The recovery of heat and energy is therefore important. Hoar and R.G. A low grade order produces a low yield of metal. Molten copper is poured from here into rectangular moulds, the resulting ingots subjected to electrolysis producing a metal of 99.9% purity. The earliest evidence of copper smelting occurs in Serbian artefacts dating from around 5000 BC. 39. The pyrometallurgical zinc smelting process produces zinc by taking advantages of the differences in the boiling points of zinc and other components. The idea for direct sulfide electrolysis dates to as early as 1906. Demand for copper is going to rise, which makes its future supply a key issue for society. The required heat comes A high grade ore produces a high yield of metal. Smelting Response to Energy Challenge 15 Specific Energy Reduction of 35-40% for 2014 compared to 1976 Ref. b. PEng PhD. Smelting 875-899. The information presented is largely based on environmental permit The flash furnace offgas contains anywhere from 10 to 80 percent by volume sulfur dioxide (SO 2). Primary production uses about 170 x 10/sup 12/ Btu total energy annually (about 100 x 10/sup 6/ Btu/ton pure copper produced from ore). Conventional smelting or converting produces a sulphide matte of about 0.2% PGMs, which is further treated in the base metals refinery to recover … Week's top; ... "If you look at the energy consumption of a copper smelter … Toivo 1. Only the pyrometallurgical flash smelting process is in use in Finland to recover nickel from sulphide concentrates and it is the main process described in this report. Mining and milling use about 60% of the total consumption, because low-grade ore (0.6% copper) is now being mined. Self-heat smelting can not only reduce the energy consumption of smelting process, but also reduce the flue gas volume, thus reducing possible environmental pollution. The demand for copper wire is anticipated to grow worldwide as electricity consumption increases. [15], as well as Calvo et al. In 2010, the foreseen increase of copper grade in feed concentrate at the Horne Smelter was a significant challenge to maintain a steady copper flow throughout the process. Topics. Create free account to access unlimited books, fast download and ads free! Download full Advances In Sulfide Smelting Technology And Practice Book or read online anytime anywhere, Available in PDF, ePub and Kindle. The temperature in the furnace reaches between 1200 and 1300 C. The Noranda process takes advantage of the heat energy available from the copper ore. In figurative terms, one tonne of copper is in about 60,000 mobile phones, 400 computers, 40 cars and electricity distribution to 30 homes. Copper is used in hundreds of metal alloys, including bronze (with tin) and brass (with zinc). “They are dependent on electricity already to exist. Higher energy consumption and lower product purity are the two major drawbacks (European Environment Agency, 2019). sulphide charge to provide much or all of the energy required for smelting. They both confirm In smelting ores and concentrates of copper or nickel, matte fall is obtained by recycle of ferrous sulfate which is produced when the matte is leached with sulfuric acid. Some impurities are removed forming a matte (a mixture of liquid copper and iron sulphide). It is highly energy-intensive, ranking third in specific energy consumption (SEC) among the five major basic metals (aluminum, copper, iron, lead and zinc) . types have self-generating energy by the exothermic oxidation of hydrogen sulfide, shown in the reaction below. Most copper is extracted by smelting sulfide ores, with concomitant production of sulfur dioxide. Primary copper production is a major activity in the mining sector. Antoine Allanore, the Thomas B. The design includes state-of-the-art energy recovery and efficiency. It does not include the mining and concentration of the raw materials, which is covered in the EHS Guidelines for Mining. 3 Energy. This study focuses on key issues related to plants processing copper sulphide ores and concentrates of different complexity. Application of rich-oxygen air blast offers high smelting temperature, enhances hearth capacity and generates high concentration SO 2 gas suitable for sulfuric acid-making; 3. At the end of this smelting process the copper is about 99% pure.. Oxide Ore. Each year, the smelter and refinery plants use approximately 2.8 billion cubic feet of natural gas, 200 gigawatt-hours … Smelting and Extraction. King Assistant Professor of Metallurgy at […] A typical copper ore contains between 0.5% and 2.0% copper. 1. Flash smelting of copper requires 40% oxygen and 473K of hot air smelting; the output of 65% copper matte can be implemented by thermal smelting. Figure 1: National energy consumption in copper mining, Terajoule, 2001 – 2014 Source: Developed by Cochilco In the case of fuels, pit mining is the mining process with the highest usage, reaching 59,974 TJ, Copper Smelter processes generate significant off-gas flows at high temperatures. This is an opportunity to reduce the carbon footprint of this metal by substituting conventional energy sources. The dried copper concentrates are sent to the smelting operation where it is reduced and melted in several operations. The remaining thermal energy is supplied by oil burners, or by coal mixed with the ore concentrates. The EHS Guidelines for Smelting & Refining cover information relevant to base metal smelting and refining of lead, zinc, copper, nickel, and aluminum. Copper smelting experiments are now an established part of the Almyras Project. 1970s technology 18,018 MJ/t Anode copper Today technology 11,720 +/- 1,000MJ/t Anode copper Abstract . Waste gas volumes are significantly reduced allowing smaller fans etc to be used. Prolonging smelting time was in favor of metal recovery but would cause higher energy consumption. Replacing the lost copper with new metal produced by the traditional method of cooking copper sulfide ores requires a multistep process to extract the copper and produces troublesome byproducts. point of view of energy consumption, cover and grinding media, and also for metal re-covery (copper, Cu). For these reasons, copper must the reduction of emissions and energy use of the primary nickel production in Finland. About 80% of the worlds’ reserves for platinum group metals (PGMs) are in South Africa’s Bushveld Igneous Complex. Copper has always played an important role in human development. Currently, the supply chain from copper mining to copper wire production is . 4. Thus India is emerging as a net exporter of refined copper. In a presentation for the Copper International Conference in Santiago, Chile, in December 2013, Allanore noted the proof of concept for producing copper and sulfur by electrodecomposition of copper sulfide, achieved by T.P. An Overview of Energy Consumption and Waste Generation in the Recovery of Cobalt from Copper Sulphide Smelting and Converting Slag and the Proposed Solution. collected that examines total final energy consumption in copper, gold, nickel, lithium and iron ore. 40. Click Get Books and find your favorite books in the online library. Furnace lining material can also influence the energy balance of a melting operation. Approximately 59.7 percent of the energy is in the form of diesel or light fuel, 36.1 percent electricity, 2.4 percent gasoline, 1.0 percent natural gas, and 0.7 percent in some other form.3 Hauling operations account The primary objective of matte smelting is to produce a liquid matte containing almost all the copper present in the charge and a slag with least copper. Because average copper grades of copper sulphide ores in Chile have decreased from 1.18% to 0.90% over the period 2003e2012 (Cochilco, 2012), greater consumption of water, energy and chem-ical reagents is required to efficiently process low-grade copper sulphide ores. 1 : Copper Consumption Copper, and a total of 6.5 lakh tons copper is produced annually. The above flowsheet is designed for the treatment by flotation of copper as chalcopyrite with gold and silver values. In addition, since unlike iron, the non -ferrous metals, except aluminium, are obtained from relatively lean ores, tremendous amount of energy consumption is involved in the mineral dressing circuit. [16], use data from sustainability and other company reports to assess the relationship between energy consumption and ore grade. The ore, ranging from 60-65% silica, with pyrite, arsenopyrite, and calcite with 3 to 4% copper. Indian demand for refined copper is around 4.5 lakh tons which is 3% of the global copper market. With the dynamic smelting processes such are Flesh; INCO …, copper content in the silicate slag could reach up to 2%, which Similar to concentrators, water usage can vary between operations. 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. H.H. King Assistant Professor of Metallurgy at MIT, wants to simplify copper extraction and eliminate noxious byproducts through electrolysis. Energy requirements for crushing and grinding can vary considerably based on size of material fed to the crusher, desired grinding size for optimum recoveries, mineralogy, and Bond work index. Hydrometallurgy, or “hydromet” for short, is a metal processing technology that uses a chemical process combining water, oxygen or other substances in a pressurized or other vessel to dissolve a metal from its ore, concentrate or an intermediate product (such as matte). His work included a stint as Supervisor of the new 100 t/day pilot plant for the continuous smelting and converting of copper concentrate, later called the Noranda Process. Copper can be extracted from sulfide ores (usually higher grade ores) by direct smelting. With the stationary smelting processes, such is smelting in reverberatory furnace, this loss is about 0.5% Cu which is permanent because of disposal of such slag to the waste yard. Gold–copper ore processing BioSulphideÒ technology involving biogenic sulphide gen- eration and its techno-economically effective use in the This topic has been thoroughly reviewed, most recently treatment of copper cyanide solutions for copper recovery by Jay (2001) and Sceresini (2005); hence the focus here is and cyanide regeneration. The project proposes to use toll smelt (TS) and furnace/flash smelter (FFS) option for treating sulphide concentrate. However, the oft-discussed declining ore grade and, therefore, the assumed enormous increase in energy demand and global warming potential could lead to a supply constraint. Energy consumption in the copper production is mostly below 15 GJ/tCu, except in the smelters where the flame furnaces are used, where consumption is over 20 GJ/t Cu , Figure 1 [6]. This typically represents a major source of heat loss from the process; therefore, off-gas heat recovery is critical to minimizing energy consumption and reducing operating … Most copper is extracted by smelting sulfide ores, with concomitant production of sulfur dioxide. The estimate includes crushing of ore (16 kWh/t), conveyor belt, beneficiation, sintering (30 kWh/t), and loaders. The smelter furnace produces two separate molten streams: copper-iron-sulfide … its copper content can be recovered in a slag cleaning furnace, often electric. Henderson, "Energy Use in Sulfide Smelting of Copper," Extractive Metallurgy of Copper, Vol. used in transportation and energy. Niemela and Seppo U. Harkki, "The Latest Development in Nickel Flash Smelting at the Harjavalta Smelter, Outokumpu Oy, Finland" (Paper presented at the Joint Meeting MMIJ-AIME, Tokyo, May 1972). In all domestic copper smelting facilities utilizing flash smelting technology, the valuable thermal energy in this sulfide contained in copper ore. A report commissioned by the Chilean Copper … a. SMELTING AND HYDROMETALLURGY TREATMENT FOR COPPER SULPHIDE ORES AND CONCENTRATES (2019). Mining and milling use about 60% of the total consumption, because low-grade ore 0.6% copper is now being mined. After a marked improvement in energy consumption in copper smelting during the past few decades, technology development … 2012: Microstructural Development of … A Jha, Y Hara. COPPER USE IN FABRICATION IN JAPAN, KOREA, TAIWAN (CHINA) AND VIETNAM (2018). The Horne Smelter process includes a Noranda Reactor, a Noranda Converter, pyro refining vessels and anode furnaces. Copper, smelting, converting, slag cleaning, fire refining, energy, emissions. Sterlite Industries and Hindustan Fig. The physical chemistry of the matte‐slag systems is controlled by iron, copper, sulfur, oxygen and their sulfides and oxides. Open-pitmining 0.021 MJ/ton 19-25% Based on the mineral beneficiation and separation methods you learnt in this unit, explain in detail what unit operations and processing routes you think are suitable to produce high-grade concentrates of nickel and of copper separately for the given ore type. This is because actual work with authentic materials and techniques is as good a teacher of archaeometal-lurgy as any laboratory analysis. AIP Conference Proceedings, 2012. processed in cobalt refinery for cobalt and copper metal production. ROASTING OF SULFIDE MINERALS In addition to common metals like copper, lead, zinc, and nickel a number of other metals such as antimony, bismuth, cadmium, cobalt, mercury, and molybdenum occur as sulfide minerals. The traditional route for extracting copper from sulfide ores is smelting. Yet there is a growing case for leaching sulfides from lower grade ore bodies and especially for those ore bodies containing problematic elements like arsenic, which make smelting less economical.
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