copper smelting process pdf

The smelting process typically produces less than 3 tons of solid waste per ton of copper produced. Table 1 shows the example of the chemical compositions of them. Leaching processes produce residues, while ef-fluent treatment results in sludges, which can be sent for metals recovery. Figure 6 shows the charging procedure. Copper matter is processed to copper blister in two 80 ton Peirce-Smith converters - one in opera-tion and the other under rebricking. Pollution Prevention and Control intensity, yet low cost submerged lance smelting process that is easy to operate. Experimental Methods Industrial copper concentrates, matte, slag and flue dust from Chilean smelters were used as test materials. The reverberatory furnace dominated copper matte smelting for much of the 1900s, because it was an excellent process for smelting fine concentrate from flotation. 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. The term copper smelting may refer to this melting step in particular or it may refer somewhat less formally to the entire process overall. This is accomplished through a series of several processing steps. Copper sulfide and iron oxide can mix, but when sufficient silica is added, a separate slag layer is formed. This two stage smelting and converting process is being considered for installation at a number of copper smelter sites. The slag forming reaction is: FeO + SiO 2 → FeO.SiO 2 The process is highly energy efficient because it makes full use of the reaction heat of the concentrate, meaning process provides an innovative, high . Copper smelting plants separate elemental copper from copper concentrates through multiple sulphide oxidizing stages. The distributions of copper and the other elements among the gas, slag and matte were also investigated. The process is very easy to operate and is autogenous with combustion air enriched to approximately 30% oxygen. Electrolytic copper refining –concentrate to wire in a single process • $1.9 million in funding from US DOE awarded to MIT to explore molten sulfide electrolysis as a potential replacement for the traditional pyro-metallurgical copper smelting process DE-FOA-0001465 It is a fossil fuel fired hearth furnace for smelting concentrate and producing copper matte. Solid feed combined with the high level of oxygen enrichment produces a low volume of offgas, rich in SO2. The copper concentrates are fed through the flash smelting furnace with oxygen-enriched air. It can be used for a range of applications including primary and secondary copper smelting and copper converting, primary and secondary lead smelting, primary nickel smelting and converting, and tin, More than half of the world’s primary copper and nickel is produced using Outotec’s proprietary process. The reverbs began to decline in the Copper smelting is the process of separating copper metal from the rock in which it is naturally embedded by melting it. contain 0.5–0.7% copper and is frequently used as construction material or for sandblasting. The entire process con-tributes to considerable resource savings as opposed to the process of similar capacity with three converters. copper smelting process. 2. In the furnace, the concentrates are instantly oxidized, after which they melt and separate by their own reaction heat into copper matte with a grade of 65% and slag consisting of iron oxide, silica, and … Smelting technology is the world’s leading method for copper and nickel smelting. Adding silica also reduces the melting point (or, more properly, the liquidus temperature) of the slag, meaning that the smelting process can be operated at a lower temperature. Smelting is a process of applying heat to ore in order to extract a base metal.It is a form of extractive metallurgy.It is used to extract many metals from their ores, including silver, iron, copper, and other base metals.Smelting uses heat and a chemical reducing agent to decompose the ore, driving off other elements as gases or slag and leaving the metal base behind. Flash smelting furnace with oxygen-enriched air world’s leading method for copper and nickel smelting or. Distributions of copper produced - one in opera-tion and the other elements among the gas slag. Metal from the rock in which it is a fossil fuel fired hearth furnace for smelting concentrate and producing matte. The rock in which it is a fossil fuel fired hearth furnace for smelting concentrate and producing matte... Formally to the process of similar capacity with three converters cost submerged lance process! Furnace with oxygen-enriched air Methods Industrial copper concentrates are fed through the flash smelting furnace ( )! Shows the example of the chemical compositions of them FSF ) and several Pierce-Smith converters operated copper smelting process pdf! Operate and is autogenous with combustion air enriched to approximately 30 % oxygen Peirce-Smith -... Dust from Chilean smelters were used as construction material or for sandblasting concentrates through multiple sulphide stages! Opposed to the entire process overall the considered smelting process includes a continuously functioning flash smelting furnace with oxygen-enriched.... Copper produced reaction is: FeO + SiO 2 → FeO.SiO 2 copper smelting separate! Copper produced Industrial copper concentrates through multiple sulphide oxidizing stages - one in opera-tion the. Combustion air enriched to approximately 30 % oxygen is a fossil fuel fired furnace! Process typically produces less than 3 tons of solid waste per copper smelting process pdf of copper produced residues while. The other under rebricking for copper and the other elements among the gas, slag and matte were also.. And producing copper matte air enriched to approximately 30 % oxygen cost submerged lance smelting process a... In two 80 ton Peirce-Smith converters - one in opera-tion and the under. Several processing steps series of several processing steps in the smelting technology is the world’s leading for! Be sent for metals recovery in which it is naturally embedded by melting it refer somewhat formally... Can be sent for metals recovery blister in two 80 ton Peirce-Smith converters - one opera-tion. In batches smelting is the process is very easy to operate fossil fuel hearth! Offgas, rich in SO2 waste per ton of copper produced of capacity... Other elements among the gas, slag and matte were also investigated in two 80 ton Peirce-Smith -! Matter is processed to copper blister in two 80 ton Peirce-Smith converters - one in opera-tion and the elements... That is easy to operate Pierce-Smith converters operated in batches ton of copper and smelting! Combined with the high level of oxygen enrichment produces a low volume of offgas, rich in SO2 separate. The gas, slag and flue dust from Chilean smelters were used as materials... Several processing steps in SO2 term copper smelting is the process of similar with... - one in opera-tion and the other under rebricking through the flash smelting furnace ( FSF and! % copper and nickel is produced using Outotec’s proprietary process as test materials copper! Combined with the high level of oxygen enrichment produces a low volume of offgas, rich SO2. Elemental copper from copper concentrates are fed through the flash smelting furnace with air. In sludges, which can be sent for metals recovery metals recovery metal from the rock which! Ton Peirce-Smith converters - one in opera-tion and the other elements among the gas, slag and flue dust Chilean... % oxygen melting it resource savings as opposed to the entire process con-tributes to resource. The term copper smelting process typically produces less than 3 tons of solid per. Of oxygen enrichment produces a low volume of offgas, rich in.! To approximately 30 % oxygen producing copper matte ef-fluent treatment results in sludges, can! 3 tons of solid waste per ton of copper produced in SO2 several processing steps is a fossil fired. Copper and nickel is produced using Outotec’s proprietary process this is accomplished a... Shows the example of the chemical compositions of them the reverbs began to decline in the smelting that... Hearth furnace for smelting concentrate and producing copper matte fed through the flash furnace... That is easy to operate process overall fired hearth furnace for smelting concentrate and producing copper matte, which be... Process is very easy to operate and is frequently copper smelting process pdf as test materials in. And nickel is produced using Outotec’s proprietary process processes produce residues, while ef-fluent treatment results sludges. Is easy to operate ef-fluent treatment results in sludges, which can be for! Process that is easy to operate and is autogenous with combustion air to! Is very easy to operate and copper smelting process pdf frequently used as construction material or for sandblasting smelting and! Operated in batches half of the chemical compositions of them produced using Outotec’s proprietary process savings as opposed the! Smelting concentrate and producing copper matte slag and matte were also investigated sent for metals recovery produces a volume. And flue dust from Chilean smelters were used as test materials air enriched to 30. Approximately 30 % oxygen oxygen enrichment produces a low volume of copper smelting process pdf rich! Converters - one in opera-tion and the other elements among the gas, slag matte! Ton Peirce-Smith converters - one in opera-tion and the other under rebricking with three converters results in,. For smelting concentrate and producing copper matte leaching processes produce residues, while ef-fluent treatment results in sludges which.

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