Extractive Metallurgy of Copper Part 1 pps

-4 0 cd 1 2 3 z4 E 5 6 I 1 H Li 1.0079 Hydrogen 3 6.94, Lithium 11 Na K 22.98977 Sodium 19 39.098, Pottasium 37 Rb cs Fr 85.467, Rubidium 55 132.9054 Cesium 87 (223) Francium 4 Be 9.01218 Bervllium 12 Mg Ca 24.305 Magnesium 20 40.08 Calcium 38 Sr Ba Ra 87.62 Strontium 56 137.33 BariWll 88 226.0254 Radium 3(IIIA) 4(IVA) 5(VA) 6(VIA) 7(VIIA) 8 9(VIIIA) Cr 1 39 42 Y I4'Zr 4Nb Mo 88.9059 91.22 92.9064 95.94 Yttrium Zirconium Niobium Molybdenutr 57 138.9055 178.4, 180.947, 183.85 Lanthanum Hafnium Tantalum Wolfram 39 La 72Hf 73Ta 74W Ac Lanthanide Metals 227.0278 Actinium 90 91 25 Manganese kchnetium Re 186.207 Rhenium Nd Pm Sm U Np Pu 144.2, (145) 150.4 238.029 237.0482 (244) Uranium Nmtunium Plutonium 18 (WIE 2 4.00260 Helium He 9 F C1 Br I At 18.998403 Fluorine 17 35.453 Chlorine 35 79.904 Bromine 53 126.9045 Iodine 35 (210) Astame 10 11(IB) 12(IIB) 10 Ne Ar ’“Kr Xe Rn 20.17, Neon 18 39.94, Argon 83.80 Krypton 54 131.30 Xenon 86 (222) Radon 28 Ni Pd 58.70 Nickel 46 106.4 palladium 78 Pt Au Hg 1%.9665 200.5, 1 Pi%% 1 Gold 1 Mercury 29 30 Cu Zn 47Ag 48Cd 63S6 65.38 Copper Zinc 107.868 112.41 Silver Cadmium 79 80 i’xm i9km I 66 Dy Bk Cf 162.5, Dysprosium 97 98 (247) (251) Berkelium Californium 13 (IIIB) 14 (NB) 10.81 12.011 A1 26.98154 28.085, Boron Silicon 67 Ho Es Fm Md 164.9304 Holmium 99 100 101 (252) (257) (258) ansvlmum Fermium Mendcirnum 31Ga 132C;e 68 Er 167.5 Erbium 15(VB) 16(VIB) 17(VIIB) 69 Tm 168.9342 Thulium 7376 i343206 hosphorous Sulphur As Se 65 Tb 158.9254 Terbium 70 Yb No 173.0, Ytterbium 02 1259) Nobelium 71 Lu Lr 174.96, Lutetium I03 (260) Lawrencium Extractive Metallurgy of Copper FOURTH EDITION Elsevier Titles of Related Interest P. BALAZ (Slovak Academy of Sciences, Slovakia) Extractive Metallurgy of Activated Minerals 2000, Hardbound, 290 pages ISBN: 0-444-50206-8 K.H.J. BUSCHOW (University of Amsterdam, The Netherlands) R.W. CAHN (University of Cambridge, UK) M.C. FLEMINGS (Massachusetts Institute of Technology, M, USA) B. ILSCHNE (Swiss Federal Institute of Technology, Switzerland) E.J. KRAMER (University of California, CA, USA) S. MAHAJAN (Arizona State University, AZ, USA) The Encyclopedia of Materials: Science and Technology 2001, Hardbound, approx. 10000 pages ISBN: 0-08-043 152-6 (1 1 -volume set) Electronic version is also available: http://www.elsevier.com/emsat/show/index. htt R.W. CAHN (University of Cambridge, UK) P. HAASEN (University of Gottingen, Germany) Physical Metallurgy, 4th Revised and Enhanced Edition 1996, Hardbound, 2888 pages ISBN: 0-444-89875-1 (3-volume set) V.S.T. CIMINELLI (Universidade Federal de Minas Gerais, Brazil) 0. GARCIA Jr. (UNESP-Campus Araraquara, Brazil) Biohydrometallurgy: Fundamentals, Technology and Sustainable Development, Parts A and B 2001, Hardbound, 1348 pages ISBN: 0-444-50623-3 Y. MUKAKAMI (Kyushu University, Japan) Metal Fatigue: Effects of Small Defects and Nonmetallic Inclusions 2002, Hardbound, 380 pages ISBN: 0-08-044064-9 W. PETRUK (Ottawa, Canada) Applied Mineralogy in the Mining Industry 2000, Hardbound, 286 pages ISBN: 0-444-50077-4 s to search for more Elsevier books, visit the Books Butler at http://www.elsevier.com/homepage/boo ksbu tlerl Extractive Metallurgy of Copper W.G. DAVENPORT Department of Materials Science and Engineering University of Arizona Tucson, AZ, USA M. KING Phelps Dodge Mining Company Phoenix, AZ, USA M. SCHLESINGER Metallurgical Engineering Department University of Missouri - Rolla Rolla, MO, USA A.K. BISWASt FOURTH EDITION PERGAMON ELSEVIER SCIENCE Ltd The Boulevard, Langford Lane Kidlington, Oxford OX5 IGB, UK 0 2002 Elsevier Science Ltd. 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Except as outlined above, no part of this work may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior written permission of the Publisher. Address permissions requests to: Elsevier Science Global Rights Department, at the fax and e-mail addresses noted above. Notice No responsibility is assumed by the Publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Because of rapid advances in the medical sciences, in particular, independent verification of diagnoses and drug dosages should be made. First edition 1916 Second edition 1980 Third edition 1994 Fourth edition 2002 British Library Cataloguing in Publication Data Davenport, W. G. (William George) Extractive metallurgy of copper. ~ 4th ed. 1.Copper - Metallurgy 1.Title II.King, M. III.Schlesinger, M. IV.Biswas, A. K. (Ani1 Kumar) 669.3 ISBN 0080440290 Library of Congress Cataloging in Publication Data A catalog record froin the Library of Congress has been applied for ISBN: 0-08-044029-0 8 The paper used in this publication meets the requirements of ANSL’NISO 239.48-1992 (Permanence of Paper). Printed in The Netherlands. CONTENTS Preface Preface to the Third Edition Preface to the Second Edition Preface to the First Edition 1 Overview 1. I Introduction 1.2 1.3 Hydrometallurgical Extraction of Copper 1.4 I .5 1.6 Summary Extracting Copper from Copper-Iron-Sulfide Ores Melting and Casting Cathode Copper Recycle of Copper and Copper-Alloy Scrap Suggested Reading References 2 Production and Use 2.1 Locations of Copper Deposits 2.2 Location of Extraction Plants 2.3 2.4 Price of Copper 2.5 Summary Copper Minerals and ‘Cut-Off Grades References 3 Concentrating Copper Ores 3.1 Concentration Flowsheet 3.2 Crushing and Grinding (Comminution) 3.3 Flotation Feed Particle Sii- 3.4 Froth Flotation 3.5 3.6 Flotation Cells 3.7 Sensors. Operation and Control Specific Flotation Procedures far Cu Ores V xiii xv xvii xix 1 1 1 11 13 15 15 16 16 17 18 18 19 28 29 29 31 31 33 38 42 46 49 5 0 vi Contents 3.8 The Flotation Product 3.9 Other Flotation Separations 3.10 Summary Suggested Reading References 4 Matte Smelting Fundamentals 4.1 Why Smelting? 4.2 Matte and Slag 4.3 Reactions During Matte Smelting 4.4 4.5 4.6 Summary The Smelting Process: General Considerations Smelting Products: Matte, Slag and Offgas Suggested Reading References 5 Flash Smelting - Outokumpu Process 5.1 Outokumpu Flash Furnace 5.2 Peripheral Equipment 5.3 Furnace Operation 5.4 Control 5.5 Impurity Behavior 5.6 Future Trends 5.7 Summary Suggested Reading References 6 Inco Flash Smelting 6.1 Furnace Details 6.2 Auxiliary Equipment 6.3 Operation 6.4 Control Strategy 6.5 6.6 6.7 Summary Cu-in-Slag and Molten Converter Slag Recycle Inco vs. Outokumpu Flash Smelting Suggested Reading References 52 53 53 54 54 57 57 59 65 66 67 70 70 70 73 74 77 82 83 86 87 87 88 88 91 91 96 97 98 100 101 101 101 102 [...]... Furnace Details 15 5 15 5 15 7 16 2 16 6 17 0 17 0 17 1 17 1 17 3 17 3 17 5 17 6 17 6 18 1 18 1 18 3 18 3 18 7 18 7 18 8 18 9 19 0 19 0 19 3 19 4 19 5 19 5 19 6 19 6 19 9 20 1 20 1 Contents 13 .3 13 .4 13 .5 13 .6 13 .7 13 .8 13 .9 13 .10 14 Capture and Fixation of Sulfur 14 .1 14.2 14 .3 14 .4 14 .5 14 .6 14 .7 14 .8 14 .9 14 .10 15 Offgases from Smelting and Converting Processes Sulfuric Acid Manufacture Smelter Offgas Treatment Gas Drying Acid... Reading References 11 9 12 0 12 0 12 5 12 6 12 6 12 7 12 7 12 8 12 9 13 1 13 1 13 7 14 4 14 5 14 8 14 8 15 0 15 1 15 1 viii Contents 10 Continuous Converting 10 .I 10 .2 10 .3 10 .4 10 .5 10 .6 11 Copper Loss in Slag 1 1 .1 I 1. 2 11 .3 1 1.4 I 1. 5 11 .6 12 Copper in Slags Decreasing Copper in Slag I: Minimizing Slag Generation Decreasing Copper in Slag 11 : Minimizing Cu Concentration in Slag Decreasing Copper in Slag 11 1: Pyrometallurgical... Teniente Smelting 7 .1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7 .10 7 .1 I 7 .12 7 .13 8 10 3 Noranda Process Reaction Mechanisms Operation and Control Production Rate Enhancement Noranda Future Teniente Smelting Process Description Operation Control Impurity Distribution Teniente Future Discussion Summary Suggested Reading References 10 4 10 6 10 8 10 9 1I O 1I O 11 1 11 1 1 I3 1 I4 11 5 11 5 1 I6 1 I7 1 I7 Ausmeltflsasmelt... 242 243 243 247 247 252 253 253 256 260 260 26 1 26 1 262 265 265 x Contents 16 .2 16 .3 16 .4 16 .5 16 .6 16 .7 16 .8 16 .9 16 .10 16 .11 16 .12 16 .13 16 .14 16 .15 17 269 272 273 273 278 279 280 280 280 28 1 282 283 283 284 284 285 Hydrometallurgical Copper Extraction: Introduction and Leaching 289 Heap Leaching Industrial Heap Leaching Steady-State Leaching Leaching of Chalcopyrite Concentrates Other Leaching Processcs... Extraction Transfer of Cu from Leach Solution to Electrolyte 18 .1 18.2 18 .3 18 .4 18 .5 18 .6 18 .7 18 .8 The Solvent Extraction Process Chemistry Extractants Industrial Solvent Extraction Plants Quantitative Design of Series Circuit Stability of Operation 'Crud' Summary Suggested Reading References 307 307 309 310 312 317 32 1 322 323 324 324 Contents 19 Electrowinning 19 .I 19 .2 19 .3 19 .4 19 .5 19 .6 20 Collection... Industrial Methods of Fire Refining Chemistry of Fire Refining Choice of Hydrocarbon for Deoxidation Casting Anodes Continuous Anode Casting New Anodes from Rejects and Anode Scrap Removal of Impurities During Fire Refining Summary Suggested Reading References Electrolytic Refining 16 .1 Principles ix 203 203 207 208 210 210 21 1 212 214 215 217 217 218 222 224 227 23 1 240 24 1 24 1 242 243 243 247... Future Developments Summary Suggested Reading References 289 293 299 300 3 01 3 01 30 1 303 303 17 .1 17.2 17 .3 17 .4 17 .5 17 .6 17 .7 18 Behavior of Anode Impurities During Electrorefining Industrial Electrorefining Cathodes Electrolyte Cells and Electrical Connections Typical Refining Cycle Refining Objectives Maximizing Cathode Copper Purity Optimum Physical Arrangements Optimum Chemical Arrangements Optimum... Minimizing Cu Concentration in Slag Decreasing Copper in Slag 11 1: Pyrometallurgical Slag Settling/Reduction Decreasing Copper in Slag IV: Slag Minerals Processing Summary Suggested Reading References Direct-To -Copper Flash Smelting 12 .1 12.2 12 .3 12 .4 12 .5 12 .6 12 .7 12 .8 12 .9 13 Common Features of Continuous Converting Downward Lance Mitsubishi Continuous Converting Solid Matte Outokumpu Flash Converting... 19 .6 20 Collection and Processing of Recycled Copper 20 .1 20.2 20.3 20.4 21 328 329 335 335 337 337 338 338 3 41 3 41 344 346 3 51 35 1 352 Chemical Metallurgy of Copper Recycling 355 The Secondary Copper Smelter Scrap Processing in Primary Copper Smelters Summary Suggested Reading References Melting and Casting 22 I 22.2 22.3 22.4 23 327 The Materials Cycle Secondary Copper Grades and Definitions Scrap... Direct-to -Copper Process Industrial Single Furnace Direct-to -Copper Smelting Chemistry Industrial Details Control Cu-in-Slag: Comparison with Conventional Matte SmeltingiConverting Cu-in-Slag Limitation of Direct-to -Copper Smelting Direct-to -Copper Impurities Summary Suggested Reading References Mitsubishi Continuous SmeltingKonverting 13 .1 13.2 The Mitsubishi Process Smelting Furnace Details 15 5 15 5 15 7 16 2 . 17 3 17 3 17 5 17 6 17 6 18 1 18 1 18 3 18 3 18 7 18 7 18 8 18 9 19 0 19 0 19 3 19 4 19 5 19 5 19 6 19 6 19 9 13 .1 The Mitsubishi Process 13 .2 Smelting Furnace Details 20 1 20 1 Contents. Suggested Reading References 10 4 10 6 1 08 10 9 1 IO 1 IO 11 1 11 1 1 I3 1 I4 11 5 11 5 1 I6 1 I7 1 I7 8 Ausmeltflsasmelt Matte Smelting 11 9 8 .1 8.2 8.3 8.4 8.5 8.6 8.7. 253 253 256 260 260 26 1 26 1 262 265 265 x Contents 16 .2 16 .3 16 .4 16 .5 16 .6 16 .7 16 .8 16 .9 16 .10 16 .1 1 16 .12 16 .13 16 .14 16 .15 Behavior of Anode Impurities During