Market Survey on Copper - Indian Bureau of Mines

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The description of smelters of HCL, SIL, and Birla Copper is given below: i) Hindustan copper Ltd. (HCL) HCL has smelters and refineries at Khetri Nagar in Rajasthan and at Ghatsila in Jharkhand and a continuous cast wire rod plant at Taloja in Maharashtra. The total installed smelting capacity of the plants of HCL is about 51,500 tpy. The capacity of HCL’s Continuous Cast Copper Wire Rod Plant (CCWR) at Taloja is 60,000 tpy. (a) Khetri Copper Complex (KCC): This smelter with a capacity of 31,000 tpy is located at Khetri Nagar in Jhunjhunu district, Rajasthan. HCL has taken up technological upgradation and debottlenecking scheme of KCC Smelter leading to enhancements of the capacity from 31000 tpy to 45000 tpy. Smelting takes place in Outokumpo Flash Furnace. Dried concentrate together with hot air (400 o C) and silica is fed into the vertical reaction shaft of the furnace via uptake shaft and pass on to a waste heat recovery boiler, electrostatic precipitator and finally to acid plant/main stack. The slag (1.5-2% Cu) after cooling is crushed in a jaw crusher and then recycled back to the concentrator. The matte (45% Cu) after cooling is crushed in a jaw crusher and then recycled back to the concentrator. The matte (45% Cu) is treated in two long Pierce Smith Converters, one of which is standby. Air is supplied by steam driven turbo-blowers and is oxygen enriched. The blister copper from converter is refined in two drum type anode furnaces employing oil reduction technology. The copper is cast into anodes on a casting wheel assaying 99.4% Cu and 1, 400 ppm oxygen. Some steam generated (45 kg/cm 2 ) in waste heat boiler is also used for cooling exhaust gases from flash furnace from a temperature of 1,350 o C to 360 o C. Cyclones and electrostatic precipitators are provided in both dryer and flash furnace exhaust gas circuits to recover copper bearing dust for recycling. The cleaned flash furnace gases containing over 4% SO2 is sent to acid plant. Oxygen enrichment of air in the converter has led to effective control and generation/accumulation of secondaries. Refining of anode copper to produce cathode copper is carried out by using conventional electro-refining technology. HCL has modernised its refining plant and has introduced different automatic process controls and operation systems to ensure quality output on sustained basis. The Khetri Copper Complex, in addition, has a sulphuric acid and a phosphatic fertilizer plant with capacities of 1, 82,000 tonnes and 90,000 tonnes, respectively. (b) Indian Copper Complex (ICC): It has a smelter of 20,500 tpy capacity located at Ghatsila, dist. East Singhbhum, Jharkhand and has planned to increase the capacity to 25,000 tpy. In addition to this the complex consists of a 8,400 tpy wire bar casting plant, a 54,000 tpy sulphuric acid plant and a brass rolling mill. There is also a precious metal recovery plant for recovery of gold, 48
silver, selenium, tellurium, nickel sulphate, copper sulphate etc. The smelting and refining process is the same as is being practiced at KCC. All mines at Indian Copper Complex (ICC), Jharkhand were earlier closed on economic considerations. Out of the closed mines at ICC, Company has since re-opened the mine at Surda in association with an Australian Mining Company, viz. M/s Monarch Gold CO. Ltd./ India Resources Ltd.(IRL). The mine has started production of Copper Ore and its beneficiation into Copper concentrate from January, 2008. The target of ore production from Surda mine during the year 2010-11 is 4.00 Lakh tonnes and has plans to scale-up production to achieve a futuristic target of 900,000 tonnes per annum via decline development. Copper concentrates production has also started at Mosabani Concentrator Plant from January 2008. All copper concentrate produced at Surda is sold to HCL to the nearby Maubhandar Works, a unit of ICC. The current production is limited only by existing shaft hoisting capacity and meets only 47% of the concentrator capacity. (c) Continuous Cast Copper Wire Rod Plant, Taloja: The plant with a capacity of 60,000 tpy is located at Taloja in Maharashtra. It was commissioned in December, 1989 and commenced commercial production in April, 1991. The installed capacity is likely to be increased to its licensed capacity of 80,000 tpy. (d) Leaching Facilities at Malanjkhand: In 1989, HCL created chemicalcum-bio-heap leaching and concentration facilities to produce 2.5 tonnes cement copper per day from oxides copper ore. Based on the experience acquired, the company has conducted field studies for the recovery of copper from lean chalcopyrite ore by bio-leaching SX-EW Route. The successful implementation of this project would augment resource base and metal production. Short description of chemical-cum-leaching process adopted since 1989, is as follows: Oxide ore (1.25% Cu) containing over 80% oxide copper is crushed to (-) 150 mm and loaded on to HDP liners on the leach pad. The first layer is about 3 m thick. Concentrated H2SO4 is sprinkled over this layer followed continuously with dilute sulphuric acid sprinkling for about three months. A second layer of oxide is then deposited followed by another cycle of acid leaching. This continues up to a thickness of 10 m for each pad. The pregnant solution is collected and pumped to launders where the copper is precipitated by scrap iron in the form of cement copper. Cementation process is to be replaced by solvent extraction electro-winning (SX-EX) process. (ii) Sterlite Industries Ltd.: The Sterlite's Copper smelter plant with an installed capacity of 4, 00,000 tpy of copper anodes, is located at Tuticorin in the coastal belt of Tamil Nadu. It was commissioned in November, 1996 and is based on 'Isasmelt' technology using imported concentrates. Sterlite Industries (India) Ltd. is the largest producer of continuous cast copper rods in India. Besides copper, the company also manufactures sulphuric acid & phosphoric 49
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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
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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 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: ii) Malanjkhand Copper Project The
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
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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
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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
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ased on imported concentrates. Indi
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Annexure: 3 - I LIST OF THE UNITS R
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Sl. No. NAME OF THE UNIT CAPACITY (
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Annexure: 3 - II LIST OF THE UNITS
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Sl. NAME OF THE UNIT CAPACITY WASTE
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Sl. NAME OF THE UNIT CAPACITY No. (
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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
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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
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Company Name Operations Countries N
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Worldwide List of Countries Produci
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Country Operations Companies Laos K
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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
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Concentration and separation involv
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single pit: today the working area
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One of the first of the recent seri
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Annexure: 5 - I Average Monthly Pri
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Market Survey on Copper - Indian Bureau of Mines

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