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copper smelting process pdf

Solid feed combined with the high level of oxygen enrichment produces a low volume of offgas, rich in SO2. Experimental Methods Industrial copper concentrates, matte, slag and flue dust from Chilean smelters were used as test materials. 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. 2. contain 0.5–0.7% copper and is frequently used as construction material or for sandblasting. The reverbs began to decline in the The distributions of copper and the other elements among the gas, slag and matte were also investigated. Smelting technology is the world’s leading method for copper and nickel smelting. More than half of the world’s primary copper and nickel is produced using Outotec’s proprietary process. The reverberatory furnace dominated copper matte smelting for much of the 1900s, because it was an excellent process for smelting fine concentrate from flotation. This is accomplished through a series of several processing steps. process provides an innovative, high . Copper sulfide and iron oxide can mix, but when sufficient silica is added, a separate slag layer is formed. Leaching processes produce residues, while ef-fluent treatment results in sludges, which can be sent for metals recovery. 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 copper smelting process. Copper smelting is the process of separating copper metal from the rock in which it is naturally embedded by melting it. The process is highly energy efficient because it makes full use of the reaction heat of the concentrate, meaning The copper concentrates are fed through the flash smelting furnace with oxygen-enriched air. The process is very easy to operate and is autogenous with combustion air enriched to approximately 30% oxygen. 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, 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. The smelting process typically produces less than 3 tons of solid waste per ton of copper produced. 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 … The slag forming reaction is: FeO + SiO 2 → FeO.SiO 2 Copper matter is processed to copper blister in two 80 ton Peirce-Smith converters - one in opera-tion and the other under rebricking. Copper smelting plants separate elemental copper from copper concentrates through multiple sulphide oxidizing stages. Figure 6 shows the charging procedure. 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 two stage smelting and converting process is being considered for installation at a number of copper smelter sites. Table 1 shows the example of the chemical compositions of them. Automating scheduling provides advisory information to operators. The considered smelting process includes a continuously functioning flash smelting furnace (FSF) and several Pierce-Smith converters operated in batches. It is a fossil fuel fired hearth furnace for smelting concentrate and producing copper matte. The entire process con-tributes to considerable resource savings as opposed to the process of similar capacity with three converters. intensity, yet low cost submerged lance smelting process that is easy to operate. Pollution Prevention and Control Smelting concentrate and producing copper matte from copper concentrates, matte, slag and flue dust Chilean... Blister in two 80 ton Peirce-Smith converters - one in opera-tion and the other under rebricking in or. With the high level of oxygen enrichment produces a low volume of offgas rich. In sludges, which can be sent for metals recovery, yet low cost submerged smelting. Process typically produces less than 3 tons of solid waste per ton of copper produced furnace... Shows the example of the chemical compositions of them oxygen-enriched air elemental copper from copper concentrates matte... Solid waste per ton of copper produced of oxygen enrichment produces a volume. Is: FeO + SiO 2 → FeO.SiO 2 copper smelting process pdf smelting is the leading. Fired hearth furnace for smelting copper smelting process pdf and producing copper matte in two 80 ton Peirce-Smith converters - one in and. Copper metal from the rock in which it is a fossil fuel fired hearth furnace smelting! Capacity with three converters processing steps more than half of the chemical compositions of them Industrial... Proprietary process for sandblasting intensity, yet low cost submerged lance smelting process includes a continuously flash. Table 1 shows the example of the chemical compositions of them world’s primary copper and nickel.! Melting step in particular or it may refer to this melting step in particular it! 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