This multi-author new edition revises and updates the classic reference by William G. Davenport et al (winner of, among other awards, the 2003 AIME Mineral Industry Educator of the Year Award "for inspiring students in the pursuit of clarity"), providing fully updated coverage of the copper production process, encompassing topics as diverse as environmental technology for wind and solar energy transmission, treatment of waste by-products, and recycling of electronic scrap for potential alternative technology implementation. The authors examine industrially grounded treatments of process fundamentals and the beneficiation of raw materials, smelting and converting, hydrometallurgical processes, and refining technology for a mine-to-market perspective - from primary and secondary raw materials extraction to shipping of rod or billet to customers. The modern coverage of the work includes bath smelting processes such as Ausmelt and Isasmelt, which have become state-of-the-art in sulfide concentrate smelting and converting.
1. 1.1. Introduction 2. 1.2. Extracting Copper from Copper–Iron–Sulfide Ores 3. 1.3. Hydrometallurgical Extraction of Copper 4. 1.4. Melting and Casting Cathode Copper 5. 1.5. Recycle of Copper and Copper-alloy Scrap (Chapters 18 and 19Chapter 18Chapter 19) 6. 1.6. Summary 7. Chapter 2. Production and Use 8. 2.1. Copper Minerals and Cut-off Grades 9. 2.2. Location of Extraction Plants 10. 2.3. Price of Copper 11. 2.4. Summary 12. Chapter 3. Production of High Copper Concentrates – Introduction and Comminution 13. 3.1. Concentration Flowsheet 14. 3.2. The Comminution Process 15. 3.3. Blasting 16. 3.4. Crushing 17. 3.5. Grinding 18. 3.6. Recent Developments in Comminution 19. 3.7. Summary 20. Chapter 4. Production of Cu Concentrate from Finely Ground Cu Ore 21. 4.1. Froth Flotation 22. 4.2. Flotation Chemicals (Nagaraj & Ravishankar, 2007; Woodcock, Sparrow, Bruckard, Johnson, & Dunne, 2007) 23. 4.3. Specific Flotation Procedures for Cu Ores 24. 4.4. Flotation Cells 25. 4.5. Sensors, Operation, and Control 26. 4.6. The Flotation Products 27. 4.7. Other Flotation Separations 28. 4.8. Summary 29. Chapter 5. Matte Smelting Fundamentals 30. 5.1. Why Smelting? 31. 5.2. Matte and Slag 32. 5.3. Reactions During Matte Smelting 33. 5.4. The Smelting Process: General Considerations 34. 5.5. Smelting Products: Matte, Slag and Offgas 35. 5.6. Summary 36. Chapter 6. Flash Smelting 37. 6.1. Outotec Flash Furnace 38. 6.2. Peripheral Equipment 39. 6.3. Flash Furnace Operation 40. 6.4. Control (Fig. 6.3) 41. 6.5. Impurity Behavior 42. 6.6. Outotec Flash Smelting Recent Developments and Future Trends 43. 6.7. Inco Flash Smelting 44. 6.8. Inco Flash Furnace Summary 45. 6.9. Inco vs. Outotec Flash Smelting 46. 6.10. Summary 47. Chapter 7. Submerged Tuyere Smelting 48. 7.1. Noranda Process (Prevost, Letourneau, Perez, Lind, & Lavoie, 2007; Zapata, 2007) 49. 7.2. Reaction Mechanisms 50. 7.3. Operation and Control 51. 7.4. Production Rate Enhancement 52. 7.5. Teniente Smelting 53. 7.6. Process Description 54. 7.7. Operation (Moyano et al., 2010) 55. 7.8. Control (Morrow & Gajaredo, 2009; Moyano et al., 2010) 56. 7.9. Impurity Distribution 57. 7.10. Discussion 58. 7.11. Vanyukov Submerged-Tuyere Smelting 59. 7.12. Summary 60. Chapter 8. Converting of Copper Matte 61. 8.1. Chemistry 62. 8.2. Industrial Peirce–Smith Converting Operations 63. 8.3. Oxygen Enrichment of Peirce–Smith Converter Blast 64. 8.4. Maximizing Converter Productivity 65. 8.5. Recent Improvements in Peirce–Smith Converting 66. 8.6. Alternatives to Peirce–Smith Converting 67. 8.7. Summary 68. Chapter 9. Bath Matte Smelting 69. 9.1. Basic Operations 70. 9.2. Feed Materials 71. 9.3. The TSL Furnace and Lances 72. 9.4. Smelting Mechanisms 73. 9.5. Startup and Shutdown 74. 9.6. Current Installations 75. 9.7. Copper Converting Using TSL Technology 76. 9.8. The Mitsubishi Process 77. 9.9. The Mitsubishi Process in the 2000s 78. 9.10. Summary 79. Chapter 10. Direct-To-Copper Flash Smelting 80. 10.1. Advantages and Disadvantages 81. 10.2. The Ideal Direct-to-Copper Process 82. 10.3. Industrial Single Furnace Direct-to-Copper Smelting 83. 10.4. Chemistry 84. 10.5. Effect of Slag Composition on % Cu-in-Slag 85. 10.6. Industrial Details 86. 10.7. Control 87. 10.8. Electric Furnace Cu-from-Slag Recovery 88. 10.9. Cu-in-Slag Limitation of Direct-to-Copper Smelting 89. 10.10. Direct-to-Copper Impurities 90. 10.11. Summary 91. Chapter 11. Copper Loss in Slag 92. 11.1. Copper in Slags 93. 11.2. Decreasing Copper in Slag I: Minimizing Slag Generation 94. 11.3. Decreasing Copper in Slag II: Minimizing Copper Concentration in Slag 95. 11.4. Decreasing Copper in Slag III: Pyrometallurgical Slag Settling/Reduction 96. 11.5. Decreasing Copper in Slag IV: Slag Minerals Processing 97. 11.6. Summary 98. Chapter 12. Capture and Fixation of Sulfur 99. 12.1. Offgases from Smelting and Converting Processes 100. 12.2. Sulfuric Acid Manufacture 101. 12.3. Smelter Offgas Treatment 102. 12.4. Gas Drying 103. 12.5. Acid Plant Chemical Reactions 104. 12.6. Industrial Sulfuric Acid Manufacture (Tables 12.4, 12.5, and 12.6) 105. 12.7. Alternative Sulfuric Acid Manufacturing Methods 106. 12.8. Recent and Future Developments in Sulfuric Acid Manufacture 107. 12.9. Alternative Sulfur Products 108. 12.10. Future Improvements in Sulfur Capture 109. 12.11. Summary 110. Chapter 13. Fire Refining (S and O Removal) and Anode Casting 111. 13.1. Industrial Methods of Fire Refining 112. 13.2. Chemistry of Fire Refining 113. 13.3. Choice of Hydrocarbon for Deoxidation 114. 13.4. Casting Anodes 115. 13.5. Continuous Anode Casting 116. 13.6. New Anodes from Rejects and Anode Scrap 117. 13.7. Removal of Impurities During Fire Refining 118. 13.8. Summary 119. Chapter 14. Electrolytic Refining 120. 14.1. The Electrorefining Process 121. 14.2. Chemistry of Electrorefining and Behavior of Anode Impurities 122. 14.3. Equipment 123. 14.4. Typical Refining Cycle 124. 14.5. Electrolyte 125. 14.6. Maximizing Copper Cathode Purity 126. 14.7. Minimizing Energy Consumption 127. 14.8. Industrial Electrorefining 128. 14.9. Recent Developments and Emerging Trends in Copper Electrorefining 129. 14.10. Summary 130. Chapter 15. Hydrometallurgical Copper Extraction 131. 15.1. Copper Recovery by Hydrometallurgical Flowsheets 132. 15.2. Chemistry of the Leaching of Copper Minerals 133. 15.3. Leaching Methods 134. 15.4. Heap and Dump Leaching 135. 15.5. Vat Leaching 136. 15.6. Agitation Leaching 137. 15.7. Pressure Oxidation Leaching 138. 15.8. Future Developments 139. 15.9. Summary 140. Chapter 16. Solvent Extraction 141. 16.1. The Solvent-Extraction Process 142. 16.2. Chemistry of Copper Solvent Extraction 143. 16.3. Composition of the Organic Phase 144. 16.4. Minimizing Impurity Transfer and Maximizing Electrolyte Purity 145. 16.5. Equipment 146. 16.6. Circuit Configurations 147. 16.7. Quantitative Design of a Series Circuit 148. 16.8. Quantitative Comparison of Series and Series-Parallel Circuits 149. 16.9. Operational Considerations 150. 16.10. Industrial Solvent-Extraction Plants 151. 16.11. Summary 152. Chapter 17. Electrowinning 153. 17.1. The Electrowinning Process 154. 17.2. Chemistry of Copper Electrowinning 155. 17.3. Electrical Requirements 156. 17.4. Equipment and Operational Practice 157. 17.5. Maximizing Copper Purity 158. 17.6. Maximizing Energy Efficiency 159. 17.7. Modern Industrial Electrowinning Plants 160. 17.8. Electrowinning from Agitated Leach Solutions 161. 17.9. Current and Future Developments 162. 17.10. Summary 163. Chapter 18. Collection and Processing of Recycled Copper 164. 18.1. The Materials Cycle 165. 18.2. Secondary Copper Grades and Definitions 166. 18.3. Scrap Processing and Beneficiation 167. 18.4. Summary 168. Chapter 19. Chemical Metallurgy of Copper Recycling 169. 19.1. Characteristics of Secondary Copper 170. 19.2. Scrap Processing in Primary Copper Smelters 171. 19.3. The Secondary Copper Smelter 172. 19.4. Summary 173. Chapter 20. Melting and Casting 174. 20.1. Product Grades and Quality 175. 20.2. Melting Technology 176. 20.3. Casting Machines 177. 20.4. Summary 178. Chapter 21. Byproduct and Waste Streams 179. 21.1. Molybdenite Recovery and Processing 180. 21.2. Flotation Reagents 181. 21.3. Operation 182. 21.4. Optimization 183. 21.5. Anode Slimes 184. 21.6. Dust Treatment 185. 21.7. Use or Disposal of Slag 186. 21.8. Summary 187. Chapter 22. Costs of Copper Production 188. 22.1. Overall Investment Costs: Mine through Refinery 189. 22.2. Overall Direct Operating Costs: Mine through Refinery 190. 22.3. Total Production Costs, Selling Prices, Profitability 191. 22.4. Concentrating Costs 192. 22.5. Smelting Costs 193. 22.6. Electrorefining Costs 194. 22.7. Production of Copper from Scrap 195. 22.8. Leach/Solvent Extraction/Electrowinning Costs 196. 22.9. Profitability 197. 22.10. Summary 198. Index
This multi-author new edition revises and updates the classic reference by William G. Davenport et al (winner of, among other awards, the 2003 AIME Mineral Industry Educator of the Year Award "for inspiring students in the pursuit of clarity"), providing fully updated coverage of the copper production process, encompassing topics as diverse as environmental technology for wind and solar energy transmission, treatment of waste by-products, and recycling of electronic scrap for potential alternative technology implementation. The authors examine industrially grounded treatments of process fundamentals and the beneficiation of raw materials, smelting and converting, hydrometallurgical processes, and refining technology for a mine-to-market perspective - from primary and secondary raw materials extraction to shipping of rod or billet to customers. The modern coverage of the work includes bath smelting processes such as Ausmelt and Isasmelt, which have become state-of-the-art in sulfide concentrate smelting and converting.
1. 1.1. Introduction 2. 1.2. Extracting Copper from Copper–Iron–Sulfide Ores 3. 1.3. Hydrometallurgical Extraction of Copper 4. 1.4. Melting and Casting Cathode Copper 5. 1.5. Recycle of Copper and Copper-alloy Scrap (Chapters 18 and 19Chapter 18Chapter 19) 6. 1.6. Summary 7. Chapter 2. Production and Use 8. 2.1. Copper Minerals and Cut-off Grades 9. 2.2. Location of Extraction Plants 10. 2.3. Price of Copper 11. 2.4. Summary 12. Chapter 3. Production of High Copper Concentrates – Introduction and Comminution 13. 3.1. Concentration Flowsheet 14. 3.2. The Comminution Process 15. 3.3. Blasting 16. 3.4. Crushing 17. 3.5. Grinding 18. 3.6. Recent Developments in Comminution 19. 3.7. Summary 20. Chapter 4. Production of Cu Concentrate from Finely Ground Cu Ore 21. 4.1. Froth Flotation 22. 4.2. Flotation Chemicals (Nagaraj & Ravishankar, 2007; Woodcock, Sparrow, Bruckard, Johnson, & Dunne, 2007) 23. 4.3. Specific Flotation Procedures for Cu Ores 24. 4.4. Flotation Cells 25. 4.5. Sensors, Operation, and Control 26. 4.6. The Flotation Products 27. 4.7. Other Flotation Separations 28. 4.8. Summary 29. Chapter 5. Matte Smelting Fundamentals 30. 5.1. Why Smelting? 31. 5.2. Matte and Slag 32. 5.3. Reactions During Matte Smelting 33. 5.4. The Smelting Process: General Considerations 34. 5.5. Smelting Products: Matte, Slag and Offgas 35. 5.6. Summary 36. Chapter 6. Flash Smelting 37. 6.1. Outotec Flash Furnace 38. 6.2. Peripheral Equipment 39. 6.3. Flash Furnace Operation 40. 6.4. Control (Fig. 6.3) 41. 6.5. Impurity Behavior 42. 6.6. Outotec Flash Smelting Recent Developments and Future Trends 43. 6.7. Inco Flash Smelting 44. 6.8. Inco Flash Furnace Summary 45. 6.9. Inco vs. Outotec Flash Smelting 46. 6.10. Summary 47. Chapter 7. Submerged Tuyere Smelting 48. 7.1. Noranda Process (Prevost, Letourneau, Perez, Lind, & Lavoie, 2007; Zapata, 2007) 49. 7.2. Reaction Mechanisms 50. 7.3. Operation and Control 51. 7.4. Production Rate Enhancement 52. 7.5. Teniente Smelting 53. 7.6. Process Description 54. 7.7. Operation (Moyano et al., 2010) 55. 7.8. Control (Morrow & Gajaredo, 2009; Moyano et al., 2010) 56. 7.9. Impurity Distribution 57. 7.10. Discussion 58. 7.11. Vanyukov Submerged-Tuyere Smelting 59. 7.12. Summary 60. Chapter 8. Converting of Copper Matte 61. 8.1. Chemistry 62. 8.2. Industrial Peirce–Smith Converting Operations 63. 8.3. Oxygen Enrichment of Peirce–Smith Converter Blast 64. 8.4. Maximizing Converter Productivity 65. 8.5. Recent Improvements in Peirce–Smith Converting 66. 8.6. Alternatives to Peirce–Smith Converting 67. 8.7. Summary 68. Chapter 9. Bath Matte Smelting 69. 9.1. Basic Operations 70. 9.2. Feed Materials 71. 9.3. The TSL Furnace and Lances 72. 9.4. Smelting Mechanisms 73. 9.5. Startup and Shutdown 74. 9.6. Current Installations 75. 9.7. Copper Converting Using TSL Technology 76. 9.8. The Mitsubishi Process 77. 9.9. The Mitsubishi Process in the 2000s 78. 9.10. Summary 79. Chapter 10. Direct-To-Copper Flash Smelting 80. 10.1. Advantages and Disadvantages 81. 10.2. The Ideal Direct-to-Copper Process 82. 10.3. Industrial Single Furnace Direct-to-Copper Smelting 83. 10.4. Chemistry 84. 10.5. Effect of Slag Composition on % Cu-in-Slag 85. 10.6. Industrial Details 86. 10.7. Control 87. 10.8. Electric Furnace Cu-from-Slag Recovery 88. 10.9. Cu-in-Slag Limitation of Direct-to-Copper Smelting 89. 10.10. Direct-to-Copper Impurities 90. 10.11. Summary 91. Chapter 11. Copper Loss in Slag 92. 11.1. Copper in Slags 93. 11.2. Decreasing Copper in Slag I: Minimizing Slag Generation 94. 11.3. Decreasing Copper in Slag II: Minimizing Copper Concentration in Slag 95. 11.4. Decreasing Copper in Slag III: Pyrometallurgical Slag Settling/Reduction 96. 11.5. Decreasing Copper in Slag IV: Slag Minerals Processing 97. 11.6. Summary 98. Chapter 12. Capture and Fixation of Sulfur 99. 12.1. Offgases from Smelting and Converting Processes 100. 12.2. Sulfuric Acid Manufacture 101. 12.3. Smelter Offgas Treatment 102. 12.4. Gas Drying 103. 12.5. Acid Plant Chemical Reactions 104. 12.6. Industrial Sulfuric Acid Manufacture (Tables 12.4, 12.5, and 12.6) 105. 12.7. Alternative Sulfuric Acid Manufacturing Methods 106. 12.8. Recent and Future Developments in Sulfuric Acid Manufacture 107. 12.9. Alternative Sulfur Products 108. 12.10. Future Improvements in Sulfur Capture 109. 12.11. Summary 110. Chapter 13. Fire Refining (S and O Removal) and Anode Casting 111. 13.1. Industrial Methods of Fire Refining 112. 13.2. Chemistry of Fire Refining 113. 13.3. Choice of Hydrocarbon for Deoxidation 114. 13.4. Casting Anodes 115. 13.5. Continuous Anode Casting 116. 13.6. New Anodes from Rejects and Anode Scrap 117. 13.7. Removal of Impurities During Fire Refining 118. 13.8. Summary 119. Chapter 14. Electrolytic Refining 120. 14.1. The Electrorefining Process 121. 14.2. Chemistry of Electrorefining and Behavior of Anode Impurities 122. 14.3. Equipment 123. 14.4. Typical Refining Cycle 124. 14.5. Electrolyte 125. 14.6. Maximizing Copper Cathode Purity 126. 14.7. Minimizing Energy Consumption 127. 14.8. Industrial Electrorefining 128. 14.9. Recent Developments and Emerging Trends in Copper Electrorefining 129. 14.10. Summary 130. Chapter 15. Hydrometallurgical Copper Extraction 131. 15.1. Copper Recovery by Hydrometallurgical Flowsheets 132. 15.2. Chemistry of the Leaching of Copper Minerals 133. 15.3. Leaching Methods 134. 15.4. Heap and Dump Leaching 135. 15.5. Vat Leaching 136. 15.6. Agitation Leaching 137. 15.7. Pressure Oxidation Leaching 138. 15.8. Future Developments 139. 15.9. Summary 140. Chapter 16. Solvent Extraction 141. 16.1. The Solvent-Extraction Process 142. 16.2. Chemistry of Copper Solvent Extraction 143. 16.3. Composition of the Organic Phase 144. 16.4. Minimizing Impurity Transfer and Maximizing Electrolyte Purity 145. 16.5. Equipment 146. 16.6. Circuit Configurations 147. 16.7. Quantitative Design of a Series Circuit 148. 16.8. Quantitative Comparison of Series and Series-Parallel Circuits 149. 16.9. Operational Considerations 150. 16.10. Industrial Solvent-Extraction Plants 151. 16.11. Summary 152. Chapter 17. Electrowinning 153. 17.1. The Electrowinning Process 154. 17.2. Chemistry of Copper Electrowinning 155. 17.3. Electrical Requirements 156. 17.4. Equipment and Operational Practice 157. 17.5. Maximizing Copper Purity 158. 17.6. Maximizing Energy Efficiency 159. 17.7. Modern Industrial Electrowinning Plants 160. 17.8. Electrowinning from Agitated Leach Solutions 161. 17.9. Current and Future Developments 162. 17.10. Summary 163. Chapter 18. Collection and Processing of Recycled Copper 164. 18.1. The Materials Cycle 165. 18.2. Secondary Copper Grades and Definitions 166. 18.3. Scrap Processing and Beneficiation 167. 18.4. Summary 168. Chapter 19. Chemical Metallurgy of Copper Recycling 169. 19.1. Characteristics of Secondary Copper 170. 19.2. Scrap Processing in Primary Copper Smelters 171. 19.3. The Secondary Copper Smelter 172. 19.4. Summary 173. Chapter 20. Melting and Casting 174. 20.1. Product Grades and Quality 175. 20.2. Melting Technology 176. 20.3. Casting Machines 177. 20.4. Summary 178. Chapter 21. Byproduct and Waste Streams 179. 21.1. Molybdenite Recovery and Processing 180. 21.2. Flotation Reagents 181. 21.3. Operation 182. 21.4. Optimization 183. 21.5. Anode Slimes 184. 21.6. Dust Treatment 185. 21.7. Use or Disposal of Slag 186. 21.8. Summary 187. Chapter 22. Costs of Copper Production 188. 22.1. Overall Investment Costs: Mine through Refinery 189. 22.2. Overall Direct Operating Costs: Mine through Refinery 190. 22.3. Total Production Costs, Selling Prices, Profitability 191. 22.4. Concentrating Costs 192. 22.5. Smelting Costs 193. 22.6. Electrorefining Costs 194. 22.7. Production of Copper from Scrap 195. 22.8. Leach/Solvent Extraction/Electrowinning Costs 196. 22.9. Profitability 197. 22.10. Summary 198. Index
