Biswas / Davenport / Hopkins Extractive Metallurgy of Copper

International Series on Materials Science and Technology
2. Auflage 2013
ISBN: 978-1-4831-8221-6
Verlag: Elsevier Science & Techn.
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 454 Seiten, Web PDF

Extractive Metallurgy of Copper details the process of extracting copper from its ore. The book also discusses the significance of each process, along with the concerns in each process, such as pollution, energy demand, and cost. The text first provides an overview of the metallurgical process of copper extraction, and then proceeds to presenting the step-by-step representation of the whole process of copper extraction. The coverage of the book includes mineral beneficiation, roasting, smelting, converting, refining, casting, and quality control. The text will be of great use to metallurgists, materials engineers, and other professionals involved in mining industry.

Professor William George Davenport is a graduate of the University of British Columbia and the Royal School of Mines, London. Prior to his academic career he worked with the Linde Division of Union Carbide in Tonawanda, New York. He spent a combined 43 years of teaching at McGill University and the University of Arizona. His Union Carbide days are recounted in the book Iron Blast Furnace, Analysis, Control and Optimization (English, Chinese, Japanese, Russian and Spanish editions). During the early years of his academic career he spent his summers working in many of Noranda Mines Company's metallurgical plants, which led quickly to the book Extractive Metallurgy of Copper. This book has gone into five English language editions (with several printings) and Chinese, Farsi and Spanish language editions. He also had the good fortune to work in Phelps Dodge's Playas flash smelter soon after coming to the University of Arizona. This experience contributed to the book Flash Smelting, with two English language editions and a Russian language edition and eventually to the book Sulfuric Acid Manufacture (2006), 2nd edition 2013. In 2013 co-authored Extractive Metallurgy of Nickel, Cobalt and Platinum Group Metals, which took him to all the continents except Antarctica. He and four co-authors are just finishing up the book Rare Earths: Science, Technology, Production and Use, which has taken him around the United States, Canada and France, visiting rare earth mines, smelters, manufacturing plants, laboratories and recycling facilities. Professor Davenport's teaching has centered on ferrous and non-ferrous extractive metallurgy. He has visited (and continues to visit) about 10 metallurgical plants per year around the world to determine the relationships between theory and industrial practice. He has also taught plant design and economics throughout his career and has found this aspect of his work particularly rewarding. The delight of his life at the university has, however, always been academic advising of students on a one-on-one basis. Professor Davenport is a Fellow (and life member) of the Canadian Institute of Mining, Metallurgy and Petroleum and a twenty-five year member of the (U.S.) Society of Mining, Metallurgy and Exploration. He is recipient of the CIM Alcan Award, the TMS Extractive Metallurgy Lecture Award, the AusIMM Sir George Fisher Award, the AIME Mineral Industry Education Award, the American Mining Hall of Fame Medal of Merit and the SME Milton E. Wadsworth award. In September 2014 he will be honored by the Conference of Metallurgists' Bill Davenport Honorary Symposium in Vancouver, British Columbia (his home town).

Autoren/Hrsg.

Biswas, A. K.

Davenport, W. G.

Hopkins, D. W.

Inhaltsverzeichnis

1;Front Cover;1
2;Extractive Metallurgy of Copper;4
3;Copyright Page;5
4;Table of Contents;6
5;Preface to the Second Edition;12
6;Preface to the First Edition;14
7;Acknowledgements;16
8;Chapter 1. Synopsis;18
8.1;1.1 Introduction;18
8.2;1.2 Extraction of Copper from Sulphide Ores;18
8.3;1.3 Extraction of Copper from Oxide: Ores Hydrometallurgy;35
8.4;1.4 Melting and Casting of Copper;37
8.5;1.5 Miscellaneous Copper Processes;37
8.6;1.6 Summary of Chapter;38
8.7;Suggested Reading and References;39
8.8;Reference;39
9;Chapter 2. Production Statistics, Ores, Benefìciation;40
9.1;2.1 Copper Statistics;40
9.2;2.2 Benefìciation of Copper Ores;49
9.3;2.3 Comminution;51
9.4;2.4 Froth Flotation;63
9.5;2.5 Specific Flotation Procedures for Copper Ores;69
9.6;2.6 The Flotation Product;72
9.7;2.7 Improvements in Flotation Practice;73
9.8;2.8 Summary of Chapter;77
9.9;Suggested Reading and References;78
9.10;References;78
10;Chapter 3. Roasting of Copper Concentrates;80
10.1;3.1 Roasting Prior to Smelting;81
10.2;3.2 Roasting Prior to Leaching;83
10.3;3.3 Chemistry of Roasting;84
10.4;3.4 Choice of Roasting Temperature;87
10.5;3.5 Kinetics of Roasting;88
10.6;3.6 Roasting Furnaces and Methods;89
10.7;3.7 Summary of Chapter;97
10.8;Suggested Reading and References;97
10.9;References;97
11;Chapter 4. Matte Smelting;99
11.1;4.1 Physical Chemistry of Matte Smelting;100
11.2;4.2 Formation, Constitution and Characteristics of Matte;102
11.3;4.3 Formation, Constitution and Characteristics of Slags;106
11.4;4.4 The Smelting Criterion: Separating Matte from Slag;108
11.5;4.5 Magnetite in Matte Smelting;114
11.6;4.6 Behaviour of Other Metals during Smelting;115
11.7;4.7 Summary of Chapter;116
11.8;Suggested Reading and References;117
11.9;References;117
12;Chapter 5. Blast-Furnace Matte Smelting;119
12.1;5.1 Process Description;120
12.2;5.2 Reactions in the Blast Furnace;123
12.3;5.3 Recent Developments in Blast Furnace Smelting;124
12.4;5.4 Summary of Chapter;127
12.5;Suggested Reading and References;128
12.6;Appendix 5A: The TORCO (Segregation) Process;129
12.7;References;131
13;Chapter 6. Reverberatory-Furnace Matte Smelting;132
13.1;6.1 Description of Process;133
13.2;6.2 Construction Details;138
13.3;6.3 Combustion, Temperatures, Heat Balances;140
13.4;6.4 Production Rates;144
13.5;6.5 Charging Methods;147
13.6;6.6 Reverberatory Slags;149
13.7;6.7 Magnetite Formation and Hearth Control;150
13.8;6.8 Recent Developments in Reverberatory Smelting;152
13.9;6.9 Summary of Chapter;155
13.10;Suggested Reading and References;155
14;Chapter 7. Electric-Furnace Matte Smelting;157
14.1;7.1 Advantages and Disadvantages;158
14.2;7.2 Description of Process;159
14.3;7.3 Construction Details;162
14.4;7.4 Electrical System;162
14.5;7.5 .atte and Slag Conductivities, Automatic Power Control;168
14.6;7.6 Power Input, Productivity, Temperature Control;169
14.7;7.7 Energy Requirements and Costs;171
14.8;7.8 Slag and Hearth Control;171
14.9;7.9 Summary of Chapter;173
14.10;Suggested Reading and References;174
14.11;References;174
15;Chapter 8. Flash-Furnace Matte Smelting;175
15.1;8.1 Advantages and Disadvantages;178
15.2;8.2 INCO Oxygen Flash Smelting Process;179
15.3;8.3 Outokumpu Flash Smelting Process;180
15.4;8.4 Heat Balances for Flash Smelting;183
15.5;8.5 Comparison of INCO and Outokumpu Processes;187
15.6;8.6 Computer Control of Flash Smelting;189
15.7;8.7 Future of Flash Smelting;193
15.8;8.8 Use of Oxygen in Flash Smelting;193
15.9;8.9 Summary of Chapter;194
15.10;Suggested Reading and References;195
15.11;References;195
16;Chapter 9. Converting of Copper Matte;196
16.1;9.1 Stages of the Converting Process;199
16.2;9.2 Magnetite Formation in the Converter;204
16.3;9.3 Industrial Converting Operations;205
16.4;9.4 Recent Developments in Copper Converting;213
16.5;9.5 Summary of Chapter;220
16.6;Suggested Reading and References;221
16.7;References;221
17;Chapter 10. Copper Losses in Slags;223
17.1;10.1 Magnitude of the Copper-loss Problem;224
17.2;10.2 Copper Losses in Smelting Furnace Slags;226
17.3;10.3 Treatment of Flash-furnace Slags;229
17.4;10.4 Treatment of Converter Slags;229
17.5;10.5 Summary of Chapter;235
17.6;Suggested Reading and References;236
17.7;References;236
18;Chapter 11. Continuous Production of Blister Copper : Single-step and Multistep Processes;238
18.1;11.1 Single-step Processes;239
18.2;11.2 Noranda Process;245
18.3;11.3 Worera Process;250
18.4;11.4 Mitsubishi Process;253
18.5;11.5 Comparison of Continuous Copper-making Processes;258
18.6;11.6 Summary of Chapter;260
18.7;Suggested Reading and References;261
18.8;References;261
19;Chapter 12. Preparation of Anodes : Sulphur and Oxygen Removal;263
19.1;12.1 Industrial Methods of Anode Preparation;264
19.2;12.2 Chemistry of Fire Refining;267
19.3;12.3 Choice of Hydrocarbons for Deoxidation;269
19.4;12.4 Casting of Anodes;272
19.5;12.5 Summary of Chapter;275
19.6;Suggested Reading and References;275
20;Chapter 13. Hydrometallurgical Copper Extraction : Introduction and Leaching;277
20.1;13.1 Leaching: Ores and Reagents;278
20.2;13.2 Chemistry of Leaching Processes;281
20.3;13.3 Bacterial Leaching of Sulphides;281
20.4;13.4 Leaching Methods;284
20.5;13.5 Discussion of Leaching Methods;292
20.6;13.6 Summary of Chapter;292
20.7;Suggested Reading and References;293
20.8;References;293
21;Chapter 14. Recovery of Copper from Dilute Leach Solutions: Cementation and Solvent Extraction;294
21.1;14.1 Cementation;295
21.2;14.2 Solvent Extraction;301
21.3;14.3 Use of Solvent Extraction for Strong Leach Liquors;314
21.4;14.4 Summary of chapter;315
21.5;Suggested Reading and References;315
21.6;References;316
22;Chapter 15. Electrolytic Relining of Copper;318
22.1;15.1 Principles of Electrolytic Copper Refining;318
22.2;15.2 Behaviour of Anode Impurities;321
22.3;15.3 Industrial Tankhouse Equipment;323
22.4;15.4 Tankhouse Procedures;329
22.5;15.5 Control of the Refining Process;331
22.6;15.6 The Electrolyte;332
22.7;157. Purification of Electrolyte;333
22.8;15.8 Organic Additions to Electrolyte;335
22.9;15.9 Current Density and Production Rate;336
22.10;15.10 Current Efficiencies, Voltages. Energy Requiremenrs;338
22.11;15.11 Recent Developments in Electrorefining;340
22.12;15.12 Summary of Chapter;344
22.13;Suggested Reading and References;345
22.14;References;345
23;Chapter 16. Electrowinning of Copper;347
23.1;16.1 Electrowinning Reactions;347
23.2;16.2 Cell Voltage and Energy Consumption;348
23.3;16.3 Cathode Current Efficiency: Intrerfering Iron Reactions;351
23.4;16.4 Purity of Cathode: Behaviour of Electrolyte Impurities;353
23.5;16.5 Electrowinning Tankhouse Practice;354
23.6;16.6 Special Problems of Solvent Extraction Electrolytes;355
23.7;16.7 Recent Improvements in Electrowinning Practice;356
23.8;16.8 Summary of Chapter;357
23.9;Suggested Reading and References;357
23.10;References;357
24;Chapter 17. Melting and Casting; Quality Control; Recovery of Copper from Scrap;359
24.1;17.1 Melting and Casting of Cathode Copper;359
24.2;17.2 Melting Techniques;362
24.3;17.3 Casting into Fabrication Shapes;367
24.4;17.4 Continuous Casting;370
24.5;17.5 Southwire Continuous Rod and Hazelett Contirod Systems;379
24.6;17.6 Quality Control of Final Copper Product;381
24.7;17.7 Recovery of Copper from Scrap;389
24.8;17.8 Smelting and Refining of Low-grade Scrap;390
24.9;17.9 Summary of Chapter;392
24.10;Suggested Reading and References;394
24.11;References;394
25;Chapter 18. The Sulphur Problem and Possible Solutions;396
25.1;18.1 The Fixing of SO2;398
25.2;18.2 SO2 Concentrations in Smelter Gases;403
25.3;18.3 Hydrometallurgical Answers to the Sulphur Problem;406
25.4;18.4 Discussion and Summary of Chapter;411
25.5;Suggested Reading and References;412
25.6;References;412
26;Chapter 19. Costs of Extracting Copper;414
26.1;19.1 Overall Capital Costs: Mine to Refinery;415
26.2;19.2 Overall Direct Operating Costs: Mine to Refinery;418
26.3;19.3 Total Production Costs: Selling Prices; Profitability;419
26.4;19.4 Beneficiation Costs;421
26.5;19.5 Smelting Costs;422
26.6;19.6 Electrorefining Costs;426
26.7;19.7 Costs of Hydrometallurgical Processes;428
26.8;19.8 Discussion and Summary of Chapter;430
26.9;Suggested Reading and References;431
26.10;References;431
27;Appendixes A.I: Units and Conversion Factors;432
28;Appendixes A.II:
Stoichiometric Data;433
29;Appendixes A.III:
Thermodynamic Data;435
30;Appendixes A.IV:
Properties of Electrolytic Tough Pitch Copper;444
31;Index;446