Copper Industry.ppt
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Copper is produced through a multi-stage process beginning with mining copper ore from the ground. The ore is crushed, ground, and concentrated to increase the copper content. It then undergoes further processing through smelting, electrowinning or leaching, and electrolytic refining to produce pure copper cathodes. The production process allows copper to be extracted from ore and purified in a series of physical and chemical steps.
Copper Industry.ppt
- 2. Facts about Copper Copper has been used for over 10,000 years. The discovery of copper dates from prehistoric times. There are reports of copper beads dating back to 9000 BC found in Iraq. Part of the reason for it being used so early is simply that it is relatively easy to shape. However it is somewhat too soft for many tools and around 5000 years ago it was discovered that when copper is mixed with other metals the resulting alloys are harder than copper itself. Brass is a mixture of copper and zinc Bronze is a mixture of copper and tin. Prior to 3,000 BC, the supply of copper was almost never adequate for all the needs people had for it. Because of this, its value increased; and by 3,000 BC civilizations in the Middle East and Asia were actually exploring far beyond their known borders, seeking new sources of copper Copper's use in the period from 2500 BC to 18th century, remained less important since other metals like iron, gold and silver became more prominent.
- 3. Facts about Copper With the beginning of the Industrial Age in the late 18th century, and use of electricity, the new Copper Age began. Up to the 19th century, copper demand all around the world was relatively limited, and mines in Spain, North America and Europe were small and sufficient to handle the demand for copper. However, with new applications of copper in electric wiring, in light bulbs, and in electrical generation; and its use in building homes and other structures, the search for copper reserves and mine sites increased tremendously Arizona became one of the best new sources for copper in the world, and miners flocked to the state to look for the mineral in places. The technology and equipment used to search for copper and determine the concentration of copper in the rock began to improve. Copper has made possible the continued, efficient development of the electrical industry because it has the highest conductivity of the commercial metals. From high voltage transmission cables to microcircuits, and from megawatt generators to computers, copper is the metal of choice in many aspects of electricity generation, transmission, and use.
- 4. Every year there is a need for 10 billion pounds of copper worldwide A child born today will use approximately 1,750 pounds of copper in his or her lifetime in housing, transportation, electrical use and consumer products. Building construction is the largest end-use market for copper products of total U.S. consumption. Consumer and general products 10% Transportation equipment 9 % Building construction 45% Industrial machinery and equipment 10% Electrical and electronic products 26% Facts about Copper The cost to develop copper mines is very expensive and requires up to 9 years before mines yield a profit. Mine production is essentially concentrated on Chile, USA, NIS, Canada, Zambia, Zaire ( 70 % of total) and the production of refined copper is shared among 7 countries: USA, NIS, Chile, Japan, Canada, China, Germany, Zambia.
- 5. Copper has many very important characteristics that have led to its use as a vital component in many industries throughout the world. Copper is second only to silver in its ability to conduct electricity (and is far cheaper and more abundant). Copper is biostatic which means bacteria will not grow on it. Copper is essential to human beings as a micronutrient in our diets. It is used by the body to form bone cartilage, tendons and the sheathing around nerves. It is also a critical element in the manufacture of hemoglobin in the blood of higher animals. Copper's melting point is 1083 Centigrade and boiling point is 2570 Copper is perpetually recyclable, meaning that it can be used over and over again without losing its original form or composition. Copper does not corrode, rust, or damage easily. Facts about Copper
- 6. The copper mineral found naturally in the crust of the Earth that can be mined and eventually refined is called copper ore. Copper ore occurs in two basic forms in nature: Sulfide ore: Natural mixture of rocks containing copper, iron and sulfur. This mixture requires a grinding process to separate the copper from the rest of the materials 2CuS + 3O2 --> 2SO2 + 2CuO Oxide ore: Ores that contains copper and other minerals in oxide form and require a somewhat simpler and newer refining process Cu2O (cuprite) 2Cu2O + C --> CO2(g) + 4Cu CuO (tenorite) 2CuO + C --> CO2(g) + 2Cu Facts about Copper
- 7. Copper Production Process Basic Description: • Copper is produced from various primary and secondary raw materials. • The primary process uses sulphidic concentrates or sulphidic/oxide mixed ores. • The Secondary processes employ recycled oxidised or metallic products. (25 % of total consumption) • The industry can be divided into two sections, secondary copper production and primary copper production with the additional use of secondary material.
- 8. Concentrating Grinding Mining, Crushing Copper Production Process From its original home buried underground in a mine to its use in a finished product copper passes through a number of stages: Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into.. The Primary Copper Production
- 9. Concentrating Grinding Mining, Crushing Copper Production Process The beginning for all copper is to mine sulfide and oxide ores through digging or blasting and then crushing it to walnut-sized pieces Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into..
- 10. Copper mining 1) Exploration: Providing information about the shape and site of an ore deposit, geological characteristics, average grade, and feasibility studies. 2) Mine Development: Drilling. 3) Production: Removing ore from mine. Typical Cost to Develop, Operate and Reclaim a Mine Exploration Reclamation: Making the productivity of the land equal that of the premine surface, leave the mined area in a condition that will not contribute to environmental degradation
- 11. Copper mining methods Surface Mining: used when ore deposits lie relatively near the Earth’s surface. Quarrying overlying rock and soil are removed to expose the ore body, which is then, blasted and loaded into trucks or railroad cars for haulage from the pit. Underground Mining extraction of ore through vertical shafts from the surface, or horizontal tunnels, drifts or crosscuts driven into the ore body
- 12. Copper mining methods Underground Mining When ore deposits are far below the earth’s surface, an underground mine is constructed. It consists of a series of vertical (shafts) and horizontal tunnels (drifts) which allow miners and their machinery access to the ore deposit. Underground mines can be as deep as 4000m. The various stoping methods have evolved over the years. In selecting the most appropriate stoping methods, the size and shape of the ore body, strength of ore and enclosing wall rock, water, value of ore, and other factors must be taken into account. Copper Mines of Tasmania Open Stoping leaving no pillar of ore in place to support the walls of the stope. Room and pillar mining Pillars are left in place in a regular pattern while the rooms are mined out. Shrinkage Stoping allowing broken ore to support the stope walls, but leaving a space above the broken ore just sufficient for the miners to stand on and drill overhead.
- 13. Grinding Copper Production Process Crushed ore becomes powder usually containing less than 1 percent in large, rotating, cylindrical machines. Sulfide ores are moved to a concentrating stage, while oxide ores are routed to leaching tanks. Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into..
- 14. Grinding Copper Production Process • Minerals are concentrated into a slurry that is about 15% copper. • The ground ore is then mixed with water, chemicals, and air. This mixture causes the copper- bearing minerals to stick to air bubbles in the cells. • When the bubbles float off the top, they're collected as a liquid called concentrate, which is now 28% copper. • Waste slag is removed. Water is recycled. • Tailings (left-over earth) containing copper oxide are routed to leaching tanks or are returned to the surrounding terrain. Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into..
- 15. Grinding Copper Production Process Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into.. Once copper has been concentrated it can be turned into pure copper cathode in two different ways: • Leaching & electrowinning or • smelting and electrolytic refining
- 16. Grinding Copper Production Process • Leaching: Oxide ore and tailings are leached by a weak acid solution, producing a weak copper sulfate solution. • Electrowinning: The copper-laden solution is treated and transferred to an electrolytic process tank. When electrically charged, pure copper ions migrate directly from the solution to starter cathodes made form pure copper foil. Precious metals can be extracted from the solution. Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into.. Cathode: a flat plate of 99.99+% pure copper
- 17. Grinding Copper Production Process Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into.. Extraction of copper from sulphide ores Sulphide copper ores are normally treated in two stages: the matte making stage: matte and slag are produced by smelting the converting stage: iron and sulphur in matte are progressively oxidised for the production of blister copper.
- 18. Grinding Copper Production Process Smelting: • Several stages of melting and purifying the copper content result, successively, in matte, blister and, finally, 99% pure copper. • The concentrates are blended with a binding agent, sulphite liquor, and the resulting material is fed into furnaces where it is smelted, producing copper "matte" and waste "slag". • Matte contains approximately 60 % copper. The slag can be further treated and used in road construction. • The matte is transferred to siphon converters where sulphur is oxidised, impurities are vaporised and iron is removed. • The blister copper produced from the converters contains approximately 98.5 %copper. • Blister copper is further refined in an anode furnace before being cast containing 99 %. copper which are then transferred to the electrolytic tank house for further refining. Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into..
- 19. Grinding Copper Production Process Electrolytic Refining • In the electrolytic tank house, anodes are suspended in tanks containing electrolyte, which is a solution of sulphuric acid, copper sulphate and additional agents. • Thin copper plates ("cathode starting sheets") are placed between the anodes and a low voltage electrical current is passed between them, dissolving copper from the anodes and depositing it evenly on the cathode starting sheets. • The copper cathodes resulting from the build up of copper the cathode starting sheets contain at least 99.99 % copper. Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into..
- 20. Mitsubishi Process Three- furnace system comprising continuous smelting, slag cleaning, converting. An anode casting stage is then used to produce copper anodes. Copper Production Process
- 21. Mitsubishi Process Copper Production Process Converting (C) Furnace. Slag Cleaning (CL) Furnace Smelting (S) Furnace • The mixture of matte and slag formed in the S-Furnace flows continuously to the CL- Furnace, where the denser copper matte separates from the discard slag. • The matte is then siphoned to the C-Furnace, to be continuously converted to blister copper. • The latter is water granulated, dried, and recycled to the S-Furnace, while blister copper is siphoned continuously from the C-Furnace to the Anode Furnace.
- 22. Mitsubishi Process Smelting Furnace Copper Production Process • a continuous-operation furnace that produces a high-grade copper sulphide matte as well as a fayalite (silaceous) slag. The smelting reactions are: 2 CuFeS2 + 4 O2 Cu2S (matte) + 2 FeO + 3 SO2 FeS (matte) + 3/2 O2 FeO + SO2 FeS2 + 9/2 O2 FeO + 2 SO2
- 23. Mitsubishi Process Slag Cleaning Furnace Copper Production Process The intimate mixture of slag and matte produced by the S-Furnace flows to the slag cleaning furnace (CL-furnace), where that separate from each other by density difference into two distinct layers. The matte syphons continuously from the electric furnace and flows via a sloping launder into the converting (C) furnace. The discard slag continuously overflows and is water-granulated delivery to slag storage.
- 24. Mitsubishi Process Converting Furnace & Anode Furnace Matte is continuously converted to blister copper. Inputs to this furnace includes oxygen enriched blowing air (30-35%) The blister copper (99% Cu and 0.5% S) is steadily syphoned from the C-Furnace then delivered to the anode furnace for further processing. The C-slag contains 12-18% copper, mostly as Cu2O, overflows the furnace and is water-granulated then recycled to the S-Furnace Copper Production Process •The converter reactions are: Cu2S (matte) + O2 2 Cu (blister) + SO2 3 FeS (matte) + 5 O2 Fe3O4 (slag) + 3 SO2 CaCO3 (flux) CaO (slag) + CO2 In addition, some Cu2S is oxidized to Cu2O: Cu2S (matte) + 2 O2 2 Cu2O (slag) + SO2 2 Cu2O + Cu2S 6 Cu + 5 O2
- 25. Copper Production Process Electrolytic Refining • Electrorefining is an age-old process (1847). • Electrorefining utilizes the electrochemical dissolution of an impure copper anode in an electrolytic cell containing a copper sulfate-sulfuric acid solution. • Copper ions are transported to the cathode where they are deposited with suitable purity. • The basic electrochemical reactions involved are:
- 26. Grinding Copper Production Process Cathodes of 99.9% purity may be shipped as melting stock to mills or foundries. Cathodes may also be cast into wire rod, billets, cakes or ingots, generally, as pure copper or alloyed with other metals. Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into..
- 27. Grinding Copper Production Process • Wire Rod to make pure copper wire of all gages. • Billet drawn as tube, rod and bar stock of many varied sizes and shapes. • Cake to produce plate, sheet, strip and foil. • Ingot: Bricks of pure copper may be used by mills for alloying with other metals or used by foundries for casting. Concentrating Mining, Crushing Leaching Smelting Electrowinning Electrolytic Refining Pure Copper Cathodes Cathode is converted into..
- 28. Copper Production Process • Depending on the metal content and the type of feed, the smelting step to produce copper metal from secondary materials may comprise several stages, like reduction, oxidation/slagging and volatilisation, for upgrading the metal content and separating other components from copper. • The subsequent fire and electrolytic refining is analogue to the primary copper production. • Depending on the purity and composition of the copper containing materials, they are added at different stages of the process. The Secondary Copper Production
- 29. Copper Production Process • Copper cathodes and recycling copper are melted in a shaft furnace. • The molten copper is fed continuously via a launder to the grooved periphery of the casting wheel. • After being shaved, the cast bar is fed to a rolling mill. The rolled rod is treated in a pickler with isopropanol, dilute sulphuric acid, water or steam rinsing to remove the oxidised surface and then coated with wax Fabrication of Wire rod
- 30. Copper Production Process • Another process to produce wire rod is the CONTIROD process. There, the copper is melted in a furnace and caste in a Hazellet-Caster. The caster is followed by a hot-rolling mill to produce wire rod which is sent to a coiler after being treated in a pickler. Fabrication of Wire rod
- 31. Effect on Environment • Fugitive emissions: arise from gases or particulate matter emitted to the surrounding air without being captured, purified or treated in any other way and caused by open handling and storing of materials. Fugitive emissions should be avoided by hoods, closed transport systems and good housekeeping. • Stack emissions: arise when captured offgases are emitted after purification (clean gas) can usually be captured and cleaned by appropriate gas cleaning devices. • Particulate matter: a small discrete mass of solid or liquid matter that remains individually dispersed in gas or liquid emissions (usually considered to be an atmospheric pollutant)
- 32. Effect on Environment The potential sources of water pollution
- 33. Production is started in 1937 by Etibank Visible copper metal reserve in world = 550,000,000 tonne in Turkey = 1,658,715 tonne. This amount will be sufficient in 1015 years with current usage. Most important regions : Eastern Black-Sea, Southeast Anatolia and Thrace Export in 2001 = 33 million $ to Bulgaria, Japan, China, Finland Copper consumption is 1,8 kg per head in Turkey while 10 kg in developped countries. Copper Production in Turkey • KBİ Karadeniz Bakır İşletmeleri A.Ş. (Samsun, Artvin) • founded in 1968. • Unique blister copper producer in Turkey. • Privitisation is in progress • Mine Capacity = 2.500.000 tonne / year (0,80 % Cu) • Concentrated Cu Capacity= 75.000 tonne / year (23 & Cu) • Blister Copper capacity= 38.760 tonne / year (99.2 % Cu) • Çayeli Bakır İşletmesi (Rize) • founded in 1983. • 45 % of shares are blong to Eti Holding A.Ş. • Mine Capacity = 800.000 tonne / year • Concentrated Cu Capacity = 150.000 tonne / year 23 & Cu • Etibank Küre Bakırlı Pirit İşletmeleri (Kastamonu) • Mine Capacity = 700.000 tonne / year • Concentrated Cu Capacity = 42.000 tonne / year15 % Cu