Extractive Metallurgy of Copper (eBook)

Front Cover 1
Extractive Metallurgy of Copper 7
Copyright Page 8
Contents 9
Preface 17
Preface to the Third Edition 19
Preface to the Second Edition 21
Preface to the First Edition 23
Chapter 1. Overview 25
1.1 Introduction 25
1.2 Extracting Copper from Copper-Iron-Sulfide Ores 25
1.3 Hydrometallurgical Extraction of Copper 35
1.4 Melting and Casting Cathode Copper 37
1.5 Recycle of Copper and Copper-Alloy Scrap 39
1.6 Summary 39
Suggested Reading 40
References 40
Chapter 2. Production and Use 41
2.1 Locations of Copper Deposits 42
2.2 Location of Extraction Plants 42
2.3 Copper Minerals and ‘Cut-Off Grades 43
2.4 Price of Copper 52
2.5 Summary 53
References 53
Chapter 3. Concentrating Copper Ores 55
3.1 Concentration Flowsheet 55
3.2 Crushing and Grinding (Comminution) 57
3.3 Flotation Feed Particle Size 62
3.4 Froth Flotation 66
3.5 Specific Flotation Procedures far Cu Ores 70
3.6 Flotation Cells 73
3.7 Sensors, Operation and Control 74
3.8 The Flotation Product 76
3.9 Other Flotation Separations 77
3.10 Summary 77
Suggested Reading 78
References 78
Chapter 4 Matte Smelting Fundamentals 81
4.1 Why Smelting? 81
4.2 Matte and Slag 83
4.3 Reactions During Matte Smelting 89
4.4 The Smelting Process: General Considerations 90
4.5 Smelting Products: Matte, Slag and Offgas 91
4.6 Summary 94
Suggested Reading 94
References 94
Chapter 5. Flash Smelting-Outokumpu Process 97
5.1 Outokumpu Flash Furnace 98
5.2 Peripheral Equipment 101
5.3 Furnace Operation 106
5.4 Control 107
5.5 Impurity Behavior 110
5.6 Future Trends 111
5.7 Summary 111
Suggested Reading 112
References 112
Chapter 6. Inco Flash Smelting 115
6.1 Furnace Details 115
6.2 Auxiliary Equipment 120
6.3 Operation 121
6.4 Control Strategy 122
6.5 Cu-in-Slag and Molten Converter Slag Recycle 124
6.6 Inco vs. Outokumpu Flash Smelting 125
6.7 Summary 125
Suggested Reading 125
References 126
Chapter 7. Noranda and Teniente Smelting 127
7.1 Noranda Process 128
7.2 Reaction Mechanisms 130
7.3 Operation and Control 132
7.4 Production Rate Enhancement 133
7.5 Noranda Future 134
7.6 Teniente Smelting 134
7.7 Process Description 135
7.8 Operation 135
7.9 Control 137
7.10 Impurity Distribution 138
7.11 Teniente Future 139
7.12 Discussion 139
7.13 Summary 140
Suggested Reading 141
References 141
Chapter 8. Ausmelt/lsasmelt Matte Smelting 143
8.1 Basic Operations 143
8.2 Feed Materials 144
8.3 The Isasmelt Furnace and Lance 144
8.4 Smelting Mechanisms 149
8.5 Startup and Shutdown 150
8.6 Current Installations 150
8.7 Other Coppermaking Uses of Ausmelt/Isasmelt Technology 151
8.8 Summary 151
Suggested Reading 152
References 153
Chapter 9. Batch Converting of Cu Matte 155
9.1 Chemistry 155
9.2 Industrial Peirce-Smith Converting Operations 161
9.3 Oxygen Enrichment of Peirce-Smith Converter Blast 168
9.4 Maximizing Converter Productivity 169
9.5 Recent Developments in Converting–Shrouded Blast Injection 172
9.6 Alternatives to Peirce-Smith Converting 172
9.7 Summary 174
Suggested Reading 175
References 175
Chapter 10. Continuous Converting 179
10.1 Common Features of Continuous Converting 179
10.2 Downward Lance Mitsubishi Continuous Converting 181
10.3 Solid Matte Outokumpu Flash Converting 186
10.4 Submerged-Tuyere Noranda Continuous Converting 190
10.5 % Cu-in-Slag 194
10.6 Summary 194
Suggested Reading 195
References 195
Chapter 11. Copper Loss in Slag 197
11.1 Copper in Slags 197
11.2 Decreasing Copper in Slag I: Minimizing Slag Generation 199
11.3 Decreasing Copper in Slag II: Minimizing Cu Concentration in Slag 200
11.4 Decreasing Copper in Slag III: Pyrometallurgical Slag Settling/Reduction 200
11.5 Decreasing Copper in Slag IV: Slag Minerals Processing 205
11.6 Summary 205
Suggested Reading 207
References 207
Chapter 12. Direct-To-Copper Flash Smelting 211
12.1 The Ideal Direct-to-Copper Process 211
12.2 Industrial Single Furnace Direct-to-Copper Smelting 212
12.3 Chemistry 213
12.4 Industrial Details 214
12.5 Control 214
12.6 Cu-in-Slag: Comparison with Conventional Matte Smelting/Converting 217
12.7 Cu-in-Slag Limitation of Direct-to-Copper Smelting 218
12.8 Direct-to-Copper Impurities 219
12.9 Summary 219
Suggested Reading 220
References 220
Chapter 13. Mitsubishi Continuous Smelting/Converting 223
13.1 The Mitsubishi Process 225
13.2 Smelting Furnace Details 225
13.3 Electric Slag Cleaning Furnace Details 227
13.4 Converting Furnace Details 227
13.5 Recent Mitsubishi Process Developments 231
13.6 Reaction Mechanisms in Mitsubishi Smelting 232
13.7 Optimum Matte Grade 234
13.8 Impurity Behavior in Mitsubishi Smelting/Converting 234
13.9 Process Control in Mitsubishi Smelting/Converting 235
13.10 Summary 236
Suggested Reading 238
References 239
Chapter 14. Capture and Fixation of Sulfur 241
14.1 Offgases from Smelting and Converting Processes 241
14.2 Sulfuric Acid Manufacture 242
14.3 Smelter Offgas Treatment 246
14.4 Gas Drying 248
14.5 Acid Plant Chemical Reactions 251
14.6 Industrial Sulfuric Acid Manufacture 255
14.7 Recent and Future Developments in Sulfuric Acid Manufacture 264
14.8 Alternative Sulfur Products 265
14.9 Future Improvements in Sulfur Capture 265
14.10 Summary 266
Suggested Reading 267
References 267
Chapter 15. Fire Refining and Casting of Anodes: Sulfur and Oxygen Removal 271
15.1 Industrial Methods of Fire Refining 271
15.2 Chemistry of Fire Refining 276
15.3 Choice of Hydrocarbon for Deoxidation 277
15.4 Casting Anodes 277
15.5 Continuous Anode Casting 280
15.6 New Anodes from Rejects and Anode Scrap 284
15.7 Removal of Impurities During Fire Refining 284
15.8 Summary 285
Suggested Reading 285
References 286
Chapter 16. Electrolytic Refining 289
16.1 Principles 289
16.2 Behavior of Anode Impurities During Electrorefining 293
16.3 Industrial Electrorefining 296
16.4 Cathodes 297
16.5 Electrolyte 297
16.6 Cells and Electrical Connections 302
16.7 Typical Refining Cycle 303
16.8 Refining Objectives 304
16.9 Maximizing Cathode Copper Purity 304
16.10 Optimum Physical Arrangements 304
16.11 Optimum Chemical Arrangements 305
16.12 Optimum Electrical Arrangements 306
16.13 Minimizing Energy Consumption 307
16.14 Recent Developments in Electrorefining 307
16.15 Summary 308
Suggested Reading 308
References 309
Chapter 17. Hydrometallurgical Copper Extraction: Introduction and Leaching 313
17.1 Heap Leaching 313
17.2 Industrial Heap Leaching 317
17.3 Steady-State Leaching 323
17.4 Leaching of Chalcopyrite Concentrates 324
17.5 Other Leaching Processcs 325
17.6 Future Developments 325
17.7 Summary 325
Suggested Reading 327
References 327
Chapter 18. Solvent Extraction Transfer of Cu from Leach Solution to Electrolyte 331
18.1 The Solvent Extraction Process 331
18.2 Chemistry 333
18.3 Extractants 334
18.4 Industrial Solvent Extraction Plants 336
18.5 Quantitative Design of Series Circuit 341
18.6 Stability of Operation 345
18.7 'Crud' 346
18.8 Summary 347
Suggested Reading 348
References 348
Chapter 19. Electrowinning 351
19.1 Electrowinning Reactions 352
19.2 Electrowinning Tankhouse Practice 353
19.3 Maximizing Copper Purity 359
19.4 Maximizing Current Efficiency 359
19.5 Future Developments 361
19.6 Summary 361
Suggested Reading 362
References 362
Chapter 20. Collection and Processing of Recycled Copper 365
20.1 The Materials Cycle 365
20.2 Secondary Copper Grades and Definitions 368
20.3 Scrap Processing and Beneficiation 370
20.4 Summary 375
Suggested Reading 375
References 376
Chapter 21. Chemical Metallurgy of Copper Recycling 379
21.1 The Secondary Copper Smelter 379
21.2 Scrap Processing in Primary Copper Smelters 384
21.3 Summary 387
Suggested Reading 387
References 388
Chapter 22. Melting and Casting 391
22.1 Product Grades and Quality 391
22.2 Melting Technology 394
22.3 Casting Machines 398
22.4 Summary 404
Suggested Reading 405
References 405
Chapter 23. Costs of Copper Production 409
23.1 Overall Investment Costs: Mine through Refinery 410
23.2 Overall Direct Operating Costs: Mine through Refinery 413
23.3 Total Production Costs, Selling Prices, Profitability 413
23.4 Concentrating Costs 415
23.5 Smelting Costs 417
23.6 Electrorefining Costs 419
23.7 Production of Copper from Scrap 421
23.8 Leach/Solvent Extraction/Electrowinning Costs 421
23.9 Profitability 422
23.10 Summary 423
References 423
Appendices 425
A. Stoichiometric Data for Copper Extraction 425
B. Lesser-Used Smelting Processes 427
C. Copper Recovery from Anode Slimes 437
D. Sketch of Series-Parallel Solvent Extraction Circuit 439
E. Extended List of Chinese Copper Refineries and their Capacities 440
Index 441