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http://mine-engineer.com/mining/minproc/copper1.htmThe above flowsheet shows a basic copper mine process, from mine to metal. There are two distinct types of copper ore, the sulfide ore and the oxide ore. The sulfide ores are beneficiated in flotation cells, while theoxide ores are generally leached. First the copper ore from a open pit mine is blasted, loaded and transportedto the primary crushers. Then the ore is crushed and screened, with the fine sulfide ore (~-0.5 mm) going tofroth flotation cells for recovery of copper. The coarser ore goes to the heap leach, where the copper issubjected to a dilute sulfuric acid solution to dissolve the copper. Then the leach solution containing thedissolved copper is subjected to a process called solvent extraction (SX). The SX process concentrates and purifies the copper leach solution so the copper can be recovered at a high electrical current efficiency by theelectrowinning cells. It does this by adding a chemical reagent to the SX tanks which selectively binds withand extracts the copper, is easily separated from the copper (stripped), recovering as much of the reagent as possible for re-use. The concentrated copper solution is dissolved in sulfuric acid and sent to the electrolyticcells for recovery as copper plates (cathodes). From the copper cathodes, it is manufactured into wire,appliances, etc. that are used in every day life. Below are some photos of the process equipment at anArizona Copper Mine.Copper Ore being loadedinto a 300 ton truck for transport to the crusher.
 
The primary crusher at a copper mine.The truck dumps ore into the crusher whichcrushes the ore. Screens size and distributethe classified ore to a series of conveyors,like those above, for transportation to themill for further processing.Conveyors and trucksdeposit coarse ore on a heapleach pad, which has a seriesof pipes and hosesdispensing a diluted sulfuricacid solution to the ore.Copper is dissolved andflows to a pond at the bottom of the pad. This process can take severalmonths. The leachedsolution is pumped to the SX(Solvent Extraction) circuit,which looks like a series of agitation tanks or cells. Thefine sulfide ore is sent tofroth flotation cells like those below for recovery.The froth flotation cellsrecover the copper from sulfideores by chemically attachingthe copper to a chemical bubble and overflowing thefroth (bubbles with copper).The concentrates from theflotation cells are sent to thesmelter for processing to acopper plate. The copper plateis then dissolved in sulfuricacid and sent to theelectrowinning cells for platingonto cathodes, along with theconcentrated copper from the
 
SX circuits. The copper leach solution typically consists of 40 gm of copper and 200 gm sulfuric acid per liter. Current densities on the electrowinning cells can be 20-25 amperes per square foot, or more.Banks of electrowinning cells with cathodes.Copper on the annodes ranges from 99.0 to99.5 percent pure. Power consumed inelectroplating copper ranges from 0.08 to0.20 KWH per pound of copper. Any gold or silver in the copper does not plate out anddrops to the bottom of the cell with thesludge to be recovered later.Machine transporting and handling the copper cathodes that were removed from theelectrowinning cells. That's it, the rest ismanufacturing products from the pure copper!
COPPER MINE & PLANT
Areal view of surface facilities at underground copper mine. The towering structures are the headframes of the elevators that lower men, supplies and remove the ore from the mine. This particular mine went 4,500 ft
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