Extractive Metallurgy of Copper

Preface to the Second Edition Preface to the First Edition Acknowledgments1 Synopsis 1.1 Introduction 1.2 Extraction of Copper from Sulphide Ores 1.3 Extraction of Copper from Oxide Ores 1.4 Melting and Casting of Copper 1.5 Miscellaneous Copper Processes 1.6 Summary of Chapter Suggested Reading and References2 Production Statistics, Ores, Beneficiation 2.1 Copper Statistics 2.2 Beneficiation of Copper Ores 2.3 Comminution 2.4 Froth Flotation 2.5 Specific Flotation Procedures for Copper Ores 2.6 The Flotation Product 2.7 Improvements in Flotation Practice 2.8 Summary of Chapter Suggested Reading and References 3 Roasting of Copper Concentrates 3.1 Roasting Prior to Smelting 3.2 Roasting Prior to Leaching 3.3 Chemistry of Roasting 3.4 Choice of Roasting Temperature 3.5 Kinetics of Roasting 3.6 Roasting Furnaces and Methods 3.7 Summary of Chapter Suggested Reading and References 4 Matte Smelting 4.1 Physical Chemistry of Matte Smelting 4.2 Formation, Constitution and Characteristics of Matte 4.3 Formation, Constitution and Characteristics of Slags 4.4 The Smelting Criterion: Separating Matte from Slag 4.5 Magnetite in Matte Smelting 4.6 Behavior of Other Metals during Smelting 4.7 Summary of Chapter Suggested Reading and References 5 Blast-Furnace Matte Smelting 5.1 Process Description 5.2 Reactions in the Blast Furnace 5.3 Recent Developments in Blast Furnace Smelting 5.4 Summary of Chapter Suggested Reading and References Appendix 5A The TORCO (Segregation) Process 6 Reverberatory-Furnace Matte Smelting 6.1 Description of Process 6.2 Construction Details 6.3 Combustion, Temperatures, Heat Balances 6.4 Production Rates 6.5 Charging Methods 6.6 Reverberatory Slags 6.7 Magnetite Formation and Hearth Control 6.8 Recent Developments in Reverberatory Smelting 6.9 Summary of Chapter Suggested Reading and References 7 Electric-Furnace Matte Smelting 7.1 Advantages and Disadvantages 7.2 Description of Process 7.3 Construction Details 7.4 Electrical System 7.5 Μatte and Slag Conductivities, Automatic Power Control 7.6 Power Input, Productivity, Temperature Control 7.7 Energy Requirements and Costs 7.8 Slag and Hearth Control 7.9 Summary of Chapter Suggested Reading and References 8 Flash-Furnace Matte Smelting 8.1 Advantages and Disadvantages 8.2 INCO Oxygen Flash Smelting Process 8.3 Outokumpu Flash Smelting Process 8.4 Heat Balances for Flash Smelting 8.5 Comparison of INCO and Outokumpu Processes 8.6 Computer Control of Flash Smelting 8.7 Future of Flash Smelting 8.8 Use of Oxygen in Flash Smelting 8.9 Summary of Chapter Suggested Reading and References 9 Converting of Copper Matte 9.1 Stages of the Converting Process 9.2 Magnetite Formation in the Converter 9.3 Industrial Converting Operations 9.4 Recent Developments in Copper Converting 9.5 Summary of Chapter Suggested Reading and References 10 Copper Losses in Slags 10.1 Magnitude of the Copper-loss Problem 10.2 Copper Losses in Smelting Furnace Slags 10.3 Treatment of Flash-furnace Slags 10.4 Treatment of Converter Slags 10.5 Summary of Chapter Suggested Reading and References11 Continuous Production of Blister Copper: Single-step and Multistep Processes 11.1 Single-step Processes 11.2 Noranda Process 11.3 W or era Process 11.4 Mitsubishi Process 11.5 Comparison of Continuous Copper-making Processes 11.6 Summary of Chapter Suggested Reading and References 12 Preparation of Anodes: Sulphur and Oxygen Removal 12.1 Industrial Methods of Anode Preparation 12.2 Chemistry of Fire Refining 12.3 Choice of Hydrocarbons for Deoxidation 12.4 Casting of Anodes 12.5 Summary of Chapter Suggested Reading and References13 Hydrometallurgical Copper Extraction: Introduction and Leaching 13.1 Leaching: Ores and Reagents 13.2 Chemistry of Leaching Processes 13.3 Bacterial Leaching of Sulphides 13.4 Leaching Methods 13.5 Discussion of Leaching Methods 13.6 Summary of Chapter Suggested Reading and References14 Recovery of Copper from Dilute Leach Solutions: Cementation and Solvent Extraction 14.1 Cementation 14.2 Solvent Extraction 14.3 Use of Solvent Extraction for Strong Leach Liquors 14.4 Summary of Chapter Suggested Reading and References15 Electrolytic Relining of Copper 15.1 Principles of Electrolytic Copper Refining 15.2 Behavior of Anode Impurities 15.3 Industrial Tankhouse Equipment 15.4 Tankhouse Procedures 15.5 Control of the Refining Process 15.6 The Electrolyte 15.7 Purification of Electrolyte 15.8 Organic Additions to Electrolyte 15.9 Current Density and Production Rate 15.10 Recent Developments in Electrorefining 15.11 Summary of Chapter 15.12 Suggested Reading and References Suggested Reading and References16 Electrowinning of Copper 16.1 Electrowinning Reactions 16.2 Cell Voltage and Energy Consumption 16.3 Cathode Current Efficiency: Interjering Iron Reactions 16.4 Purity of Cathode: Behavior of Electrolyte Impurities 16.5 Electrowinning Tankhouse Practice 16.6 Special Problems of Solvent Extraction Electrolytes 16.7 Recent Improvements in Electrowinning Practice 16.8 Summary of Chapter Suggested Reading and References 17 Melting and Casting; Quality Control; Recovery of Copper from Scrap 17.1 Melting and Casting of Cathode Copper 17.2 Melting Techniques 17.3 Casting into Fabrication Shapes 17.4 Continuous Casting 17.5 Southwire Continuous Rod and Hazelett Contirod Systems 17.6 Quality Control of Final Copper Product 17.7 Recovery of Copper from Scrap 17.8 Smelting and Refining of Low-grade Scrap 17.9 Summary of Chapter Suggested Reading and References 18 The Sulphur Problem and Possible Solutions 18.1 The Fixing of SO2 18.2 SO2 Concentrations in Smelter Gases 18.3 Hydrometallurgical Answers to the Sulphur Problem 18.4 Discussion and Summary of Chapter Suggested Reading and References 19 Costs of Extracting Copper 19.1 Overall Capital Costs: Mine to Refinery 19.2 Overall Direct Operating Costs: Mine to Refinery 19.3 Total Production Costs: Selling Prices: Profitability 19.4 Beneficiation Costs 19.5 Smelting Costs 19.6 Electrorefining Costs 19.7 Costs of Hydrometallurgical Processes 19.8 Discussion and Summary of Chapter Suggested Reading and ReferencesAppendixes A.I Units and Conversion Factors A.II Stoichiometric Data A.III Thermodynamic Data A.IV Properties of Electrolytic Tough Pitch CopperIndex