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(cufes 2 ) and reacting it with SiO 2, and O 2 to produce slag (waste), copper matte and sulphur dioxide (gas). The SO 2 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.
Smelting Off Gases (CO 2,SO 2,H 2 O,N 2 ) Oxygen (O 2 ) Air (N 2,O2) Natural Gas (C,H) Concentrates (CuFeS 2 ) Flux (SiO 2 ) Coal (C,H) 10CuFeS 2 + 15½O 2 + 3½SiO 2 5Cu 2 S + 3FeS (matte) Isasmelt Lance + 3½Fe 2 SiO 4 (slag) + 12SO 2 (gas) Isasmelt Furnace Rotary Holding Furnace 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 Flux (SiO 2 ) Off Gases (SO 2 ) Pierce Smith Converter Matte (Cu 2 S FeS) Air (N 2,O 2 ) Slag Blow Oxygen (O 2 ) 2FeS + 3O 2 + SiO 2 Fe 2 SiO 4 (slag) + 2SO 2 (gas) Slag Blister Copper Copper Blow Cu 2 S + O 2 2Cu (blister) + SO 2 (gas) 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