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By Gary Walters, Matthew White, Thomas W. Gonzales

The copper smelting industry has transitioned into the 21st century compliant with environmental regulations, new smelter installations and brown field expansions. The industry faces new challenges as copper in concentrate grades have decreased while contained impurities have increased. A new benchmarking survey was undertaken to update the last survey of 2016 for operating copper smelters in the world. The information collected was separated based on primary smelting technology rather than by geographical location and supplemented from published literature. Each smelting technology’s unique use of specialized process equipment, concentrate smelting capacity, and impurity flexibility are discussed INTRODUCTION The 20th century was a remarkable time for the growth of copper smelting. Electric, blast and reverberator furnaces dominated the smelting technology well past WWII. In the 1970s, SO2 regulations and high energy cost drove the development of new primary smelting technology. Technological advancements decreased energy consumption and enriched sulfur dioxide concentrations of the process off-gas to levels where sulfur capture in sulfuric acid plants was economically viable. The new smelting technologies began to replace reverberatory and electric furnaces starting in the late 1940s. A new paradigm in copper smelting was established and the enabler was then Outkumpu’s® flash smelting technology from the 1940s through to today. Now, Outotec had become the dominant primary smelting technology with over 44 copper flash smelting furnace installations world-wide. Figure 1 shows the historical installation statistics of primary smelting technologies over the last 70 years (ICSG 2018). The dominance and acceptance of the Outotec® smelting technology from the 1940s to current can be seen. Isasmelt® technology for copper was introduced in the 1970s and did not see advancement in new installations until the 1990s through today. Isasmelt® has 12 world-wide copper furnace installations to date. Mitsubishi® also introduced continuous smelting and converting technology in the 1970s, but had no new installations until the 1990s with a total of 5 copper smelters. Outotec Ausmelt® smelting technology had 3 installations in the 1990s and totals 10 furnaces. Most recently the Chinese technology of Bottom Blown and Submerged Lance Smelting began commercial operations in 2005 for total installations of 11, mostly in China. Other technologies, such as, El Teniente, Noranda, Inco, and Vanyukov furnaces have contributed to the overall global smelting capacity, but have not penetrated the smelting industry to challenge the existing dominant smelting technologies. The technology distribution in Figure 1 also shows flash smelting technology for sulfide concentrate domination untill 2000, bottom blow technology has become the preference in China. Currently, China is the only country building new smelting capacity. Isasmelt® technology also seen a large increase in installations in the current decade.

Jan 1, 2019

By Ali Bunjaku, Lauri Pesonen, Hannu Johto

It is well known that there are many ways to process copper concentrates into copper anodes using the pyrometallurgical route. All modern copper smelting technologies are fundamentally energy efficient and environmentally safe options, and therefore choosing one depends on the desired capacity range, feed impurity levels, plant location, flexibility needs, overall energy use, and of course smelter economics in both the short and long term. This paper focuses on comparing different solutions which have potentially the lowest variable opex (operational expense), meaning in practice finding out which technology offers the best chances for profit maximization under certain scenarios. For the comparison, we chose to have a closer look at Outotec Flash Smelting (FSF) – Peirce-Smith Converting (PSC), Outotec Flash Smelting (FSF) – Outotec- Kennecott Flash Converting (FCF), Outotec Ausmelt TSL Smelting (ASF) - Peirce-Smith Converting (PSC), Outotec Ausmelt TSL Smelting (ASF) - Outotec Ausmelt TSL Converting (ACF), Mitsubishi Smelting Process (MIT), Bottom Blowing Reactor (BBR) – Bottom Blowing Continuous Converting (BCC), and Side Blowing Furnace (SBF) - Top Blowing Converting (TBC) since these seem to be the main state-of-art technologies now being applied in many recent copper smelter projects around the world. The work was carried out by modelling each smelting route by using the new HSC SIM 9 simulation software and applying operation time, energy, and consumables consumption numbers for each unit process and stream. Combined with cost data, the exercise produced a rich set of information which will be shown in detail for each area per scenario. The authors’ goal here was to provide a fair comparison where each technology can be evaluated from various perspectives such as electricity use or refractory consumption. INTRODUCTION Copper can be produced either pyrometallurgically or hydrometallurgically. The hydrometallurgical route is used only for a limited amount of the world’s copper production (~20%) and is normally only considered in connection with in-situ leaching of copper ores. On the other hand, most of the copper extraction from Cu-Fe-S minerals is pyrometallurgical (~80%) (Schlesinger 2011, ICSG 2017). Thus, several different processes can be applied for copper production, including the following state-of-the-art technologies: Outotec Flash Smelting (FSF) – Outotec-Kennecott Flash Converting (FCF) Outotec Flash Smelting (FSF) – Peirce-Smith Converting (PSC) Outotec Ausmelt TSL Smelting (ASF) - Peirce-Smith Converting (PSC) Outotec Ausmelt TSL Smelting (ASF) - Outotec Ausmelt TSL Converting (ACF) Mitsubishi Smelting Process (MIT) Bottom Blowing Reactor (BBR) – Bottom Blowing Continuous Converting (BCC) Side Blowing Furnace (SBF) - Top Blowing Converting (TBC)

Jan 1, 2019

By T. A. Apelt, B. J. Elliot

"In September 1993, the flash furnace at Kalgoorlie Nickel Smelter, KNS, was brought off line after almost 12 years of operation. This is a record campaign life for a flash furnace. The furnace was' totally rebuilt and the capacity of the plant increased from 540 000 tpo to 750 000 tpa of concentrate throughput. The throughput increase was' achieved through the construction of a 525 t/day oxygen plant and upgrading of various plant ancillaries. A number of significant design modifications were also built into the flash furnace and oxygen enrichment was implemented in the operation of the Peirce-Smith converters.This paper discusses the rebuilding of the flash furnace and design modifications made to furnace equipment and ancillary plant. Some preliminary post-startup operating data are presented.IntroductionIn September 1993, Campaign 6 of the flash furnace was concluded and the furnace brought off line for rebuilding. The campaign length was almost 12 years and set a new record for campaign length. Planning for the rebuild took place over the last five years of the campaign. A number of modifications to the design of the furnace and the ancillary plant were planned to coincide with the furnace rebuild. The furnace was rebuilt and recommissioned in 70 days. The increased plant capacity of 750000 tpa has been achieved by the construction of a 525 t/day oxygen plant and modifications made to ancillary plant which centred around increased p~ control, efficiency and hygiene. This paper examines the development and implementation of the modifications made to the furnace and ancillary plant. Preliminary post-shutdown performance data are presented."

Jan 1, 1995

By Audrey Wagenaar

Introduction ?? Rising public pressures are being placed on companies worldwide to protect the environment and the health and safety of their workers and local communities. ?? International bodies and shareholders want to make sure developments and companies can meet internationally acceptable standards for EHS. In 2005, Golder Associates was asked by the IFC to conduct a comprehensive review and update for their Environmental Health & Safety Guidelines including the mining sector.

May 1, 2008

By J. Oliveira, A. R. Barnes, R. Pandher

Sub-stoichiometric roasting of arsenic-bearing copper ores is a well established practice. However, ores containing calcium commonly prove challenging where very low arsenic levels are desired, but the reasons for this phenomenon have largely been speculative. In the course of treating arsenicbearing copper ores by partial roasting in fluid bed reactors, XPS encountered one of these Ca-bearing ores which proved a challenge to roast to acceptably low levels of arsenic. Mineralogical examination of the calcines using a combination of XRD (X-ray diffraction), QEMSCAN (Quantitative Evaluation of Materials by Scanning Electron Microscope) and EPMA (Electron Probe Micro-Analysis) helped to identify the arsenic bearing species and assisted in developing a workable theory on the sequence of reactions occurring during the roast. With the assistance of thermo-chemical modelling, this allowed adjustment of the roasting conditions to minimise the amount of arsenic retention in the calcine in spite of the presence of calcium in the ore and advance the roasting program to a commercially acceptable solution.

Jan 1, 2014

By Robert A. Creaser, Iain Mitchell, Robert L. Linnen

Abstract - The Bermuda Zn-Pb showing is hosted by dolomitized Blue Fiord Formation of Devonian age, located east of the Ensorcellement dome on the Grinnell Peninsula of Devon Island. Fluid inclusions in hydrothermal calcite indicate that the mineralization precipitated from low-temperature, highly saline brines. The ?34S compositions of sphalerite, galena, and marcasite range from 16.1‰ to 35.2‰. Consequently, the Bermuda showing is interpreted to be Mississippi Valley-type (MVT) mineralization. The apparent age of mineralization has been determined by the Rb-Sr method from sphalerite separates, and a Late Devonian age of 357 ± 50 Ma (MSWD=65), with an initial 87Sr/86Sr ratio of 0.7083 ± 0.0020 is indicated. This date, within error, is the same as the Polaris deposit. This suggests that the mineralization formed during the Ellesmerian Orogen, although it is also possible that mineralization is associated with extension, related to the opening of the Sverdrup basin. The strontium and sulfur isotopes and fluid inclusion analyses indicate the involvement of a brine that acquired its salinity from interaction with evaporites, lower in the stratigraphic succession. The Polaris mine is the type deposit in the Cornwallis Zn-Pb district and is hosted by the Thumb Mountain Formation. The results of this study are significant because they demonstrate that regional brine movement is more widespread than previously recognized, and that MVT mineralization in the Cornwallis Zn-Pb district is not restricted to the Thumb Mountain Formation.

Jan 1, 2004

By R. A. McIvor, R. S. Rafuse

"INCO Limited purchased a custom designed mobile hoist rope winder/tensioner in 1988 from TimberLand Equipment Limited to handle Large hoist ropes and serve as an emergency hoist. This paper describes the operation of the winder/tensioner and some of the different applications that the machine has been used to handle large loads.IntroductionINCO Limited operates 24 mine hoists in the Ontario Division and has approximately 50 miles of mine hoist rope hanging in the shaft plus an equal amount on spare reels. The mine hoist ropes range in size from )( inch to 2.305 inches in diameter with the majority being 1 3/4 inches and above. Prior to the procurement of a new high powered winder/tensioner in 1988, the mine hoist ropes were handled with a variety of methods and equipment using hydraulic or pneumatic powered reel winders. The largest such reel winder has a pull rating of 8000 Ibs and travels approximately 40 ft/min. Head ropes for the tower mounted friction hoists were installed and removed using a magazine on the hoist drum to wind and unwind the rope because the loads were greater than the capacity of the existing machinery. It was recognized that a large high capacity machine would improve the productivity for handling the larger hoist ropes and a feasibility study was undertaken to determine the parameters for such a machine."

Jan 1, 1995

By S. Shokri

The increasing size and complexity of mega construction projects result in having several geographically distributed stakeholders, collaborating with each other to successfully deliver the project. Electronic Product and Process Management Systems (EPPMS) are recently emerging to facilitate the collaboration between stakeholders, reduce the surprises and issues, and improve the project productivity. These are commercially successful but evolving systems. An important component of EPPMS is the Interface Management System, which aims at formalizing and automating the communication channels between stakeholders. An interface is generally considered the link between construction elements, phases, or stakeholders. An interface Management System (IMS) involves five iterative steps: (1) Interface Identification, (2) Interface Documentation, (3) Interface Transferring, (4) Interface Communication, and (5) Interface Closing. A fundamental part of step 2 is recognizing different roles in dealing with interfaces. Each stakeholder is assigned a different role, such as responsible, accountable, consulted, and informed. In a mega project, several thousands of interfaces exist with complex relationships between stakeholders. Therefore, identifying stakeholders with higher responsible roles has been requested as useful information to the project owner in dealing with some of the project risks. After the interfaces are determined, and the responsibilities are allocated, the critical stakeholders are identified using the centrality concept in Social Network Analysis. The critical stakeholders can be determined at the highest level, considering all types of interfaces, as well as for each specific type or discipline-related interfaces. The proposed methodology is applied on a hypothetical offshore project with over 500 interfaces. In fact, this project is a simplified representation of a real scale Liquid Natural Gas project. In order to reduce the complexity of calculations and clarity of explanations, the simplified case study is used. By implementing IMS in mega projects, different parties not only formalize the communication between each other, but also gain better visibility concerning their roles and responsibilities. In addition, the owner benefits from analysing the complex relationships between stakeholders to further identify critical ones, along with other criteria like package cost, stakeholders? experiences, etc.

Aug 1, 2013

Fiabilité Totale d?Usine (FTU) Plan de la présentation ?Théorie de l?entretien ?Analyse comparative juin 2005 ?Session de travail 2005-2006 ?Suiviet Résultats(IndicateursdePerformance)

Feb 1, 2008

By H. J. Meyer

"A hydrostatic elevation difference meter has been developed for use in measuring elevations along gravity traverses. Elevations of stations 100 feet apart can be obtained at a rate of 1/2 mile per hour and to an accuracy better than 1/3 foot. This can be done along traverses which have not been cut and chained. The instrument is durable, lightweight and constructed of materials which will withstand any temperature encountered in field work.It is believed that this device will more than double the rate at which gravity surveys over mining prospects can be carried out."

Jan 1, 1972

By H. Weissenbaeck, B. Nowak, M. Oesterreicher, R. Stastny

The producers of certain metals like nickel and cobalt increasingly face a shortage of easy-to-mine and easy-to-process ore bodies. Their focus is shifting towards alternative raw materials which in turn demand new, different extraction techniques. One potential route for processing a ferrous ore with a non-ferrous target metal is atmospheric leaching with hydrochloric acid followed by purification of the pregnant leach solution (PLS). For the separation of iron from the PLS, and, in turn, the extraction of the non-ferrous compounds, the following flow sheet is proposed. Pre-concentration of the PLS, oxidation of ferrous (if present) to ferric chloride, hydrolysis of ferric chloride leading to the precipitation of hematite and the evaporation of hydrochloric acid, followed by crystallization of non-hydrolysable metal chlorides by means of sparging hydrogen chloride into the solution. Hydrogen chloride required in the latter step is produced internally by super-azeotropic distillation of regenerated hydrochloric acid. The liquid filtrate from the crystallization step is recycled to hydrolysis. Depending on the specific composition of the PLS, the hematite produced contains only traces of other impurities, whereas the crystallized mix of non-hydrolysable metal chlorides – containing also the target metal in enriched form – contains ferric chloride only in an amount referring to the filter cake moisture. These crystals can then undergo further hydrometallurgical separation and extraction processes. As an example, this flow sheet is proposed for treating nickel laterite ores. Experiments related to the demonstration of crucial assumptions in the flow sheet are presented. Based on those experiments a mass and energy balance of the flow sheet was calculated and is presented here together with a table of the major consumables in order to provide a basis for an operating cost estimate and other process economics.

Jan 1, 2016

By T. Sun, J. Kou, C. Sun, China Railway Resources Group Limited

"The polymetallic sulfide ore in Jiama county of Tibet contains 0.78% Cu, 0.046% Mo, 0.31 g/t Au and 17.9 g/t Ag in average. However, heavy loss of valuable metals was observed using high-pH process and Butyl xanthate as the collector. In this paper, the flotation was optimized through the adoption of a novel collector C-7, which is a mixture of xanthate ester and thionocarbamate. This collector showed better flotation performance under weak base conditions. The recoveries of Cu, Mo, Au and Ag increased to 93.24%, 84.60%, 78.13% and 75.41%, respectively, under 15 g/t of C-7 at pH of 8.0. The adsorption mechanism of C-7 was investigated by micro-flotation tests, zeta potential measurements, FTIR analysis and adsorption quantity measurements. Chemisorption of C-7 on chalcopyrite surface is demonstrated with adsorption density 3.8 times higher than on pyrite.INTRODUCTIONXanthates are the most commonly used collectors of strong collecting ability for separating copper sulfide minerals from gangue in froth flotation. However, the selectivity of xanthates themselves is poor to realize separation of chalcopyrite and pyrite whose floatability are quite similar (Heyes & Trahar, 1977; Chandraprabha, Natarajan, & Modak, 2004). High pH process with xanthates as collectors is proved effective in copper-sulfur separation and is widely used in treatment of copper sulfide ore flotation (Smith, 1996; Valdivieso, Cervantes, Song, Cabrera, & Laskowski, 2004). This method could get ideal separation results, but large amount of lime must be added, and could bring about increased cost, device corrosion and environmental pollution. In addition, there could also be high depression and heavy loss of associated noble metal such as Mo, Au and Ag. Consequently, a large amount of research has been conducted on substitutions of xanthates for selective flotation of copper sulfide ores under low pH conditions (Gholivand, Khodadadian, & Ahmadi, 2010; Li, 2010)."

Jan 1, 2016

By Mike McKevitt

We are trying to promote a concept and a change in management?s approach to the iterative process of grade control. This is important as grade control must routinely try and achieve the long term objectives set by the mine plan ??BackgroundBackground ??Factors contributing to variation from planFactors plan ??Basis of OptimisationBasis Optimisation ??Ore Block Optimisation processOre process ??Operating mine examplesOperating examples ??Chain of Mining. ??Intention is to highlight the need for repeatable and consistent materialand material-type classification to remain consistent with the Life of Mine Plan ??We can drill another hole or reWe re-optimise a plan, but once excavated, the final decision has been made ??The grade control decision is the last decision made in the resource exploitation sequence.

May 1, 2009

? The Mining Association of British Columbia (MABC) was established through an Act of Parliament in 1901 ? The MABC represents the interests of B.C.?s ? Coal and mineral mining companies ? Smelting companies ? Advanced stage development projects ? Key areas of work: ? Environment, Health and Safety ? Policy & Government Relations ? Knowledge and Information Services

May 1, 2008

By Lastram Rolando, Larry J. Hulbert, Louis J. Cabri, J. H. Gille Laflamme, John L. Campbell, Soey H. Sib, Chris G. Ryan

"The mineralogy of samples from the Wellgreen Cu-Ni-Pt-Pd deposit, Yukon Territory, is complex and the metals of interest are contained within fine-grained minerals which vary in size and mineral associations from sample to sample.The major Ni carriers are pentlandite and violarite; the major Cu carrier is chalcopyrite. About 700/0 of the major Ni carriers and 78% of the major Cu qurier will be liberated at a grind of 80% -U,.7 ,an (-500 mesh) for typical low-grade gabbro (West zone, sample No.1). For typical ""clinopyroxenite"" (West zone, sample No.2) and typical ""clinopyroxene-rich peridotite"" (East zone, sample No.3) the liberation would be 71% and 65% for Ni, 74% and 60% for Cu, respectively. Fine grinding, however, cannot liberate the Ni contained in silicates and pyrrhotite, estimated to total 24.5% for typical low-grade gabbro (West zone, sample No. I), 15% for typical ""clinopyroxenite"" (West zone, sample No.2), and 12% for typical ""clinopyroxene-rich peridotite"" (East zone, sample No.3).The principal Pt carrier (sperrylite) varies considerably in grain-size between samples and fine grinding, required to liberate the major Ni and Cu carriers, may be counterproductive in samples where sperrylite is relatively coarse-grained, as some would then be unrecovered (e.g. sample No. 1). In addition, sperrylite in samples No.2 and No.3 is closely associated with magnetite. Palladium occurs in diverse ways. It occurs in the form of several Pd minerals (e.g. sudburyite, testibiopalladite, merenskyite), as a replacement for Ni in several tellurides, antimonides and tellurantimonides (e.g. melonite), or as very low concentrations in pentlandite (up to 34 ppm), chalcopyrite (up to 9 ppm), and pyrrhotite (up to 5.6 ppm). Palladium minerals and Pd-bearing minerals are strongly associated with chalcopyrite in sample No. 1 and will thus report to a Cu concentrate.However, 22% of the total Pd is in solid solution in pentlandite in this sample and will thus report to the Ni concentrate. In samples No.2 and No.3, less Pd occurs in solid solution in pentlandite, and the PGM are distributed mainly among pentlandite, chalcopyrite, and magnetite in sample No. 2, and among pentlandite, pyrrhotite, chalcopyrite, and magnetite in sample No.3. Therefore, the feasibility of magnetic concentration should be investigated for samples like No. 2 and No.3, in order to improve Pt and Pd recoveries. Rhodium was found to occur as rare hollingworthite, in sparse cobaltite (up to 2.7%) and, as low concentrations in chalcopyrite (to 10 ppm) and pentlandite (to 12 ppm) by proton microprobe. Iridium occurs in hollingworthite (up to 7.8%) and very rarely as the native metal or in an undefined Re-Ir-Qs..Ru alloy. Ruthenium was determined by proton microprobe analyses to occur in pentlandite (up to 13 ppm) and chalcopyrite (up to 10 ppm), in addition to rare laurite and Re alloy."

Jan 1, 1993

By S. Zakaria

"Inco's Automated Haulage Truck System (AHT) is a revolutionary automatic guided vehicle that performs all load, haul and dump operations without human intervention. The high level of sophistication and the short period it has been in operation has only allowed a select few Inco personnel to become familiar with the ART operation and maintenance. As an aid to operations an expert system using the knowledge gained from the experienced specialists was implemented in the field.The AHT operating and maintenance assistance expert system will reason through the information given, arrive at conclusions and give advice to operations, technical and management personnel. It will provide comprehensive real-time troubleshooting assistance for the hydraulic, electrical and mechanical subsystems of the ART. The ART expert system has many benefits to Inco which include increased skill levels of ART operations and maintenance personnel, reduction in ART downtime, standardization of troubleshooting procedures and reduction in ART operating and maintenance costs. In the future, the expert system application will be linked to SCADA (Supervisory Control and Data Acquisition), maintenance and statistical software to display current and historical trends of variables from a centralized historical database. As well, a wide variety of features will be integrated into the system including AutoCad drawings, graphics, photographs, voice and video capabilities."

Jan 1, 1994

By J. H. Rickard, D. H. Watkinson

"Abstract - Detailed petrographic and quantitative (electron microprobe, SEM-EDS) mineralchemical analyses of sulfide ore from the 100 orebody at the Copper Cliff North mine, Copper Cliff, Ontario, reveal numerous stages of ore development. Sharp contacts between weakly mineralized quartz diorite and blebby to massive sulfides indicate multiple intrusive events within the Copper Cliff offset dike. A spatial association of sulfides and hydrous minerals, such as amphibole, biotite, chlorite and epidote, suggests that most primary ore has been affected by later hydrothermal fluids. Sulfides are often enclosed or bordered by these secondary silicate phases. The ore consists primarily of pyrrhotite, pentlandite, chalcopyrite, with trace michenerite, cobaltite/gersdorffite, irarsite, hessite, tsumoite, and bismuth tellurides.Geological and petrological comparison of the 100 orebody and the adjacent 900 and 890 orebodies has revealed distinct similarities in ore distribution. Data show that the 100 orebody is depleted in platinum-group elements (PGE) relative to the 900 orebody. Platinum-group elements from the 100 orebody may have been hydrothermally remobilized and partly emplaced in the 900 orebody, in adjacent veins, or in magmatic breccia. Analysis of Cu, Ni, and PGE assay data of ore samples has characterized their distribution among the eight different ore textures in the orebody. There is a strong association between Pt and interstitial sulfide, and to a lesser extent massive sulfide, but little correlation between chalcopyrite-rich ore and PGE in the 100 orebody, unlike many other deposits in the Sudbury region."

Jan 1, 2001

By M. Hall

"SomarioEl circuito de molienda a Selbaie consta de molino semiaut6geno en un circuito cerrado y molino de balas en un circuito cerrado. El amperaje del motor de se usa controlar el tonelaje el molino. Este sistema estabiliza el circuito pero no mejora activamente el rendirniento del circuito. Se desarroll6 auxiliar el rendimiento del circuito un sistema experto en manipular las objetivos de existir control proporcional-integral. Se ejecut6 el sistema con el Comdale /C conjunto del sistema experto y ha side funcional hace tiempo el mayo de 1992. El sistema experto ha resultado en un aumento en tonelaje de 7tph y una disminuci6n de $210,000 en el caste anual de media de molienda. Se describe el desarrollo del sistema y los provechos derivar se presenta.AbstractThe grinding circuit at Selbaie consists of SAG mill and ball mill closed circuit grinding. The SAG mill motor current is used to control throughput. This system stabilizes the circuit but does not actively optimize circuit performance. An expert system was developed to aid the optimization of the circuit by manipulating the set-points of existing PI control loops. The system was implemented with the Comdale /C expert system package and has been on line since May 1992. The expert system has resulted in a net increase in tonnage of 7tph and a decrease in annual grinding media costs of $210,000. The system development is described and the benefits derived are presented."

Jan 1, 1994

By H. Sakurai, M. Kato, F. Tanaka

The Mitsubishi Continuous Copper Smelting/Converting Process employs an electric furnace (CL- furnace) for settling the slag/matte mixture formed in the smelting furnace. The conditions in the CL- furnace change its settling efficiency, resulting in high variability of copper losses in slag. Modifications of the operation and maintenance procedures for the CL-furnace have significantly and sustainably reduced the copper losses in Gresik smelter to below 0.7%. A series of flow patterns evaluation in the CL-furnace demonstrated how the chemical reactions and settling conditions of the CL-furnace has been improved by the new operating procedures. Settling mechanisms for the matte droplets in the CL-furnace is also discussed using image analysis of solidified slag. INTRODUCTION The Mitsubishi Continuous Copper Smelting/Converting Process employs an electric furnace (CL- furnace) for settling the slag/matte mixture formed in the smelting furnace. Since the top-blowing in the S- furnace agitates the molten bath strongly, matte droplets are dispersed over the slag phase when melts flow out of the S-furnace. Thus, the CL-furnace has an important role to settle and recover matte droplets efficiently. Since many papers have ascribed major part of copper losses to matte droplets suspended in slag (Tanaka 2007; Genevski et al., 2008; Starodub et al., 2016), flow patterns of slag in the CL-furnace can affect greatly on the profitability of smelters which have adopted the Mitsubishi process. PROCESS DESCRIPTION Figure 1 illustrates the Mitsubishi process schematically. The Mitsubishi process is the only system for continuous production of blister copper from copper concentrates and consists of 3 furnaces connected by enclosed launders those ensure the minimum emission of fugitives. In a smelting furnace (S-furnace) copper concentrates are fed with flux, oxygen-enriched air to form a mixture of slag and matte which cascades down to a slag-cleaning furnace (CL-furnace). The CL-furnace settle matte droplets in the mixture on the crucible from which matte is siphoned to a converting furnace (C-furnace), while discharging the cleaned slag (CL-slag). The C-furnace converts matte to blister copper by the top-blowing of oxygen- enriched air.

Jan 1, 2019

By A. Uribe-Salas, J. A. Finch, B. J. Huls

Froth depth or interface level is an important control variable in column flotation which can influence both grade and recovery. A common method of locating the level is based on sensing the hydrostatic pressure at one or more points along the column. The level indicated can be in considerable error, largely because of variations in froth and collection zone bulk densities. A portable conductivity probe has been developed to detect the position of the interface from conductance measurements across the interface. The location of the interface corresponds to the position where a large change in conductance is observed, which is primarily a consequence of the difference in gas holdup between the collection and froth zone. This probe detects the position of the interface to an accuracy of ± 5 cm. The probe can be used while the column is in operation, which allows for on-line recalibration of the level detection system. Results obtained in its application in a pilot-scale column (0.91 m in diameter) are described.

Jan 1, 1990