Market Survey on Copper - Indian Bureau of Mines

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acid, and recovers gold and silver as by-products. The smelting process adopted in the Sterlite Industries (India) Ltd., Tuticorin, Tamil Nadu is given below: Smelting Process Sterlite Copper smelter is custom smelter operating on imported concentrates on Isasmelt Technology. The Isasmelt Technology is based on submerged bath smelting, developed by Common Wealth Scientific and Industrial Research Organisation (CSIRO) and MIM Technologies Ltd., Australia. Isasmelt Furnace is Shaft type with smelt set concentrates, operated at 1180- 1200 o C. Oxygen enriched blast air with oil is passed through a Lance (Burner) into the molten bath where the concentrate is mixed with fluxes (river sand and limestone). The molten mass enriched from 30% Cu to 60% Cu. The molten mixture of matte and slag is transferred to RHF-(Rotary Holding Furnace) through Launder where the matte and slag are separated due to differential density. The slag which floats on the top of the bath is discarded by granulation and the molten matte of 60% Cu is taken through pots with the help of the cranes. The matte is further enriched in the converters to 98% Cu and taken to anode furnaces for further fire refining to remove traces of sulphur. After refining, copper is cast in the form of anodes and dispatched to refining at Silvassa refinery, Gujarat for electrolytic refining. iii) Hindalco Industries Ltd, (Birla Copper) : The company's smelter commissioned in May, 1998 is located at Lakhigam Vaghera in Dahej Taluka of Bharuch District, Gujarat and is having a capacity of 5,00,000 tpy copper cathode . It is based on Outokumpu (Finland) technology. The plant is the largest of its kind in India. In the process of extraction of copper metal, sulphuric acid, phosphoric acid, di-ammonium phosphate, other phosphoric fertilizers, phosphogypsum, gold and silver are recovered as byproducts. The entire requirement of copper concentrate is being met through imports from other countries. Information on smelting process adopted in Birla Copper unit of M/s Hindalco Industries Ltd. is given below: Smelting Process At Birla Copper, various copper concentrates are blended to achieve desired copper concentrate & Sulphur/Copper ratio in the blend for efficient smelting. Concentrate blend is mixed with silica and dried from 6-8% moisture content to less than 0.2% moisture. The dried concentrate is smelted in a flash smelting furnace with oxygen enriched air. The furnace is preheated to 1,300 o C by means of furnace oil fired burners before cone feeding. Furnace oil fired burners are installed in the settler and reaction shaft of the Flash Smelting Furnace for maintaining smelting temperature. Molten matte from the furnace containing about 65% copper is tapped from the furnace in ladles and transferred by means of Electrical Overhead Transport 50
ladle crane to the Pierce Smith Converter. Furnace oil fired burner maintains the temperature of converter between two converter operations. In converter, air is blown through the liquid matte at a pressure through side blown tuyers and quartz is added as flux, resulting in production of blister copper (98%) and slag (containing about 5% Cu). The slag from flash smelting furnace and converters is treated in a sub-merged arc slag cleaning furnace for reducing copper content in discard slag to below 0.7% Cu. The slag is allowed to settle in slag cleaning furnace where two layers of molten matte and slag are formed. Matte from slag cleaning furnace is treated in converters whereas slag is tapped, granulated and sent to the dump yard. Blister copper from converters is poured into ladles and transferred to anode furnace by means of Electrical Overhead Transport crane for fire refining. Fuel used for the heating burner in the Anode Furnace is naphtha, which is low sulphur fuel suitable to maintain the quality of refined copper. Controlled air blowing first oxidises remaining sulphur to remove it as sulphur dioxide. However, in the process, a part of copper is also oxidized, which is reduced back by reduction with hydrocarbons available from cracking of propane injected under the metal bath. The fire refined copper containing 99.5% Cu poured on rotating anode casting wheel as anode and dispatched to refinery tank house for electro-refining to produce copper cathodes. Through this most efficient process, copper recovery of 98.5% and sulphur recovery of 95% is achieved. Gases rich in sulphur dioxide are processed in Sulphuric Acid Plant (double conversion double absorption (DCDA) process) to produce sulphuric acid. iv) Jhagadia Copper Ltd., (Formerly SWIL Ltd.) : SWIL Ltd. has been renamed as Jhagadia Copper Ltd. w.e.f. 05.01.2006. Its smelter is installed at Jhagadia in Bharuch district of Gujarat. It is a scrap based electrolytic smelter to make cathodes with a capacity of 50,000 tpy. The plant has an additional capacity of 20,000 tpy copper anodes. Out of the total capacity, 6000 tpy output is used for producing wires, strips, etc., 20,000 tpy are exported and 24,000 tpy are sold in domestic markets. The plant is set up in technical collaboration with Boliden Contech AB of Sweden. 3.3 PRODUCTION 3.3.1 Production of Ore The history of production of base metals including copper is dated back to ancient times. The presence of extensive dumps near the old working, huge heaps of old slag are evidences of ancient copper mining in India particularly in Khetri and Singhbhum are the silent testimonies of once thriving mining activity. Both opencast and underground methods of mining were adopted. The sulphide ores are very important. The primary mineral chalcopyrite and the secondary mineral chalcocite account for lion's share of copper production in 51
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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
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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 and 62: ii) Malanjkhand Copper Project The
Page 63: silver, selenium, tellurium, nickel
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
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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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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
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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
Page 208 and 209:
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