Professional Documents
Culture Documents
smelters
V.”Ram”Ramachandran,
Consulting Engineer,
9650, E.Peregrine Place,
Scottsdale, AZ 85262, USA.
Carlos Diaz,
Director, Centre for Chemical Metallurgy,
Adjunct Professor,
Faculty of Applied Science and Engineering,
University of Toronto,
Room 140, 184, College Street, Toronto,Ontario,
Canada M5S 3E4
Tony Eltringham
Vice-President-Operating Excellence
BHP Billiton Base Metals,
1360 Post Oak Blvd, Suite 150,
Houston, Texas 77056-3020, USA
C.Y.Jiang,
Director- Non-Ferrous, Mining and Mineral Processing, Hatch China,
310, East Ocean Center, A 24 Jian Guo Men Wai Avenue
Beijing, 100004, PR China
Theo Lehner,
Manager, Research and Development,
Boliden Mineral AB
Smelter Operations, Ronnskar,
SE-932 81 Skelleftehamn,, Sweden
Phillip. J. Mackey,
Principal Scientist,
Noranda Inc.Technology Centre,.
240, Hymus Blvd,
Pointe-Claire, Quebec
Canada H9R 1G5
C.J. Newman,
Technical Manager,
Kennecott Utah Copper Corporation,
12000 West 2100 South
P.O.Box 329, Magna,
Utah 84044, USA
A.Tarasov,
General Director, Gintsvetmet
13, Acad. Korolyov Street,
129515, Moscow.
ABSTRACT
Since the last survey of copper smelters in 1988, the copper industry has gone
through considerable changes. Technological innovations, along with stringent
environmental regulations, have caused major changes in many areas. Hence a new
survey was made to review the progress in technology for copper recovery in the last
decade and update data on all the operating copper smelters in the world.
Data summarizing the operations and equipment of 52 copper smelters have been
tabulated and reviewed. Information has been included on all standard aspects of smelter
operation from feed preparation, feed analysis, through to casting and sulfur fixation. The
questionnaires, on which this paper is based on were completed by the respective smelter
personnel during 2002 and 2003.
INTRODUCTION
The survey presents data for a total of 52 operating copper smelters from all over
the world. This is the first time that smelters from Russia and China have been included
in a survey. The smelters surveyed represent together a total annual production of a little
over 9.71 million metric tons from 23 countries out of which about 200,000 mtpy is
secondary copper. This tonnage includes a) the proposed production of 290,000 mtpy
from Alto Norte which has just been commissioned ,but does not include a) production
from Jinchang smelter in China(80,000 mtpy design) to be commissioned in July/August
2003 and b)future production from expansion plans of Sterlite Copper and Indo Gulf
Fertilisers(~150,000mtpy each). The list in this survey is far from complete. Data from
a number of smelters are not included as they did not respond to the survey. The data
presented here have been assembled from questionnaires completed during late 2002 and
early 2003 by the staff of the participating copper companies and their contributions are
gratefully acknowledged.
One of the changes in the copper smelting industry is that the capacity of plants
has been increasing, in part to improve efficiency and lower plant unit cost. This trend
can be illustrated by the results of the present survey and by comparing theses results
with that of the 1988 survey(1).In 1988, for example, 20% of capacity was in smelters
sized less than 100,000 tpy. The percentage of capacity in smelters less than 100,000tpy
had dropped to about 7% in 2003(refer to the following two figures). In 1988, 80% of the
capacity was represented by smelters in the range up to 200,000 tpy, whereas by 2003,
only about 25% of the smelter production was in plants under 200,000 tpy of Cu , i.e.,
75% in plants over 200,000tpy; In 2003, 35% of the capacity was in plants greater than
300,000tpy,while in 1988, this percentage was only 6%.
45
% of total plant capacity in each capacity
40
35
30
range
25
20
15
10
0
< 100 100 to 200 200 to 300 300 to 400 400 to 500 500 to 600 600 to 700
Smelter capacity range, k tpy of produced copper
Breakdown of total survey smelting capacity by plant size - 2003 and 1988 cpmpared
In 2003, approx. 75% of survey smelter capacity is with plants >200 k tpy copper;
In 1988, this was only 20% of smelters; in 2003 35% was in plants > 300 k tpy, in 1988, this was only 6% of
plants
Capacity represented, mill tpy Cu : 2003 - 9.7; 1988- 5.7
70
% of capacity - 1988
% of total plant capacity in each capacity range
% of capacity - 2003
60
50
40
30
20
10
0
< 100 100 to 200 200 to 300 300 to 400 400 to 500 500 to 600 600 to 700
Smelter capacity range, k tpy of produced copper
RAW MATERIALS
Feed
Furnace Flux
Feed Preparation
PRIMARY SMELTING
Since the last copper smelter survey was done in 1988, considerable advances
have occurred in the primary smelting of copper concentrates with a goal to increase
productivity and reduce unit cost. Major changes include a) single-line smelters
producing around 250,000 metric tons of anode copper b) increased process intensity
accompanied by improved vessel integrity c) a high degree of oxygen enrichment during
smelting and d) higher matte grades. Tighter environmental regulations-probably the
most important factor influencing technological change in the smelting industry in the
last 40 years-have forced smelters to routinely capture well over 95-97% of sulfur as
sulfuric acid. With the adoption of flash smelting and flash converting at Kennecott and
the use of acid plant tail gas scrubbing at other plants (mainly in Japan) sulfur capture has
exceeded 99.9%.
In the last 25 years, there has been a trend towards building large capacity
smelters. Twenty four smelters reported in this survey produced over 200,000 mtpy each,
while five smelters in the100,000-200,000 mtpy range produced over 170,000 mtpy each.
Table I shows the plant tonnage range versus number of plants in each range.
Table I - Plant Tonnage Ranges and Number of Plants in Each Range
<100,000 11*
100,000 – 200,000 12
200,000 – 300,000 16
300,000 – 400,000 4
400,000 – 500,000 3
500,000 – 600,000 0
600,000 – 700,000 1
No data 1
* At URAL Metallurgical Co, Russia, production from five small plants has been
combined in to one.
During the last 30 years, considerable progress has been made in bath smelting of
copper concentrates. In year 2000, about 30% of the world’s copper production will be
produced by this technology. In “bath smelting” the concentrate feed is “enveloped and
reacted in a turbulent bath of matte”. Five major technologies using this smelting
technology are: a) Mitsubushi Continuous Smelting b)El Teniente Converter(TC) c)
Noranda Technology and d) Top Submerged Lance Technology(TSL) -Isasmelt and
Ausmelt . The advantage of this important smelting method is the high intensity mode of
smelting which enables the added charge to quickly reach smelting temperatures and the
chemical reactions to rapidly proceed to completion; this feature translates to smaller
sized furnaces per unit capacity and a high overall efficiency.
Of the smelters surveyed, about 35% use flash smelting, 35% use bath smelting;
rest of the technologies cover the balance of 30%.
Other technologies in use-however not on a large scale-are the reverberatory
furnace(six), blast furnace(two), and electric furnace(three). It is the authors’ belief that
most of them would have changed to either flash or bath smelting by the time the next
survey of copper smelters is done.
Carlos Diaz (2) and Mackey and Campos(3) have done an excellent review of all
aspects of copper smelting and converting technology in their papers from which some of
the above information has been gathered. Both the papers would make interesting
reading for students of copper metallurgy.
In view of the increasing interest towards producing high matte grades – the
matte grades of all the smelters along with the corresponding smelting furnace slag are
tabulated in descending order in Table II.
Table II – Smelter Primary Furnace Matte and Slag Analysis Arranged in Descending
Order of Matte Copper Analysis
Another change in the copper smelting industry has been a gradual increase
inmate grade produced in the smelting furnaces. This trend was noted in 1988 survey (1),
and it continues such that a greater proportion of plants are operating at higher matte
grades. For example, in 1988, only 26% of plants had a matte grade over 60 % Cu, while
the present survey indicate that about 55% of plants surveyed had a matte grade over 60
% Cu. Also, in 1988, 51% of plants in the survey had matte grades up to 50% Cu; this
percentage has dropped to 24% in the present survey.
The average matte grade in this survey was 58.6% Cu compared to 53.0%
reported in the last survey. Eliminating the lowest three matte grades –31% Cu and
below raised the average matte grade to 60.4% Cu for the remaining 49 smelters.
The trend with more plants having higher matte grades follows the trend to more
widespread use of modern flash and bath smelting technologies being used throughout
the copper industry.
CONVERTING
The Peirce –Smith(P-S) converter continues to retain its role as the major work
horse for converting copper matte to blister in most of the copper smelters in the world.
Of the 52 plants surveyed, 43 smelters use the P-S converter;next in line was Mitsubushi
continuous converter(five) and one each of Noranda, Flash , Ausmelt. Olympic dam does
not use a converter as it produces blister copper from the smelting furnace.
Iron-silicate slags produced in P-S converters are invariably recycled back to the
smelting furnace, while calcium-ferrite slags produced in continuous converters are slow
cooled and milled for copper recovery.
Readers are referred to references (2) and (3) for details of the converter
operations.
SLAG CLEANING
Since the survey of 1988, cleaning of both smelter slag and converter slag has
become common practice. Two major approaches to slag cleaning processes are use of an
electric furnace and/or slow cooling the slag and milling it to produce a copper
concentrate. Use of both these processes have gone in tandem with the move towards
production of high grade mattes in the industry. As a rule, electric furnaces have been
used for cleaning smelting furnace slags; sometimes converter slags are added along with
the smelting slag. There was no case where only converter slag was cleaned in an electric
furnace.The slow cooling and milling approach has been mostly used for converter slags
with smelting slags added at a few smelters. Smelters using the continuous converting
(Mitsubushi, Outokumpu-Kennecott, Noranda)) always slow cooled and milled their
converter slag. Only one smelter used slow cooling for smelter slag. One smelter
reported using fuel fired furnace while another uses a rotary furnace where some
reductant is added to improve copper recovery. Most smelters report average slag
cleaning copper recoveries varying between 85 to 90 %.
The average copper content of the discard slag from the electric furnace was
0.78% Cu ( compare 0.66 % Cu in the last survey with 9 smelters reporting).In slow
cooling and milling, the copper content of the tailings averaged 0.54% Cu(compared to
0.51%Cu in the last survey with 13 smelters reporting).The copper in the final slag from
the rotary furnace and the fuel fired furnace was 0.75% Cu and 0.9% Cu respectively.
The Fe/SiO2 ratio in the final slag from the electric furnace averaged at 1.31(compare
1.27 from the last survey); the ratio ranged from a low of 1.06 to a high of 1.64.Due to
the narrow range of final copper content of the discard slag from the electric furnace,
viz., from 0.6 to 1.0% Cu, there was no definite relationship between copper loss and
Fe/SiO2 ratio.
The rotary anode furnace seems to be the standard for fire refining of blister
copper all over the world. Of the 52 smelters surveyed, 39(75%) smelters use the rotary
furnace. Two smelters use the reverberatory furnace and one smelter(PASAR) uses the
Peirce-Smith type unit. Four smelters produce only blister copper and do not fire refine
copper. Six smelters did not provide any data.
A wide variety of reductants are used in fire refining with heavy oil leading the
pack at 11 smelters followed by LPG at 8 smelters and natural plus steam at 6
smelters.The rest of the reductants used for refining are:propane(two), coal, wood,
hydrocarbon fuel, ammonia, propane/butane mixture with one each.
The majority of smelters use wheel type casting machines with casting rates
averaging at 62 mtph (compare 40.4 mtph in the last survey) with a low of 30 mtph and
a high of 100 mtph. Two smelters use Hazlett type casting machines.
The average anode weight has increased from 307 kg in the last survey to 329 kg
in the current survey. Only 68% of the smelters surveyed cast an anode within 60 kg of
the average weight of 329 kg.The anode weights ranged from a low of 200 kg to a high
of 418 kg. The Pirdop smelter casts anodes with two different weights, viz., 418 kg for
the Olen refinery and 242 kg for the Pirdop refinery. Similarly, the new Altonorte smelter
casts anodes of three different weights , 333 kg, 347 kg and 400 kg for CCR, Elmet and
Altonorte respectively. Two smelters-Onahama and Kidd Creek- using Hazlett machines
cast anodes of weights 140 kg and 182 kg respectively.
CONCLUSIONS
Operating data from 52 smelters have been compiled and presented here.Based
on the figures in this survey, South America leads the list with 21% of the production.
Europe, Japan , North America,Asia have 16.2%,15.7%,14.5% and 12.9% share of the
total world production respectively.Asia’s share would increase considerably after the
completion of the expansion plans of Sterlite Copper and Indo Gulf Fertilizers. China’s
current share of 9.7% would increase to 10.4% after the commissioning of the Jinchang
smelter this year.
The current survey indicates that a major share of the copper production has
shifted to Asia and this has been accompanied by a steady decrease in production in
North America. The main reason for this shift seems to be the relatively low cost of
production in Asia .
ACKNOWLEDGEMENTS
The authors wish to thank all the smelters and their staff for participating in this
survey and their contributions are gratefully acknowledged. Our special thanks are due
to Mrs Vasanti Ramachandran without whose help in the computer area and collation
of all the survey data, this paper would not have seen the light of the day.
REFERENCES