copper smelter process flow

copper smelter process flow

Copper Mining & Extraction Process Flow Chart

Aug 26, 2015 · Copper Mining & Extraction Process Flow Chart. This flowchart made of machinery icons explains or expresses in simple but clear terms the step of the Copper Mining and Copper Extraction Process. Starting from either open-pit or underground mining and using a different relevant treatment method for oxide or sulphide copper

12.3 Primary Copper Smelting

A typical pyrometallurgical copper smelting process, as illustrated in Figure 12.3-1, includes 4 steps: roasting, smelting, concentrating, and fire refining. Ore concentration is roasted to reduce impurities, including sulfur, antimony, arsenic, and lead. The roasted product, calcine, serves as a dried and heated charge for the smelting furnace.

Copper Smelting - Metallurgist & Mineral Processing Engineer

Jan 13, 2021 · Copper Smelting Process. In the autogenous system described by this report, sulfide concentrate and silica flux are blown into the furnace through a specially designed burner with oxygen and is flash smelted to about 50-percent copper matte. The matte flows down an inclined crucible, countercurrent to the slag flow, to the converting zone at ...

Chapter 6 Copper Production Technology

Copper Production Technology The last boomin technological innovation for the copper industry occurred in the first two dec-ades of this century, whenopen pit mining, flo- tation concentration,and the reverberatory smelter were adapted to porphyry copper ores. With the exception of leaching-solvent extrac-tion-electrowinning, the basic methods ...

U.S. Geological Survey Open-File Report 2004-1395

Copper smelting generates many types of materials flows. As copper concentrate flows through the smelting process, it leaves behind an altered mine deposit, sometimes mine waste, and mill tailings. Fluxing materials, fuels, oxygen, recyclables, scrap, and water are input to the process. Dust (recycled); gases, which contain carbon dioxide (CO 2

Copper Process Flowsheet Example

Oct 01, 2015 · Copper Process Flowsheet Example. A simplified schematic drawing of copper flotation flowsheet. Run-of-mine open pit ore will be crushed in a gyratory crusher. The crushed ore will be processed by means of semi-autogenous and ball mill grinding followed by rougher flotation, regrind, cleaner flotation, and dewatering to produce copper concentrate.

Chapter 6 Copper Production Technology

Copper Production Technology The last boomin technological innovation for the copper industry occurred in the first two dec-ades of this century, whenopen pit mining, flo- tation concentration,and the reverberatory smelter were adapted to porphyry copper ores. With the exception of leaching-solvent extrac-tion-electrowinning, the basic methods ...

Copper Smelting Process - Furnaces Used, By-Products, and ...

Apr 09, 2010 · Modern copper smelters use processed copper ore fed into a flash furnace, typically fired by oxygen which produces blister copper, being further processed in a converter furnace. Molten copper is poured from here into rectangular moulds, the resulting ingots subjected to electrolysis producing a metal of 99.9% purity. Copper can be recycled indefinitely without the base metal being

(PDF) Improved Copper Flash Smelting at Olympic Dam

Figure 1 shows a typical flow sheet of the copper flash smelting process. Copper smelting is performed by injecting co ncentrate and oxygen enriched gas into a high temperature react ion shaft.

The smelting operations of Anglo American’s platinum ...

Figure 2: Schematic of process flow at Waterval Smelter (after Jacobs2) The furnace matte from all the smelters is then fed to the Anglo Platinum Converting Process (ACP) where the matte is upgraded through removal of the iron (and sulfur) to form Waterval Converter Matte (WCM). The WCM is

Copper Smelting - an overview | ScienceDirect Topics

Copper smelting plants separate elemental copper from copper concentrates through multiple sulphide oxidizing stages. The considered smelting process includes a continuously functioning flash smelting furnace (FSF) and several Pierce-Smith converters operated in batches. Automating scheduling provides advisory information to operators.

Mining Process | Konkola Copper Mines Plc

The smelter processes ore from Konkola, Nchanga and other third party concentrates and it has a capacity of 311,000t pa. The smelter has met global benchmark environmental performance as it captures 99.6% of sulphur emissions. The main refinery at Nkana uses electrolysis to process copper anodes to LME A grade copper cathodes.

Process | Umicore

The main processing steps of the Precious Metals Operations are the smelter, the copper leaching and electrowinning plant and the precious metals refinery. The operations are designed in such a way that raw materials can enter the flowsheet at the most optimal process step, determined by their physical aspect, their analytical fingerprint and ...

Pre-Feasibility Report

Process Flow Sheet for Integrated Copper Smelter Plant 160 Annexure X Material Flow Sheet for Integrated Copper Smelter Plant 161 Annexure XI Water Balance for Integrated Copper Smelter Plant 162 List of Abbreviation 163 .

Copper - Sulphuric Acid

Flash converting closely resembles flash smelting. Flash smelting is a closed process and, consequently, off-gas emissions can be efficiently controlled. Flash converting had its first application in the expansion and modernization of Kennecott's copper smelter near Salt Lake City, Utah, which was implemented during 1992-95.

Operation - Rio Tinto Kennecott

The next stage, smelting, is a process of heating and melting the copper concentrates to cause a chemical reaction, which removes the copper from other elements in the ore. At the smelter, we produce large 750-pound anodes and transport them by rail to the Refinery. The copper is

How Hydrometallurgy and the SX/EW Process Made Copper the ...

Electrowon copper cathodes are as pure as or purer than electrorefined cathodes from the smelting process. Thus they are well received by the market. Whereas the conventional process requires an estimated 65 MJ/kg of energy (not including scrap recycling ) the SX/EW process requires an estimated 15 MJ/kg (from heap or dump leaching) to 36 MJ/kg.

ISASMELT - Wikipedia

The ISASMELT process is an energy-efficient smelting process that was jointly developed from the 1970s to the 1990s by Mount Isa Mines Limited (a subsidiary of MIM Holdings Limited and now part of Glencore plc) and the Australian government’s Commonwealth Scientific and Industrial Research Organisation ("CSIRO"). It has relatively low capital and operating costs for a smelting process.

BACKGROUND REPORT PRIMARY COPPER SMELTING

location, approximate annual capacity, and processes of each of the eight primary copper smelters in the U.S. are listed in Table 2.1-1. 2.2 Process Description Copper is mined from a variety of ores, often containing less than one percent copper. This copper is typically in the form of mineral compounds with sulfur, iron, arsenic, and tin. To

COPPER Copper production - TU Delft

The reverberatory furnace dominated copper matte smelting for much of the 1900s, because it was an excellent process for smelting fine concentrate from flotation. It is a fossil fuel fired hearth furnace for smelting concentrate and producing copper matte. The reverbs began to decline in the

Processing of Complex Materials in the Copper Industry ...

Jul 06, 2020 · Figure 7 shows the process flowsheet of the lead secondary copper smelter.20 The flowsheet allows the integration and transfer of materials with the primary copper smelter. The lead smelter and refinery involve: Smelting of complex copper lead concentrates in an electric furnace. Converting of copper lead matte in a Peirce-Smith converter.

The smelting operations of Anglo American’s platinum ...

Figure 2: Schematic of process flow at Waterval Smelter (after Jacobs2) The furnace matte from all the smelters is then fed to the Anglo Platinum Converting Process (ACP) where the matte is upgraded through removal of the iron (and sulfur) to form Waterval Converter Matte (WCM). The WCM is

Reducing the health risks of the copper, rare earth and ...

Figure 4-2. Simplified process flow diagram for rare earth production from bastnäsite ore... 63 Figure 5-1. Illustration of copper and cobalt metal production from copper-cobalt ores ..... 81 Figure 5-2. Overview of the recycling process for lithium-ion batteries at Umicore ..... 82 Boxes Box 2-1.

Copper extraction - Wikipedia

The matte, which is produced in the smelter, contains 30–70% copper (depending on the process used and the operating philosophy of the smelter), primarily as copper sulfide, as well as iron sulfide. The sulfur is removed at high temperature as sulfur dioxide by blowing air through molten matte: 2 CuS + 3 O 2 → 2 CuO + 2 SO 2 CuS + O 2 ...

12.6 Primary Lead Smelting

furnace process rate is controlled by the proportion of coke in the charge and by the air flow through the tuyeres in the floor of the furnace. The charge descends through the furnace shaft into the smelting zone, where it becomes molten, and is tapped into a series of settlers that allow the separation of lead

(PDF) Energy Consumption in Copper Smelting: A New Asian ...

Based on the Fangyuan 1# smelter, the effects of major elements (Cu, Fe and S) in sulfide concentrates on arsenic removal in the SKS copper smelting process were studied in this paper.

OUTOTEC SMELTING SOLUTIONS FOR THE PGM INDUSTRY

A general flow sheet incorporating an Ausmelt furnace to smelt and convert nickel sulphide concentrate is shown in Figure 3. Figure 3-Outotec Ausmelt Process for nickel/PGM smelting During smelting, nickel sulphide concentrates are fed into the Ausmelt Smelting furnace along with

Copper Smelter Process Flowsheet Crushed Concrete ...

Slag Process Flowsheet Schroder. Recovery of value metals from copper smelter slag by,Fig 7 shows a proposed process flowsheet for the copper, zinc, and iron recovery from copper smelter slag of Balkhash copper plant In this process, crushed slag, with ammonium chloride in a weight ratio 1:2 is subjected to heat treatment for 120 min at 320 °C ...

Copper Scrap - an overview | ScienceDirect Topics

Copper scrap is often classified according to its source: (1) direct or “home scrap”, which is the scrap generated at the smelter/refinery and has the highest purity, usually recycled internally at the plant; “new scrap” is generated at downstream metal fabricators, e.g. trimmings, boring and croppings, which also usually is recycled at ...

CN103382528A - Two-step copper smelting process and ...

The invention provides a two-step copper smelting process and equipment. The process consists of the steps of bottom blowing smelting and converting. The process equipment consists of a bottom blowing smelting furnace and two converting furnaces that are laid in the shape of a Chinese character ''pin''. The three devices are all rotatable horizontal cylindrical furnaces with shells made of a ...

Upgrade of Outotec® concentrate burner at Atlantic Copper ...

Feb 19, 2018 · Uneven process air distribution in the concentrate burner has a negative impact on smelter performance, as was recently seen in the Huelva flash smelting furnace in Spain. The existing gas channel that fed process air to the burner was highly asymmetric and the air chamber was designed for a lower gas flow, and this was resulting in an uneven heat load on the reaction shaft walls. A shift ...

US5180422A - Copper smelting process - Google Patents

A copper smelting process is disclosed in which copper concentrate is smelted in a furnace to produce purified copper. Flue gas discharged from the furnace is treated to produce sulfuric acid. Furthermore, waste liquid discharged during the production of sulfuric acid is treated to produce gypsum, and the gypsum thus produced is recycled to the furnace as a flux.