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Copper Processing

This document discusses the process of copper mining and production. It begins with an overview of underground and open-cut mining methods. It then details the various processing steps including mineral separation via grinding and flotation, smelting to produce matte copper, and converting to produce blister copper. The final steps discussed are anode production through refining and casting. Throughout the document images are provided to illustrate the different stages from mining to final copper production.

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Diego Galicia
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281 views

Copper Processing

This document discusses the process of copper mining and production. It begins with an overview of underground and open-cut mining methods. It then details the various processing steps including mineral separation via grinding and flotation, smelting to produce matte copper, and converting to produce blister copper. The final steps discussed are anode production through refining and casting. Throughout the document images are provided to illustrate the different stages from mining to final copper production.

Uploaded by

Diego Galicia
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 26

Tel: (07) 3316 2531 Fax: (07)3295 9570

www.oresomeresources.com

Copper
Processing

Copper

Copper and its


Uses

Underground Mining

Mt Isa Mine Mt Isa Queensland image courtesy of Xstrata Copper

Open-cut Copper
Mining
Open-cut pit the rock is drilled and blasted then removed by a truck and
shovel operation. The ore is processed to separate the copper.

Ernest Henry Mine Cloncurry Queensland image courtesy of Xstrata Copper

Location of Copper
Mines

Image courtesy of Xstrata Copper

Underground Mining
Process

Underground mining of copper occurs adjacent to


the copper smelter in Mt Isa . In some cases remote
controlled vehicles such as boggers are used
underground.
Images courtesy of Xstrata Copper

Mineral Separation

A ROD and BALL MILL contains the ore and heavy


steel balls which break the rock up until it resembles
a fine powder.
Images courtesy of Xstrata Copper

Concentrating Flotation

Image source: Queensland Resources


Council

Froth Flotation
Process
Crushed ore is mixed with water, detergents and other
chemicals
Finely powdered mineral clings to air bubbles and floats to
the surface
Waste rock sinks to the bottom
Copper concentrate is transported to the thickeners to
remove excess water
Dried concentrate is transported to the stacker for
storage before use
Waste rock is returned to the site
Water is re-used (as much as possible).

Image source: Queensland Resources


Council

Stacker Reclaimer

Image courtesy of Xstrata Copper

Isasmelt

Image courtesy of Xstrata Copper

Smelting

The process of taking the copper


concentrate(CuFeS2) and reacting it with SiO2,
and O2 to produce slag (waste), copper matte
and sulphur dioxide (gas).
The SO2 is collected at several stages and is
used to make sulphuric acid which is further
processed into fertiliser.
The matte copper is further treated in a
copper converter.

Smelting
Off Gases
(CO2,SO2,H2O,N2)

Oxygen (O2)
Air (N2,O2)
Natural Gas (C,H)
Concentrates (CuFeS2)
Flux (SiO2)
Coal (C,H)
10CuFeS2 + 15O2 + 3SiO2
5Cu2S + 3FeS (matte)
+ 3Fe2SiO4 (slag)

Isasmelt
Lance

Isasmelt
Furnace

+ 12SO2 (gas)

Diagram courtesy of Xstrata Copper

Rotary Holding
Furnace

Silica Ratios
The correct amount of flux (SiO2) must be
added or an efficient reaction does not
occur.
Too little silica results in the formation of
magnetite (an iron oxide).
Magnetite has a much higher melting point
and can form a layer on top of the smelter
causing damage to the smelter. It can also
clog the vents from which the molten
material is removed. Some magnetite is
always made and it sticks to the walls of the
smelter. This helps to protect the bricks.
Too much silica makes the mixture too
sticky.

Converting
Flux (SiO2)

Off Gases (SO2)

Pierce
Smith
Converter
Matte (Cu2S FeS)
Air (N2,O2)
Oxygen (O2)

Slag Blow
2FeS + 3O2 + SiO2
Fe2SiO4 (slag)
+ 2SO2 (gas)

Slag

Blister
Copper

Copper Blow
Cu2S + O2 2Cu (blister)
+ SO2 (gas)
Diagram courtesy of Xstrata Copper

Converting
Blister (Cu, Trace S, Trace
O)
Off Gases (SO2, CO2, N2)

Castin
g
Anode
Furnace
Air (N2,O2)
Natural Gas
(C,H)

Anode Copper
Oxidising
S + O2 SO2
Reducing
1O2 + C + H CO2+ H2O

Slag Pouring

Image courtesy of Xstrata Copper

Anode Casting

Image courtesy of Xstrata Copper

Anodes prior to
quenching

Image courtesy of Xstrata Copper

Anode Transport

Image courtesy of Xstrata Copper

Copper Refining

Copper Refining

Copper Refining

Copper and its


Uses

Credits

Queensland Resources Council wishes to


acknowledge Xstrata Copper for the provision of
these images and teacher Alison Pound ,Wavell
State High School for her input into this
presentation.

Last Updated February 2010

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