Extractive Metallurgy of Copper
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Table of contents
- Copyright Pageiv
- Contentsv
- Prefacexiii
- Preface to the Third Editionxv
- Preface to the Second Editionxvii
- Preface to the First Editionxix
- Chapter 1. Overview1
- 1.1 Introduction1
- 1.2 Extracting Copper from Copper-Iron-Sulfide Ores1
- 1.3 Hydrometallurgical Extraction of Copper11
- 1.4 Melting and Casting Cathode Copper13
- 1.5 Recycle of Copper and Copper-Alloy Scrap15
- 1.6 Summary15
- Suggested Reading16
- References16
- Chapter 2. Production and Use17
- 2.1 Locations of Copper Deposits18
- 2.2 Location of Extraction Plants18
- 2.3 Copper Minerals and ‘Cut-Off Grades19
- 2.4 Price of Copper28
- 2.5 Summary29
- References29
- Chapter 3. Concentrating Copper Ores31
- 3.1 Concentration Flowsheet31
- 3.2 Crushing and Grinding (Comminution)33
- 3.3 Flotation Feed Particle Size38
- 3.4 Froth Flotation42
- 3.5 Specific Flotation Procedures far Cu Ores46
- 3.6 Flotation Cells49
- 3.7 Sensors, Operation and Control50
- 3.8 The Flotation Product52
- 3.9 Other Flotation Separations53
- 3.10 Summary53
- Suggested Reading54
- References54
- Chapter 4 Matte Smelting Fundamentals57
- 4.1 Why Smelting?57
- 4.2 Matte and Slag59
- 4.3 Reactions During Matte Smelting65
- 4.4 The Smelting Process: General Considerations66
- 4.5 Smelting Products: Matte, Slag and Offgas67
- 4.6 Summary70
- Suggested Reading70
- References70
- Chapter 5. Flash Smelting-Outokumpu Process73
- 5.1 Outokumpu Flash Furnace74
- 5.2 Peripheral Equipment77
- 5.3 Furnace Operation82
- 5.4 Control83
- 5.5 Impurity Behavior86
- 5.6 Future Trends87
- 5.7 Summary87
- Suggested Reading88
- References88
- Chapter 6. Inco Flash Smelting91
- 6.1 Furnace Details91
- 6.2 Auxiliary Equipment96
- 6.3 Operation97
- 6.4 Control Strategy98
- 6.5 Cu-in-Slag and Molten Converter Slag Recycle100
- 6.6 Inco vs. Outokumpu Flash Smelting101
- 6.7 Summary101
- Suggested Reading101
- References102
- Chapter 7. Noranda and Teniente Smelting103
- 7.1 Noranda Process104
- 7.2 Reaction Mechanisms106
- 7.3 Operation and Control108
- 7.4 Production Rate Enhancement109
- 7.5 Noranda Future110
- 7.6 Teniente Smelting110
- 7.7 Process Description111
- 7.8 Operation111
- 7.9 Control113
- 7.10 Impurity Distribution114
- 7.11 Teniente Future115
- 7.12 Discussion115
- 7.13 Summary116
- Suggested Reading117
- References117
- Chapter 8. Ausmelt/lsasmelt Matte Smelting119
- 8.1 Basic Operations119
- 8.2 Feed Materials120
- 8.3 The Isasmelt Furnace and Lance120
- 8.4 Smelting Mechanisms125
- 8.5 Startup and Shutdown126
- 8.6 Current Installations126
- 8.7 Other Coppermaking Uses of Ausmelt/Isasmelt Technology127
- 8.8 Summary127
- Suggested Reading128
- References129
- Chapter 9. Batch Converting of Cu Matte131
- 9.1 Chemistry131
- 9.2 Industrial Peirce-Smith Converting Operations137
- 9.3 Oxygen Enrichment of Peirce-Smith Converter Blast144
- 9.4 Maximizing Converter Productivity145
- 9.5 Recent Developments in Converting–Shrouded Blast Injection148
- 9.6 Alternatives to Peirce-Smith Converting148
- 9.7 Summary150
- Suggested Reading151
- References151
- Chapter 10. Continuous Converting155
- 10.1 Common Features of Continuous Converting155
- 10.2 Downward Lance Mitsubishi Continuous Converting157
- 10.3 Solid Matte Outokumpu Flash Converting162
- 10.4 Submerged-Tuyere Noranda Continuous Converting166
- 10.5 % Cu-in-Slag170
- 10.6 Summary170
- Suggested Reading171
- References171
- Chapter 11. Copper Loss in Slag173
- 11.1 Copper in Slags173
- 11.2 Decreasing Copper in Slag I: Minimizing Slag Generation175
- 11.3 Decreasing Copper in Slag II: Minimizing Cu Concentration in Slag176
- 11.4 Decreasing Copper in Slag III: Pyrometallurgical Slag Settling/Reduction176
- 11.5 Decreasing Copper in Slag IV: Slag Minerals Processing181
- 11.6 Summary181
- Suggested Reading183
- References183
- Chapter 12. Direct-To-Copper Flash Smelting187
- 12.1 The Ideal Direct-to-Copper Process187
- 12.2 Industrial Single Furnace Direct-to-Copper Smelting188
- 12.3 Chemistry189
- 12.4 Industrial Details190
- 12.5 Control190
- 12.6 Cu-in-Slag: Comparison with Conventional Matte Smelting/Converting193
- 12.7 Cu-in-Slag Limitation of Direct-to-Copper Smelting194
- 12.8 Direct-to-Copper Impurities195
- 12.9 Summary195
- Suggested Reading196
- References196
- Chapter 13. Mitsubishi Continuous Smelting/Converting199
- 13.1 The Mitsubishi Process201
- 13.2 Smelting Furnace Details201
- 13.3 Electric Slag Cleaning Furnace Details203
- 13.4 Converting Furnace Details203
- 13.5 Recent Mitsubishi Process Developments207
- 13.6 Reaction Mechanisms in Mitsubishi Smelting208
- 13.7 Optimum Matte Grade210
- 13.8 Impurity Behavior in Mitsubishi Smelting/Converting210
- 13.9 Process Control in Mitsubishi Smelting/Converting211
- 13.10 Summary212
- Suggested Reading214
- References215
- Chapter 14. Capture and Fixation of Sulfur217
- 14.1 Offgases from Smelting and Converting Processes217
- 14.2 Sulfuric Acid Manufacture218
- 14.3 Smelter Offgas Treatment222
- 14.4 Gas Drying224
- 14.5 Acid Plant Chemical Reactions227
- 14.6 Industrial Sulfuric Acid Manufacture231
- 14.7 Recent and Future Developments in Sulfuric Acid Manufacture240
- 14.8 Alternative Sulfur Products241
- 14.9 Future Improvements in Sulfur Capture241
- 14.10 Summary242
- Suggested Reading243
- References243
- Chapter 15. Fire Refining and Casting of Anodes: Sulfur and Oxygen Removal247
- 15.1 Industrial Methods of Fire Refining247
- 15.2 Chemistry of Fire Refining252
- 15.3 Choice of Hydrocarbon for Deoxidation253
- 15.4 Casting Anodes253
- 15.5 Continuous Anode Casting256
- 15.6 New Anodes from Rejects and Anode Scrap260
- 15.7 Removal of Impurities During Fire Refining260
- 15.8 Summary261
- Suggested Reading261
- References262
- Chapter 16. Electrolytic Refining265
- 16.1 Principles265
- 16.2 Behavior of Anode Impurities During Electrorefining269
- 16.3 Industrial Electrorefining272
- 16.4 Cathodes273
- 16.5 Electrolyte273
- 16.6 Cells and Electrical Connections278
- 16.7 Typical Refining Cycle279
- 16.8 Refining Objectives280
- 16.9 Maximizing Cathode Copper Purity280
- 16.10 Optimum Physical Arrangements280
- 16.11 Optimum Chemical Arrangements281
- 16.12 Optimum Electrical Arrangements282
- 16.13 Minimizing Energy Consumption283
- 16.14 Recent Developments in Electrorefining283
- 16.15 Summary284
- Suggested Reading284
- References285
- Chapter 17. Hydrometallurgical Copper Extraction: Introduction and Leaching289
- 17.1 Heap Leaching289
- 17.2 Industrial Heap Leaching293
- 17.3 Steady-State Leaching299
- 17.4 Leaching of Chalcopyrite Concentrates300
- 17.5 Other Leaching Processcs301
- 17.6 Future Developments301
- 17.7 Summary301
- Suggested Reading303
- References303
- Chapter 18. Solvent Extraction Transfer of Cu from Leach Solution to Electrolyte307
- 18.1 The Solvent Extraction Process307
- 18.2 Chemistry309
- 18.3 Extractants310
- 18.4 Industrial Solvent Extraction Plants312
- 18.5 Quantitative Design of Series Circuit317
- 18.6 Stability of Operation321
- 18.7 'Crud'322
- 18.8 Summary323
- Suggested Reading324
- References324
- Chapter 19. Electrowinning327
- 19.1 Electrowinning Reactions328
- 19.2 Electrowinning Tankhouse Practice329
- 19.3 Maximizing Copper Purity335
- 19.4 Maximizing Current Efficiency335
- 19.5 Future Developments337
- 19.6 Summary337
- Suggested Reading338
- References338
- Chapter 20. Collection and Processing of Recycled Copper341
- 20.1 The Materials Cycle341
- 20.2 Secondary Copper Grades and Definitions344
- 20.3 Scrap Processing and Beneficiation346
- 20.4 Summary351
- Suggested Reading351
- References352
- Chapter 21. Chemical Metallurgy of Copper Recycling355
- 21.1 The Secondary Copper Smelter355
- 21.2 Scrap Processing in Primary Copper Smelters360
- 21.3 Summary363
- Suggested Reading363
- References364
- Chapter 22. Melting and Casting367
- 22.1 Product Grades and Quality367
- 22.2 Melting Technology370
- 22.3 Casting Machines374
- 22.4 Summary380
- Suggested Reading381
- References381
- Chapter 23. Costs of Copper Production385
- 23.1 Overall Investment Costs: Mine through Refinery386
- 23.2 Overall Direct Operating Costs: Mine through Refinery389
- 23.3 Total Production Costs, Selling Prices, Profitability389
- 23.4 Concentrating Costs391
- 23.5 Smelting Costs393
- 23.6 Electrorefining Costs395
- 23.7 Production of Copper from Scrap397
- 23.8 Leach/Solvent Extraction/Electrowinning Costs397
- 23.9 Profitability398
- 23.10 Summary399
- References399
- Appendices401
- A. Stoichiometric Data for Copper Extraction401
- B. Lesser-Used Smelting Processes403
- C. Copper Recovery from Anode Slimes413
- D. Sketch of Series-Parallel Solvent Extraction Circuit415
- E. Extended List of Chinese Copper Refineries and their Capacities416
- Index417
This new edition has been extensively revised and updated since the 3rd edition published in 1994. It contains an even greater depth of industrial information, focussing on how copper metal is extracted from ore and scrap, and how this extraction could be made more efficient.
Modern high intensity smelting processes are presented in detail, specifically flash, Contop, Isasmelt, Noranda, Teniente and direct-to-blister smelting. Considerable attention is paid to the control of SO2 emissions and manufacture of H2 SO4 . Recent developments in electrorefining, particularly stainless steel cathode technology are examined. Leaching, solvent extraction and electrowinning are evaluated together with their impact upon optimizing mineral resource utilization. The book demonstrates how recycling of copper and copper alloy scrap is an important source of copper and copper alloys. Copper quality control is also discussed and the book incorporates an important section on extraction economics.
Each chapter is followed by a summary of concepts previously described and offers suggested further reading and references.
Modern high intensity smelting processes are presented in detail, specifically flash, Contop, Isasmelt, Noranda, Teniente and direct-to-blister smelting. Considerable attention is paid to the control of SO
Each chapter is followed by a summary of concepts previously described and offers suggested further reading and references.