Market Survey on Copper - Indian Bureau of Mines

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viscosity of slag during smelting affecting matte-slag separation leading to increased copper losses in slag. Roasting is generally performed employing multiple hearth of fluid bed roasters. Fluid bed roasters are preferred because of their high production rates, excellent temperature and chemical control and high SO2 concentration in effluent gases. iii) Matte Smelting : Smelting or matte smelting consists of melting concentrates or partially roasted concentrates at 1,150 - 1,200 o C to produce the separable liquid phases known as copper matte (Cu 30-60% sp, gravity > 5) and slag (sp. gravity < 3). The matte (Cu2S, FeS) form feed for production of blister copper. The slag are formed from the oxides in furnace charge (impurities in the concentrate: SiO2, Al2O3, CaO, MgO and oxides from fluxing material) and iron oxides produced by oxidation during smelting. Smelting slag generally contains 30-40% iron oxides (FeO, Fe2O3), 35-40% SiO2, 0-10% Al2O3 and 0-10% CaO. The reaction between cuprous oxide (Cu2O) and iron sulphide to produce copper sulphide (Cu2S) proceeds rapidly and fully as sulphur has greater affinity for copper than iron. This is the main smelting reaction and this is the reason why copper is concentrated in matte and iron is partially slagged off. Smelting operations are carried out in blast, reverberatory, electric and flash furnaces. As blast furnace requires lumpy feed, fine flotation concentrates are smelted in the other three furnaces only. iv) Reverberatory Smelting : The reverberatory furnace is the most widely used unit for matte smelting. It is a fuel fired hearth furnace in which concentrates or roaster calcines are melted in presence of flux to produce separate layers of molten matte and slag. The heat for smelting is provided by burning fuel in the furnace and by passing hot combustion gases over the charge. All types of material (lumpy or fine, wet or dry) can be readily smelted. However, everything is not well with the reverberatory furnace. It requires large quantity of hydrocarbon fuel because it makes little use of the energy which is potentially available from sulphide oxidation. Thermal efficiency is in the range of 25 - 30% only. The reverberatory furnace gas presents serious pollution problem because SO2 concentration is too low (0.5 to 1.5% SO2) to form a feed for sulphuric acid manufacture, the minimum SO2 concentration required is 5%. The principal products from reverberatory furnace are liquid matte (30-50% Cu; 1150 o C), which collects gold and silver, is sent forward for converting and a liquid slag (0.3 to 0.8% Cu: 1200 o C) which is discarded as effluent gas (1250 o C). v) Electric Furnace Smelting : In the regions where abundant electricity is available at low price and fossil fuels are costly, electric furnaces are frequently used in place of reverberatory furnace for copper smelting. The advantages of electric furnace smelting are: 38
a) low capital and operating cost b) high SO2 concentration (8 to 15%) in the effluent gas and c) high thermal efficiency and less air pollution. About 375 to 425 kW/h electrical energy is required to smelt a tonne of calcined concentrates. Efficient operation of the furnace depends upon slag composition (35.5 - 38.5% SiO2) as heat generated for smelting is proportional to slag. vi) Flash Furnace Smelting : It is well-known that oxidation of sulphide is an exothermic reaction. Chalcopyrite oxidation can be represented by the following equation. 2CuFeS2 + 2.5O2 +SiO2 (flux) � Cu2S. FeS + FeO.SiO2) + 2SO2 + heat (matte) (slag) It is this reaction which provides much or all of the heat required for smelting (heating and melting) forms the basis for flash smelting. Additional hydrocarbon fuel is needed when air is the combustant. SO2 concentration in the effluent gas is high (>10% SO2) and this can be profitably utilised for manufacture of H2SO4 and elemental sulphur. The major disadvantages of flash furnace smelting is higher copper losses in slag and fine dust necessitating additional treatment by flotation or electric furnace smelting. vii) Converting: Molten matte from smelting contains copper, iron, sulphur as its predominant constituents with up to 3% dissolved oxygen. In addition, it contains minor impurities (As, Sb, Bi, Ni, Pb, Zn, etc.) and precious metals. Converting is removal of iron and sulphur and other impurities from the matte by air oxidation which results in production of liquid metallic copper in crude (98.5-99.5% Cu) blister copper form. Cu2S + 1.5O2 � Cu2O+SO2 Cu2S+ 2Cu2O � 6Cu + SO2 Cu2S+O2 � Cu + SO2 viii) Slag Making FeS + O2 � Fe+ SO2 3FeO + 0.5O2 � Fe2O4 2FeO + 2SiO2 � 2FeO.SiO2 i.e. Any Cu2O formed is re-sulphidised to Cu2S as per the following action, Cu2O + FeS � FeO + Cu2S 39
Page 2 and 3: GOVERNM G MENT OF IN NDIA MINISTRRY
Page 4 and 5: PREFACE The present report on <stro
Page 6 and 7: List of Annexures Annexure:3- I Lis
Page 8 and 9: List of Figures Page No. Figure 2.1
Page 10 and 11: Chapter 1. Introduction The <strong
Page 12 and 13: Figure : 2.1 - Propperties of Coopp
Page 15 and 16: Building & Construction n 5% Transp
Page 17 and 18: The end-use of copper is determined
Page 19 and 20: a) Heat Exchangers and Condensers C
Page 21 and 22: There are good reasons why the cons
Page 23 and 24: Class & type ASTM Design -ations Ta
Page 25 and 26: 2.3 SPECIFICATIONS The specificatio
Page 27 and 28: Chapter 3. Supply Copper is an impo
Page 29 and 30: State/District Jharkhand Reserve Re
Page 31 and 32: State/District Reserve Remaining Re
Page 33 and 34: Sl. No. Table: 3.3- Statewise Resou
Page 35 and 36: State District Deposit Name Dhadkid
Page 37 and 38: State District Deposit Name Chandma
Page 39 and 40: mineralisation. Copper ore is found
Page 45 and 46: Beneficiation of copper ore depends
Page 47 and 48: B) Concentration (Froth Flotation)
Page 49 and 50: of frother molecule leads to its ad
Page 51: 3.2.2 Smelting Copper is extracted
Page 55 and 56: a large extent by volatisation of t
Page 57 and 58: indicated is a very slow process an
Page 59 and 60: eaction is identical to that in ele
Page 61 and 62: ii) Malanjkhand Copper Project The
Page 63 and 64: silver, selenium, tellurium, nickel
Page 65 and 66: ladle crane to the Pierce Smith Con
Page 67 and 68: Complex), Jharkhand (Indian Copper
Page 69 and 70: Presently, the concentrator situate
Page 71 and 72: Out of these 5 plants, no plant is
Page 75 and 76: In addition to this there are some
Page 77 and 78: International Copper Association Lt
Page 79 and 80: Chapter 4. Foreign Market</
Page 81 and 82: Thousands Tonnes Russia 5% Poland 4
Page 83 and 84: Thousands Tonnes Thousands Tonnes F
Page 85 and 86: Table: 4.1- Top 10 Copper Mines by
Page 87 and 88: India’s trade with Australia is m
Page 89 and 90: The exports of refined copper were
Page 91 and 92: East Iran and Lar in Zahedan locali
Page 93 and 94: eserves of the order of 4.23 millio
Page 95 and 96: smelter production of copper is ste
Page 97 and 98: copper which was only 105 thousand
Page 99 and 100: As it will be seen from the Table-4
Page 101 and 102: Table -4.8: Estimated Region wise W
Page 103:
Chapter 5. Prices Copper metal is t
Page 106 and 107:
Table: 5.3 - London Metal Exchange
Page 108 and 109:
10000 Figure : 5.2 - Month Wise LME
Page 110 and 111:
y the State Government in the Minin
Page 112 and 113:
The consumption given in above tabl
Page 114 and 115:
Table-6.3: Internal Apparent Demand
Page 116 and 117:
electrification will result in an i
Page 118 and 119:
consumption in General Engineering
Page 120 and 121:
The HCL has planned a number of gre
Page 122 and 123:
In earlier chapter it has already b
Page 124 and 125:
ased on imported concentrates. Indi
Page 126 and 127:
Annexure: 3 - I LIST OF THE UNITS R
Page 128 and 129:
Sl. No. NAME OF THE UNIT CAPACITY (
Page 130 and 131:
Annexure: 3 - II LIST OF THE UNITS
Page 132 and 133:
Sl. NAME OF THE UNIT CAPACITY WASTE
Page 134 and 135:
Page 136 and 137:
Page 138 and 139:
Sl. NAME OF THE UNIT CAPACITY No. (
Page 140 and 141:
Page 142 and 143:
Page 144 and 145:
Sl. No. XII TAMIL NADU NAME OF THE
Page 146 and 147:
Concld… Sl. NAME OF THE UNIT CAPA
Page 148 and 149:
Concld…. COBRA No.2 Copper Wire N
Page 150 and 151:
Annexure: 3 - IV (B) Exports of Cop
Page 152 and 153:
Annexure: 4 - II World Mine Product
Page 154 and 155:
Sl. No. Annexure: 4 - IV World Prod
Page 156 and 157:
140
Page 158 and 159:
Sl. No. Annexure: 4 - VI World Impo
Page 160 and 161:
Sl. No. Annexure: 4 - VIII India’
Page 162 and 163:
Annexure: 4 - X India’s Exports o
Page 164 and 165:
Sl. No. Annexure: 4 - XIII India’
Page 166 and 167:
Annexure: 4 - XV Worldwide List of
Page 168 and 169:
Company Name Operations Countries F
Page 170 and 171:
Company Name Operations Countries N
Page 172 and 173:
Worldwide List of Countries Produci
Page 174 and 175:
Country Operations Companies Laos K
Page 176 and 177:
Annexure: 4 - XVII Worldwide List o
Page 178 and 179:
Mine Name Country Owners Guelb Mogh
Page 180 and 181:
Mine Name Country Owners Nkana Zamb
Page 182 and 183:
Worldwide List of Copper Smelter &
Page 184 and 185:
Sl.No. Country Company Location 3.
Page 186 and 187:
Concld…. Sl.No. Country Company L
Page 188 and 189:
Production and expansions 1993 and
Page 190 and 191:
2020. In the meantime the mill will
Page 192 and 193:
The Dalam Diatreme (DD) forms the f
Page 194 and 195:
Open-pit mining The Ujina and Huinq
Page 196 and 197:
All ore is now treated in the lower
Page 198 and 199:
unoff and seepage, and from the low
Page 200 and 201:
Concentration and separation involv
Page 202 and 203:
single pit: today the working area
Page 204 and 205:
One of the first of the recent seri
Page 206 and 207:
Annexure: 5 - I Average Monthly Pri
Page 208 and 209:
192
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