Market Survey on Copper - Indian Bureau of Mines

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c) Evaporation of water from the copper free electrolyte and precipitation of nickel, iron and cobalt as sulphates from the concentrated solution. The nickel sulphate is purified and sold for electroplating and other uses. b) Hydrometallurgical Processes Copper is most often found in form of sulphide minerals which undergo pyrometallurgical operation to produce crude copper (blister copper) metal. But the same is not true with copper oxide minerals. Oxide minerals when present in sufficient quantity in the ore deposits can be smelted in blast furnace economically as has been the practice in the past. However, oxide ores are too low in copper to permit economical hydrometallurgical extraction. In addition, many oxide minerals do not readily respond to froth flotation and therefore need to be treated by non-pyrometallurgical route, preferably, hydrometallurgical techniques. Hydrometallurgical extraction comprises leaching, cementation/solvent extraction and electro winning. Hydrometallurgical techniques are applied mainly to oxidised copper ore, low grade oxide/sulphide mine wastes and roasted sulphide ores. Processes have been developed to extract copper hydrometallurgically from sulphide concentrates too. Leaching Technology Although leaching is a chemical process, physical factors play an important role. The most important factor is the ingress of leach solution into the ore. There are three types of voids in rocks - fractures, cleavage planes and fine pores. In most copper bearing rocks, copper minerals are concentrated in fractures and cleavage planes where solution can more readily come in contact with them than if they were disseminated through the entire rock. Diffusion is an important action in leaching. As the solution penetrates the interior of the rock and dissolves copper minerals, a diffusion pressure is created and soluble salts diffuse to a less concentrated solution at the surface of the rock. The actual rate of dissolution depends upon the type of leaching and the contacting conditions. Typical leaching cycles for oxidised ores are 5-12 hours for fine concentrate with agitation leaching, 5-10 days for crushed particles in vat leaching and 100-180 days in heap leaching. Factors favouring rapid leaching rates are high acid strength, elevated temperature (up to 60 o C), large contact area and good agitation. Copper sulphide minerals dissolve mainly under extremely oxidising conditions provided by high oxygen pressure. The best solvent for oxidised minerals is sulphuric acid. It is cheap and can be partly regenerated in leaching of sulphide/sulphite minerals. The best solvent for sulphide minerals is acidified ferric sulphate. In some cases, ammonia and hydrochloric acid are used for nickel-copper sulphide ores/mattes. The leaching of sulphide ores with sulphuric acid as already 42
indicated is a very slow process and that is why it is restricted mainly to long-term treatment (3-20 years) of oxide/sulphide mine wastes. Nevertheless, large quantity of copper is extracted by this long-term leaching technology. The principal sulphide minerals in leach dumps are chalcopyrite, chalcocite and pyrite. Pyrite, when leached converts to ferric sulphate which contributes to further leaching of copper minerals. Leaching methods as applied for copper extraction are: a) In situ leaching b) Dump/heap leaching c) Vat leaching/ percolation leaching d) Agitation leaching e) Bacterial leaching a) In situ Leaching: In situ leaching involves the breaking of ore in situ by conventional mining method. This is practiced for low grade-surface deposits or worked out underground mines. b) Dump/Heap Leaching: Dump leaching is applied to the low copper wastes from conventional mining methods, usually open pit operation. The waste rock is built into large dumps and the leachant is sprinkled over the surface and allowed to trickle down through the dump. Heap leaching is exactly the same as dump leaching except that surface oxide ore deposits rather than mine wastes are broken and piled into heaps of 1,00,000 to 5,00,000 tonnes. The solid material in the heaps is somewhat smaller (100 mm) than those in the dumps and leaching is faster. Copper recovery from sulphide heaps is low due to short leaching time (100-180 days). Leaching recovery seldom exceeds 60%. However, this method requires lowest capital cost. c) Vat/Percolation Leaching: Vat leaching is a high production rate method employing concentrated sulphuric acid to produce a pregnant solution of sufficient copper concentration for electro-winning from oxidised copper ores (1.02% Cu). This technique, is based on batch principle. The ore crushed and sized to 10-20 mm containing no fines or with fines, agglomerated by moistening and rolling, is leached in large rectangular vats (28 m long x 15 m wide x 6 m deep) and is capable of treating 3,000 - 5,000 tonnes. The leaching usually takes place in sequence of four to seven reinforced concrete vats arranged side by side. The pregnant solution from the these vats are used as electrolyte (after purification) while the remaining solution (being more dilute in copper) is used to leach subsequent fresh batches of ore, continuous batch leaching is now being practised in several operations. The most prominent example of vat leaching has been the Chuquicamata (Chile) plant based on sulphate ores (antlerite). Chambishis (Zambia) vat leaching plant was based on carbonate copper ore. The total process cycle may last for 100-200 hours and recovery of copper up to 95% is possible from readily soluble oxide copper ores. 43
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 and 52: 3.2.2 Smelting Copper is extracted
Page 53 and 54: a) low capital and operating cost b
Page 55: a large extent by volatisation of t
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
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10000 Figure : 5.2 - Month Wise LME
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y the State Government in the Minin
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The consumption given in above tabl
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Table-6.3: Internal Apparent Demand
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electrification will result in an i
Page 118 and 119:
consumption in General Engineering
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The HCL has planned a number of gre
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In earlier chapter it has already b
Page 124 and 125:
ased on imported concentrates. Indi
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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
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Sl. NAME OF THE UNIT CAPACITY WASTE
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Page 136 and 137:
Page 138 and 139:
Sl. NAME OF THE UNIT CAPACITY No. (
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Page 142 and 143:
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Sl. No. XII TAMIL NADU NAME OF THE
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Concld… Sl. NAME OF THE UNIT CAPA
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Concld…. COBRA No.2 Copper Wire N
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Annexure: 3 - IV (B) Exports of Cop
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Annexure: 4 - II World Mine Product
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Sl. No. Annexure: 4 - IV World Prod
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140
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Sl. No. Annexure: 4 - VI World Impo
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Sl. No. Annexure: 4 - VIII India’
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Annexure: 4 - X India’s Exports o
Page 164 and 165:
Sl. No. Annexure: 4 - XIII India’
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Annexure: 4 - XV Worldwide List of
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Company Name Operations Countries F
Page 170 and 171:
Company Name Operations Countries N
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Worldwide List of Countries Produci
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Country Operations Companies Laos K
Page 176 and 177:
Annexure: 4 - XVII Worldwide List o
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Mine Name Country Owners Guelb Mogh
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Mine Name Country Owners Nkana Zamb
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Worldwide List of Copper Smelter &
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Sl.No. Country Company Location 3.
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Concld…. Sl.No. Country Company L
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Production and expansions 1993 and
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2020. In the meantime the mill will
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The Dalam Diatreme (DD) forms the f
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Open-pit mining The Ujina and Huinq
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All ore is now treated in the lower
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unoff and seepage, and from the low
Page 200 and 201:
Concentration and separation involv
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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:
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