter 238
Suggested Reading 239
References 239
Chapter 12. Copper Loss in Slag 243
12.1 Cu Concentrations in Smelting and Converting Slags 243
12.2 Quantities and Minimization of Cu in Discard Slags 247
12.3 Settling of Cu from Molten Slag 249
12.4 Recovery of Cu from Slag by Solidification/Comminution/Flotation 254
12.5 Comparison of Settling and Solidification/Comminution/Flotation 263
12.6 Summary of Chapter 263
Suggested Reading 264
References 264
Chapter 13. Direct-to-Blister Flash Smelting 267
13.1 The Ideal Direct-to-Blister Coppermaking Process 268
13.2 Industrial Single Furnace Direct-to-Blister Smelting 24913.3 Chemistry 268
13.3 Chemistry 269
13.4 Industrial Details 271
13.5 Control 274
13.6 Cu in Slag: Comparison with Conventional Matte Smelting/Converting 275
13.7 Cu-in-Slag Limitation on Direct-to-Blister Smelting 277
13.8 Impurities in Direct-to-Blister Copper 277
13.9 Summary of Chapter 278
Suggested Reading 279
References 279
Chapter 14. Continuous Multi-Furnace Smelting—Mitsubishi Process 280
14.1 The Mitsubishi Process 281
14.2 Smelting Furnace Details 282
14.3 Electric Slag Cleaning Furnace Details 285
14.4 Converting Furnace Details 287
14.5 Recent Developments in Mitsubishi Continuous Smelting 289
14.6 Reaction Mechanisms in Mitsubishi Smelting 289
14.7 Optimum Matte Grade 291
14.8 Impurity Behaviour in Mitsubishi Smelting/Converting 292
14.9 Summary of Chapter 293
Suggested Reading 294
References 294
Chapter 15. Capture and Fixation of Sulphur 296
15.1 Offgases from Smelting and Converting Processes 297
15.2 Sulphuric Acid Manufacture 299
15.3 Alternative Sulphur Products 317
15.4 Future Improvements in Sulphur Capture 318
15.5 Summary of Chapter 319
Suggested Reading 320
References 320
Chapter 16. Fire Refining and Casting of Anodes: Sulphur and Oxygen Removal 323
16.1 Industrial Methods of Fire Refining 324
16.2 Chemistry of Fire Refining 328
16.3 Choice of Hydrocarbon for Deoxidation 329
16.4 Casting Anodes 331
16.5 Continuous Anode Casting 333
16.6 New Anodes from Rejects and Anode Scrap 335
16.7 Removal of Impurities During Fire Refining 336
16.8 Summary of Chapter 338
Suggested Reading 339
References 340
Chapter 17. Electrolytic Refining of Copper 343
17.1 Principles 347
17.2 Behaviour of Anode Impurities during Electrorefining 349
17.3 Industrial Electrorefining 352
17.4 A Typical Refining Cycle 359
17.5 Maximizing Cathode Purity 360
17.6 Optimum Physical Arrangements 360
17.7 Optimum Chemical Arrangements 361
17.8 Optimum Electrical Arrangements 365
17.9 Maximizing Cathode Production Rate 365
17.10 Energy Consumption 369
17.11 Recent Developments in Copper Refining 370
17.12 Summary of Chapter 372
Suggested Reading 373
References 373
Chapter 18. Hydrometallurgical Copper Extraction: Introduction and Leaching 377
18.1 Leaching 377
18.2 Leaching Methods—Heap and Dump Leaching 382
18.3 In Situ Leaching 390
18.4 Tailings Leaching 391
18.5 Vat Leaching 391
18.6 Agitation Leaching of Oxidic Concentrates and Roaster Calcines 393
18.7 Leaching of Sulphide Concentrates 394
18.8 Future Hydrometallurgical Developments 397
18.9 Summary of Chapter 398
Suggested Reading 399
References 399
Chapter 19. Solvent Extraction Transfer of Copper From Leach Solution to Electrolyte 402
19.1 The Solvent Extraction Process 403
19.2 Chemistry 404
19.3 The Extractants 405
19.4 Industrial Solvent Extraction Plants 406
19.5 Extractant Choice 415
19.6 Organic Loss, Degradation and Reclamation 417
19.7 Summary of Chapter 418
Suggested Reading 418
References 419
Chapter 20. Electrowinning 420
20.1 Electrowinning Reactions 421
20.2 Electrowinning Tankhouse Practice 422
20.3 Maximizing Copper Purity 428
20.4 Choice of Cathode 429
20.5 Electrowinning from Agitation Leach Solutions 430
20.6 Summary of Chapter 430
Suggested Reading 431
References 431
Chapter 21. Recycle of Copper and Copper Alloy Scrap 433
21.1 Advantages of Copper Recycle 433
21.2 New Scrap and Old Scrap 434
21.3 Categories of Scrap 436
21.4 Physical Isolation of Copper and Copper-Alloy Scrap 436
21.5 Purification of Copper Scrap 439
21.6 Sampling and Analysis 441
21.7 Turning Scrap into New Copper or Alloy All 441
21.8 Low Grade Scrap and Residues 444
21.9 Recycling Scrap in Primary Smelters 448
21.10 Summary of Chapter 450
Suggested Reading 450
References 451
Chapter 22. Melting, Casting and Quality 453
22.1 Melting of Cathodes 454
22.2 Casting into Fabrication Shapes 457
22.3 Continuous Bar Casting 457
22.4 Oxygen and Inclusion Control 463
22.5 Rod Rolling 463
22.6 Rod Quality 464
22.7 Specifications for Cathode Copper 467
22.8 Casting of Billets and Slabs 469
22.9 Summary of Chapter 471
Suggested Reading 472
References 472
Chapter 23. Costs of Extracting Copper 474
23.1 Overall Capital Costs: Mine through Refinery 476
23.2 Overall Direct Operating Costs: Mine to Refinery 479
23.3 Total Production Costs, Selling Prices, Profitability 480
23.4 Concentrator Costs 482
23.5 Smelting Costs 484
23.6 Electrorefining Costs 487
23.7 Reclamation of Copper from Scrap 489
23.8 Leach/Solvent Extraction/Electroninning Costs 490
23.9 Profitability 490
23.10 Summary of Chapter 492
References 492
Appendices 493
A.I Roasting Copper Concentrates 493
A.II Units and Conversion Factors 504
A.III Stoichiometric Data for Copper Extraction 505
Index 508