From copper ore to pure copper with the power of TAKRAF and ABB equipment Dr. Mario Dilefeld Head of Belt Conveyor Systems Stockholm, 2017-05-03
Copper 2
3 Agenda 1. Introduction Copper used in construction industry, engineering, electrical industry and vehicle construction Copper price Copper winning counties and output capacity Sulfide and oxydic copper ore 2. Processing technology and material handling Blasting, truck loading, truck transport to primary crusher Crushing und ore transport to the stockpile Sulfide ore: crushing and grinding, flotation, shiploading Oxydic ore: crushing, agglomeration, leaching process
4 Agenda 1. Introduction Copper used in construction industry, engineering, electrical industry and vehicle construction Copper price Copper winning counties and output capacity Sulfide and oxydic copper ore 2. Processing technology and material handling Blasting, truck loading, truck transport to primary crusher Crushing und ore transport to the stockpile Sulfide ore: crushing and grinding, flotation, shiploading Oxydic ore: crushing, agglomeration, leaching process
System of Elements 5
History 6
7 Copper deposits Earth crust copper content: 0,006% Position 23 in material deposits abundance ratio Reserves: native copper (nuggets), oxydic ore or sulfide ore Oxydic ore Sulfide ore Mineral Formula Mineral Formula Cuprite Cu 2 O Malachite Cu 2 [(OH) 2 CO 3 ] Azurite Cu 3 (CO 3 ) 2 (OH) 2 Chalcopyrite CuFeS 2 Bornite Cu 5 FeS 4 or Cu 3 FeS 3 Chalcocite Cu 2 S Cuprite (Source Wikipedia) Malachite (Source Wikipedia) Azurite (Source Wikipedia) Chalcopyrite (Source Wikipedia) Bornite (Source Wikipedia) Chalcocite (Source Wikipedia)
Treasure Map 8
9 Fields of application Automotive industry 8% Others 7% Building and construction industry 39% Electrical industry 37% Mechanical engineering industry 9%
World copper production 10
11 Copper price development last 15 years last year 5.637,21 USD/t 2017-04-18 Source: www.finanzen.net
12 Copper output 2014 Copper Production (thousend tonnes) Source: Wikipedia Rank Country Capacity 1 Chile 5,750 2 China 1,760 3 Peru 1,380 4 USA 1,360 5 Australia 970
13 Copper producers Source: www.reuters.com
From Copper Ore to pure Copper 14
15 Agenda 1. Introduction Copper used in construction industry, engineering, electrical industry and vehicle construction Copper price Copper winning counties and output capacity Sulfide and oxydic copper ore 2. Processing technology and material handling Blasting, truck loading, truck transport to primary crusher Crushing und ore transport to the stockpile Sulfide ore: crushing and grinding, flotation, shiploading Oxydic ore: crushing, agglomeration, leaching process
16 Primary Crushing Station Fixed Crushing Station Semi-mobile Crushing Station Mobile Crushing Station
Gyratory Crusher Typical Design: 54 x74 (54 = 1370 mm Feed Opening x 74 = 1880 mm Mantle Base Diameter) Installed Power: 450 kw Manufacturer: FFE Minerals Metso Minerals Kobe Steel Ltd. Machine Sizes: 36 x67 up to 63 x114 Capacity: up to 8.000 t/h 17
18 Semi-Mobile Brecherstation, Collahuasi / Chile Surge Bin 500 t/h live capacity Discharge Conveyor 14,000 t/h capacity 3.0 m/s belt speed 2,400 mm belt width Gyratory Crusher 60 x113
Semi-Mobile Brecherstation, Collahuasi / Chile 19
Overland Conveyor 20
Stockpile 21
From Copper Ore to pure Copper 22
23 Copper winning with Sulfidic Ore Crushing & Conveying Primary Crushed Ore Copper Concentrate Grinding & Flotation Smelting & Refining
24 Flotation Los Pelambres Concentrator
25 Flotation Grinding (Ball mills are used to grind the ore particles down to 0,22 mm average particle size) Flotation Cells
26 Flotation Cell Fine particles will be mixed with water by the addition of a surfactant or collector chemical. Activation of minerals to be recovered The slurry will be aerated to produce bubbles Activated mineral particles attach to the air bubbles which rise to surface. The froth with a higher mineral content will be removed. Repeating of the procedure with the aim to reach a concentrate with 20-30% copper content TAKRAF DELKOR BQR Flotation Cell
Shiploading 27
28 Smelting and Electrolysis Source: Metals: Scarce: Base - Copper Production: Ore Processing: Sulfide Ore- Smelting-- Web Gallery Molten copper at the Mount Isa Mines Copper Smelter Source: Glencore
From Copper Ore to pure Copper 29
Copper winning with Oxydic Ore 30
31 On Off Leach Pad System Project Gaby Stacking-System Ripios Reclaiming and Dumping
32 On Off Leach Pad System - Project Gaby Stacking System Projekt Gaby, Chile
33 On Off Leach Pad System - Project Gaby Stacking System Projekt Gaby, Chile
34 On Off Leach Pad System - Project Gaby Reclaiming System Projekt Gaby, Chile
On Off Leach Pad System Project Gaby 35
36 On Off Leach Pad System Project Gaby Ripios Disposal System Projekt Gaby, Chile
On Off Leach Pad System Project Gaby 37
38 Solvent-Extraction source: https://superfund.arizona.edu/learning-modules/tribal-modules/copper/processing
Solvent-Extraction 39
Elektrolysis 40
Actual Projects: Gearless Conveyor Drives 41
Thank you 42