COPPER

Copper is an element mineral

called native copper.

Found in chile, indonasia and

USA.

Also found in Loei and Khonkhan

but not in much quantity.

Copper is an industrial metal

widely used in unalloyed and

alloyed conditions.

It is mostly used in buildind

constructions and electronic

products.

Open-cut Copper Mining

Open-cut pit – the rock is drilled and blasted then removed by a truck and shovel operation. The ore is processed to separate the copper.

Ernest Henry Mine Cloncurry Queensland image courtesy of Xstrata Copper

Location of Copper Mines

Underground Mining Process

Underground mining of copper occurs adjacent to the copper smelter in Mt Isa . In some cases remote controlled vehicles such as boggers are used underground.

Images courtesy of Xstrata Copper

EXTRACTION OF COPPER FROM

ORES

copper ores are normally

associated with sulphur in which

copper can be

chalcocite(Cu2S),cuprite

(Cu2O) and chalcopyrite(CuFeS2)

.

There are two types of extraction

prcesses:

1. Pyrometallurgical

2. Hydrometallurgical

Cu2S

CuFeS2 Cu2O

Mineral Separation

A ROD and BALL MILL contains the ore and heavy steel balls which break the rock up until it resembles a fine powder.

Images courtesy of Xstrata Copper

Froth Flotation Process

• Crushed ore is mixed with water, detergents and other chemicals

• Finely powdered mineral clings to air bubbles and floats to the surface

• Waste rock sinks to the bottom • Copper concentrate is transported to

the thickeners to remove excess water

• Dried concentrate is transported to the stacker for storage before use

• Waste rock is returned to the site • Water is re-used (as much as

possible).

Image source: Queensland Resources Council

Concentrating - Flotation

Image source: Queensland Resources Council

Smelting

• The process of taking the copper concentrate(CuFeS2) and reacting it with SiO2,

and O2 to produce slag (waste), copper matte and sulphur dioxide (gas).

• The SO2 is collected at several stages and is used to make sulphuric acid which is further processed into fertiliser.

• The matte copper is further treated in a copper converter.

Concentrates (CuFeS2) Flux (SiO2) Coal (C,H)

Oxygen (O2) Air (N2,O2) Natural Gas (C,H)

Isasmelt Furnace

Isasmelt Lance

Off Gases (CO2,SO2,H2O,N2)

10CuFeS2 + 15½O2 + 3½SiO2

5Cu2S + 3FeS (matte)

+ 3½Fe2SiO4 (slag)

+ 12SO2 (gas)

Rotary Holding Furnace

Smelting

Diagram courtesy of Xstrata Copper

Silica Ratios

• The correct amount of flux (SiO2) must be added or an efficient reaction does not occur.

• Too little silica results in the formation of magnetite (an iron oxide).

• Magnetite has a much higher melting point and can form a layer on top of the smelter causing damage to the smelter. It can also clog the vents from which the molten material is removed. Some magnetite is always made and it sticks to the walls of the smelter. This helps to protect the bricks.

• Too much silica makes the mixture too sticky.

Converting

Matte (Cu2S FeS)

Air (N2,O2)

Oxygen (O2)

Flux (SiO2)

Slag Copper Blow

Cu2S + O2 2Cu (blister)

+ SO2 (gas)

Blister

Copper

Slag Blow

2FeS + 3O2 + SiO2

Fe2SiO4 (slag)

+ 2SO2 (gas)

Off Gases (SO2)

Pierce

Smith

Converter

Diagram courtesy of Xstrata Copper

Slag Pouring

Image courtesy of Xstrata Copper

Casting

Image courtesy of Xstrata Copper

Transport of casted copper

Image courtesy of Xstrata Copper

REFINING OF COPPER

Blister copper is fire refined in

the process called poling to

produce tough pitch copper

which can be used for some

applications other than electrical

appliances.

Most of the impurities are

oxidised and slagged of in

refining process.

Copper Refining

Properties of copper

A GOOD ELECTRICAL CONDUCTOR

A GOOD THERMAL CONDUCTOR

CORROSION RESISTANT

EASILY JOINED

DUCTILE

TOUGH

NON MEGNETIC

EASY TO ALLOY

RECYCLABLE

CATALYTIC

MALLEABILITY

REASONABLE TENSILE STRNGTH

USES OF COPPER

PLUMBING SYSTEMS

ELECTRICAL CABLES

UTENSILS

DOOR KNOBS

EASILY SHAPED INTO PIPES

COPPER TROLLEY WIRES

COPPER PLATING

COPPER FINISHED PARTS

ELECTRONIC PRODUCTS

ALSO USED IN AUTOMOBILES

Copper and its Uses

Copper roofing

COPPER PRICES

copper prices has been

promoted by growing

demands from developing

nation.

Copper price rise has

affected the companies

producing its products.

CLASSIFICATION OF COPPER

AND COPPER ALLOYS

Copper + tin = BRONZE

Copper + zinc = BRASS

Other alloys formed are as

follows:

copper + lead

copper + nickle

copper + aluminium

copper + silicon

copper + berillium

Cu+Be Bronze Brass

CU+Si Cu+Al

Cu+Pb

THANK YOU PREPARED BY: PALAV PATEL ANJANI PAREKH AMI PONKIA KARNIKA PRAJAPATI KESHA SHETH NUPUR MANDANKA