Search Documents

By Marc Lonoff

Byproducts are more important to the copper mining companies than to the copper market. Copper ores frequently contain gold, silver, molbydenum and cobalt. With the increase in the prices of these metals copper mining has become more profitable. If byproduct prices remain high, additional firms will be attracted to the copper industry; the increased supply of copper will reduce the long-run copper price. However, this is unlikely to happen because the markets for the copper byproducts, especially molybdenum and cobalt, are small. Increased recovery from copper and other sources will depress the prices of these byproducts before the copper price is significantly affected. Should byproduct prices remain high the copper market will both settle at a lower long-run price and be more unstable in the short run. Since changes in the copper price do not affect the entire earnings of a multi-metal mine, the copper price must fall further before such mines reduce output in the short run. Higher byproduct revenues will make copper supply less responsive to copper price; shifts in copper demand will result in greater copper price fluctuations in the short run than they did before.

Jan 1, 1980

In this paper, the recovery of copper minerals and molybdenite in the rougher/scavenger banks of two separate mineral processing plants is compared with recovery in laboratory (batch) cells. A number of metallurgical surveys were conducted in two plants treating porphyry copper and molyb-denum ore. Batch flotation tests were performed on plant conditioned flotation feed slurry, in parallel with the plant metallurgical surveys. The effect of flotation feed density on recovery of copper minerals and molybdenite in the plant and batch laboratory cells was investigated. Changes in flotation pulp density had little effect on copper mineral recovery, in both plant and laboratory cells. The ultimate recovery for molybdenite, on the contrary, increased considerably when the pulp density was reduced, both at plant and laboratory scale. Recovery of copper minerals in the plant and laboratory cells was comparable, while molybdenite recovery in laboratory flotation cells was 3%~13% higher than in plant. It is hypothesised that the flotation rate of molybdenite is sensitive to cell hydrodynamic conditions (i.e. local turbulent energy dissipation) more than the flotation rate of copper. The flotation behaviour of molybdenite particles is likely to be predominantly controlled by bubble-particle collision frequency, which is enhanced in high local turbulent energy dissipation environment. For chalcopyrite, the flotation recovery is mostly determined by attachment and stability efficiencies. An increase in local turbulent energy dissipation, while increasing collision efficiency, may negatively impact on attachment and stability efficiencies. The outcomes may have a considerable impact on increasing molybdenite recovery from porphyry ores.

Jan 1, 2014

By G. K. Manning, P. C. Rosenthal

USE of copper as an intentionally added alloy in steel and cast iron has rapidly expanded with-in the last fifteen years. It is estimated that in 1931 not more than 2000 tons of copper were so used; by 1941, however, this figure had grown to 13,000 tons. Tonnage figures during the war years have been restricted just as copper itself has been restricted, but copper-bearing cast irons and steels have played a part in the production of ordnance equipment. They are used in gun carriages, airplane landing-gear assemblies, scout cars, bulldozing equipment, army trucks, armor plate and many other instruments of war. These wartime applications have their counterpart in many peacetime applications; derricks, dredges, mine equipment, railway equipment, trucks, farm implements, automobiles, and tractors, all usually contain some parts made of copper-bearing steel or iron. An example of this is the Ford tractor which in 1940 contained over 300 lb. of copper-bearing steel castings. To this list should be added corrugated building sheet for exterior use most of which, at the present time, contains upward of 0.15 per cent copper. With the return to peacetime economy and the removal of wartime restrictions, it appears certain that copper cast irons and steels will find increasing application in civilian goods.

Jan 1, 1945

By Mauricio Guimarães Bergerman

At the regrind or secondary grinding stages of base metal ores, the concern about energy efficiency is usually extremely important. In general, the specific energy consumption at this stage is higher than during the primary grinding stages. In addition, a tendency of finer grinding has been observed in the new projects of metallic minerals, due to the finer mineral liberation, which leads to increasing capital and operational costs. At Vale?s new copper projects in Brazil, regrind sizes with a P80 of approximately 40 to 20 µm have been necessary. Conventional ball mills, adequate for primary grinding, usually bring about low energy efficiency with products bellow 50 µm. Vale is using the vertical mill on its copper projects ? Sossego and Salobo, in order to optimize the regrind of rougher concentrates and reduce energy consumption. This paper presents the results of industrial surveys carried out on the Vertical mill circuits of Sossego plant during its initial years of operation, and compares these results with the design criteria and laboratory regrind tests used for the mill scale up. Keywords: grinding, regrinding, copper, vertical mill, stirred mill

Sep 1, 2012

By E. L. Forner, G. M. Miller, J. Scheepers, A. J. du Toit

"The sizing, designing, and costing of copper electrowinning circuits requires an in-depth understanding of the fundamental relationships between circuit parameters and the practical operation requirements. The aim of this investigation was to optimize total copper electrowinning project cost by mapping the operating limits of key mechanical equipment. The model was compiled by mapping various cellhouse layouts in terms of number of cathodes per cell, crane productivity, stripping machine productivity, and rectifier–transformer (rectiformer) sizing using data tables for sensitivity analysis. These parameters were then collated and evaluated on a cost by size basis. The model provides an optimum band of operation for cellhouse productivity and project capital cost for a typical range of production throughputs, from 10 kt/a to 200 kt/a cathode copper. The information may be used as a high-level selection guide to assist with identifying a costeffective copper electrowinning circuit design for a specific production rate. The data was validated and compared with existing copper electrowinning cellhouses around the world that typically install no more than 84 cathodes per cell. IntroductionThe sizing, designing, and costing of copper electrowinning (EW) circuits require an indepth understanding of the fundamental parameters as well as the practical requirements to optimize cellhouse productivity and capital cost. Although a significant amount of work has been done designing new copper electrowinning circuits, an in-depth evaluation of world operating data reveals that the number of cathodes per cell, which affects cellhouse layout and productivity, is not consistent for a specific production rate (Anderson et al., 2009; Robinson et al., 2003, 2013). Based on this premise, Kafumbila (2017) suggested that there are unanswered questions, such as ‘why are the numbers of cathodes per cell different for copper production rates of 20 kt/a and 40 kt/a?’In this paper, data tables are employed to map the operating limits and costs of key Cu EW equipment. An overall Cu EW project cost map is then compiled by collating optimum cellhouse layout (number of cathodes per cell), optimum crane productivity, optimum"

Nov 1, 2018

By E. P. Wiechrnann, C. M. Castro, G. A. Vidal

In copper Eta plants the optimal current density setpoint depends on the electrolyte composition and temperature. However, conventional plants operate with large standard deviations. A value of 14% with current densities offsets up to ±50% is typical. For worst, during opencircuit or shortcircuit events this variation can be from -100% to +200%. Naturally, energy consumption and copper quality are compromised. Several devices have been successfully employed to reduce set point deviations. Last developments include; Optibar Segmented Intercell Bars, Outotec Electrodes Arranging Method and NTC Selective Electrodeposition Enhancers. This paper researches and compares these technologies. It is shown that short circuits can be effectively reduced in occurrence and magnitude. Moreover, 95% of the electrodes can be forced to operate within ±10% of the set point. The specific energy consumption is reduced from 2,000 KW per Ton to values close to 1,900 KW per Ton.

Jan 1, 2011

By W. G. Davenport

Changes in copper extraction from 1960 till today are documented. The top ten changes have been: (a) replacement of reverberatory smelting by high intensity oxygen rich smelting (b) growth of the Outokumpu flash smelting to over 50% of the world's smelting capacity (c) successful development of single furnace coppermaking but only for low slag fall concentrates (d) replacement of the batch Peirce-Smith converter by continuous converting, but only in a few cases (e) increased SO2 capture throughout the industry, mainly-as sulfuric acid (f) development of low initiation temperature `big bight' Cs catalysts for treating the continuous high-SO2 strength gases from continuous smelting/converting (g) complete replacement of reverberatory anode scrap and cathode melting furnaces by the Asarco shaft furnace (h) adoption of stainless steel permanent cathodes and automated stripping technology for electrorefining and electrowinning (i) complete elimination of wire bar casting by continuous bar casting/rod rolling (j) development and adoption of extractants for turning weak impure leach solutions into strong pure electrolytes. It is postulated that the biggest possible change over the next 20 years would be complete replacement of smelting/converting by hydrometallurgical processing. However, this seems unlikely due to copper purity, precious metal recovery, and economic concerns. The increasing value of sulfuric acid to many copper companies gives chalcopyrite smelting/oxide-supergene leaching a nice synergy especially with the energy credits now coming from continuous smelters, and their acid plants.

Jan 1, 1999

By Segnit E. R

Results are reported of a study of the reactions occurringin the combustion of chaIcopyrite particles underconditions simulating those in the shaft of a flashsmelter.The reactions were studied using kinetic and mineralogicaltechniques. Reactions. rates above 500°C wererapid, most of the reaction taking place in less than 50ms. Final products were copper-iron ferrites with spineltype structures. Probable reaction mechanisms are discussed.

Jan 1, 1977

By C. J. Burkhalter, H. Andrade, T. C. A. Gardner, J. P. Campbell

During the 1990’s several copper heap leach facilities treating crushed and agglomerated oxide and sulfide ore were constructed in South America. The majority of these facilities have been in operation for at least three years, during which time the operators have been able to monitor the performance of the heaps. The basis for the paper is a compilation of these operators’ experiences, leading to a discussion of the lessons learned over the past decade. Several key geotechnical issues are examined, focusing upon the integrity of the ore, drainage material and pipe network, along with the success of any inter-lift liners.

Jan 1, 2002

By Robert :H. . Lesemann

I recently gave a talk at a seminar on mine development in the Eighties. I had to present CRU' s long-range market outlook for copper, lead, zinc, nickel, molybdenum and silver. In reviewing the recent history of each metal, and our projections, I tried to find some common pattern of behavior that could prove a guide in projecting future market behavior. When you sweep aside your input-output models and econometric equations, what you seem to be left with is this: "When a market goes through a prolonged period of price weakness, you can usually look forward to a period of considerable improvement. " "When a market goes through a prolonged period of price strength, you can always anticipate a prolonged period of price weakness." Stated another way, "The better things are, the worse they will get."

Jan 1, 1982

By Jaeheon Lee, Junmo Ahn, Jiajia Wu

In this project, low grade copper ore samples were obtained from two mining sites in the US, and they were chalcopyrite-rich (sample A) and conichalcite-rich (sample B) ore. Copper grades were 0.6% and 0.4% for the two samples, A and B, respectively. Leaching experiments were conducted by bottle roll tests for 24 hours, and various lixiviant systems were applied. Methanesulfonic acid (MSA) and glycine were used as alternative lixiviants to sulfuric acid. Oxidants including ferric ion and hydrogen peroxide were tested. The results showed the copper extraction of sample A increased after adding 1 g/L ferric ion in sulfuric acid and MSA solution, from 20% to 36%, but further increase was not observed with higher ferric ion concentration. The copper recovery increased significantly with H2O2 concentration, and over 80% copper recovery was obtained with 10% H2O2. For sample B, the copper dissolution kinetics were relatively fast and reached the maximum value in five hours. Around 60% copper were extracted in sulfuric acid and MSA solution. Copper recovery slightly increased after adding ferric ion and H2O2. Glycine is a weaker lixiviant for both samples, the copper extractions were 36% and 4% respectively. INTRODUCTION Chalcopyrite is the most abundant copper sulfide mineral on earth, and it is one of the most refractory copper minerals regarding chemical processing. The declining copper grade and depletion of copper oxide deposits stimulate the development of hydrometallurgical process to extract copper from chalcopyrite. The dissolution of chalcopyrite by ferric ion is normally illustrated as Equation (1) and (2) (Dutrizac & MacDonald, 1974): CuFeS2 + 4Fe3+ → Cu2+ + 5Fe2+ + 2S0 (1) CuFeS2 + 4Fe3+ + 3O2 + 2H2O → Cu2+ + 5Fe2+ + 2H2SO4 (2) However, slow kinetics are usually observed from chalcopyrite leaching at ambient temperature and pressure. Researchers attribute the slow kinetics to passivation during chalcopyrite dissolution, and different passivation products are also proposed (Klauber, 2008). In recent years, many efforts have made to develop new methods to extract copper from chalcopyrite, such as utilizing bacteria or stronger oxidant (Zhao et al., 2015; Ruiz-Sánchez & Lapidus, 2017).

Jan 1, 2019

By ?. ?ivkovic

The silicate slag and copper matte that are the byproducts of smelting copper in a reverberatory furnace contain SiO2, FeO, Fe3O4, CaO and Al2O3, and Cu, Fe and S, respectively. These components influence the oxide (Cuox), sulfide (Cusul) and total (Cutotal) copper content lost in the waste slag. This paper uses multiple linear regression analysis (MLRA) to determine the degree of influence. The results of calculations obtained using MLRA were compared to actual measured results and found to have a large degree of correspondence, with the coefficient of determination R2 = 0.975. These results indicate that slag composition and copper content in the matte influence the copper losses in the waste slag with a probability of above 97%. It was determined that, of the total copper content of the slag, 74% is in sulfide and 26% in oxide form, and that this ratio is not dependent on the slag or matte composition.

Jan 1, 2010

By David B. George

Kennecott Utah Copper adopted Outokumpu Flash Smelting and Kennecott-Outokumpu Flash Converting in 1995, a process based on granulating high grade copper matte. While nickel mattes and very small quantities of copper matte had been commercially granulated for years, no large scale copper matte granulation system had been built. This paper summarizes the history and benefits of copper matte granulation, the Kennecott design basis, the successful operation for over 10 years and potential problems inherent in some matte granulation approaches.

Jan 1, 2006

Copper ores are widespread through the Lachlan Geosyncline in New South Wales, but the size of the orebodies is generally small. The largest deposits occur in the Cobar district where an iron-rich copper ore type has been developed in Silurian sediments. Similar de- . posits to the south in the Nymagee-Mt. Hope-Melrose districts are related to quartz feldspar porphyries of probable Upper Silurian age. Deposits to the east in the Tottenham-Girilambone districts are less complex mineralogically and are possibly related to an ultra-basic source.Copper mineralization in the Highlands further to the east is often developed in Ordovician andesite or MiddleUpper Silurian acid volcanic sequences. The deposits in andesite contain considerably less galena than those in the acid extrusives; a small proportion of the mineralization in the latter has texture, mineralogy, and geologic setting analogous to the Captain's Flat copper-Iead-zinc deposit, for which both syngenetic and epigenetic origins have been proposed. Very little copper mineralization occurs within granitic material, even though rocks of this type ranging from Silurian to Carboniferous in age crop out through much of the geosyncline, and the extent of the metal contribution from plutons to the deposits in volcanics is open to question. Numerous deposits are known in the contact zone around Mid-Devonian and Mid-Carboniferous granites, however, and the formation of these orebodies has undoubtedly been influenced by plutonic activity. Small occurrences of copper with associated minor nickel sulphides are developed in a narrow serpentinite belt of possible Lower-Middle Devonian age in the southern section of the Highlands.

Jan 1, 1970

By Both R. A, Daily B

The Patawarta Diapir, located in the northern Flinders Ranges (South Australia), has intruded into late Proterozoic Wilpena Group sedimentary rocks. The diapir contains disrupted blocks of a wide variety of rock types, most of which can be correlated with the Lower Callanna Beds of Willouran age, in a matrix of predominantly carbonate and siltstone breccia. Mafic rocks in the diapir appear to predate intrusion of the diapir. As with many other diapirs in the Flinders Ranges, copper mineralization is present in the diapir and occurs as narrow veins consisting essentially of carbonate with chalcopyrite and pyrite that formed after diapiric intrusion.Fluid inclusion studies demonstrate that the mineralizing fluid was a Na-Ca-K-Cl brine; probably derived by expulsion of interstitial water following emplacement of the diapir, with dissolution of evaporites within the Callanna Beds sediments and enrichment in copper by reaction with these sediments and associated basic igneous rocks. Mineral assemblages combined with fluid inclusion and geochemical data indicate a possible environment of vein formation of T ÿ 165°C, pH ÿ 4.3 ± 0.9 and log fO2 ÿ -47.3 ± 0.5. Sulphur isotope analyses indicate d34Sfluid ÿ 10 per mil, suggesting evaporites in the Proterozoic sediments as the major source of the sulphur but with some additional sulphur from an igneous source, possibly leached from the malic rocks of the diapir.

Jan 1, 1986

By E. D. Gardner

From the standpoint of tonnage and dollar value copper is the most important nonferrous metal mined in North America. The opening of copper mines has had an important bearing on the development and settlement of many sections of the continent. The prosperity of many of the mining States or provinces depends directly upon the copper-mining industry. Normally, about 35,000 men are employed in the copper mines, mills, and smelters of the United States. The United States is the most important producer of copper among the nations; more copper is mined in North America than in any other continent, and for many years the United States alone produced about half of the copper of the world. During the last 10 years increasing production in South America and Africa has reduced the relative importance of North America and the United States.

Jan 1, 1938

By S. Acar, M. Botz

Introduction In 2007, Newmont Mining Corporation will begin construction of a milling and cyanidation leaching circuit for the Yanacocha site in Peru. Ore to be processed in the circuit contains a relatively high level of cyanide-soluble copper, and as a result, leach solutions are expected to contain elevated levels of copper and WAD cyanide. As the means of controlling copper levels in leach solution, a circuit will be installed to precipitate copper sulfide from barren solution using sodium hydrosulfide. In addition, a circuit will be installed to recover cyanide from barren solution, with recovered cyanide to be returned to the leaching circuit and treated solution to be utilized as make-up in existing heap leaching facilities. As needed to support design of the copper precipitation and cyanide recovery circuits, pilot testing was conducted in 2005 to determine preferred operating conditions and evaluate the performance of the processes. This paper presents results from the pilot testing where 99% copper reduction was achieved and 95% to 98% cyanide recovery was achieved.

Jan 1, 2007

By Simon D. Strauss

This article is part of a presentation Strauss made Dec. 3, 1988 at the sixth annual American Mining Hall of Fame (AMHofF) banquet in Tucson, AZ. At the banquet, the Mining Club of the Southwest honored Strauss by naming him the 1988 recipient to the AMHofF. (Industry newswatch, page 6). Introduction In the last two decades, there have been two previous periods of sharply rising copper prices. One was in 1973-74; the other in 1979-80. In both cases, a short period of high copper prices was followed by steep and prolonged periods of low prices. In the language of the market analyst, the high prices were called spikes. Is it likely, then, that three or four years from now the present price of copper will show up as a spike in the charts? There are substantial differences between the current position and the markets of 1973-74 and 1979-80. In 1973-74, US copper prices were subject to government-imposed price ceilings of $0.60 per lb through early December, 1973. These were increased to $0.68 per lb through May, 1974. Meanwhile, mines outside the United States were free of restraint. Rising demand in London pushed the price above $1 per lb in the third quarter of 1973. In early April 1974, it reached a peak of $1.50 a lb. In May of that year, the US ceilings were removed and the domestic price began to rise. What were the causes of this price strength? While ceilings held the domestic price below the world market, domestic consumers acquired all the tonnage offered by US mines. Meanwhile, in the world market, buyers feared prolonged shortages. The Club of Rome had warned that world economic growth would be limited by impending depletion of mineral resources. There was al so concern about a copper cartel that might increase copper prices even more. In early 1974, at a special United Nations session, developing-country spokesmen warned the industrialized world to expect high commodity prices. Also adding to the concerns of copper buyers was the fear that when US wage contracts expired in mid-1974, protracted strikes might ensue. The combined effect of this atmosphere was that consumers accumulated large amounts of copper, far above their normal carry. By midsummer, the position changed radically. While some strikes did occur in the United States, they proved short-lived. The most significant development was a massive economic recession. The energy crisis was causing enormous dislocations in the world economy. Construction activities were sharply reduced and automobile sales plummeted. Public confidence was shaken. Copper sales fell precipitately as consumers decided to draw down their swollen inventories. The price came down too. In April 1974, the London price- as noted-was $1.50 per lb. By the end of the year, it was down to $0.57 per lb. In 1973-74, the copper price rise was fed by fears of shortages, cartels, and strikes. In 1979-80, the market rose on the strength of good demand plus political and military instability. The price rise was also fed by inflationary trends, exemplified by speculation in precious metals. Prior to this second spike in copper prices, the market had been depressed despite economic recovery. Despite reduced US output, copper production in the rest of the world was increasing. Though consumption was rising, surplus stocks reached unprecedented levels. At the end of 1977, the aggregate of stocks at the refineries and in the exchange warehouses was 1.5 Mt (1.67 million st). That was more than three months' shipments at then rates of consumption. In 1978, the statistical position improved. Shipments of refined copper that year were 8% greater than in 1977. The result was reduced visible stocks but -just as was to be the case in 1984-86 - the price remained depressed. In 1979, an even sharper drop in visible stocks occurred as shipments rose by another 4%. This time, though, the price responded. In December 1978, the price in current dollars had been less than $0.70 per lb. By the end of 1979, it was above $1 per lb. And in the first quarter of 1980, it averaged more than $1.20 per lb. Military and political developments were a factor. The hostage crisis in Iran was followed by the Soviet invasion of Afghanistan. To many, it appeared that war might result if the Soviets pushed on into Pakistan. At the same time, speculation drove gold and silver prices to incredible levels. As silver prices rose above $40 per oz), copper above $1 per lb did not seem unreasonable. Then, in March 1980, the precious metals price boom collapsed. Copper prices also retreated, though not as much. In February 1980, the copperprice averaged $1.32 per lb. By December, it had dropped to $0.85 per lb. In 1981 and 1982, the decline continued. The present copper situation Why is the current situation different from these two previous episodes of high prices? First of all, today's inventories are far lower than they were in either 1974 or 1980, when the price declines began. The stocks at refineries and in exchange warehouses are substantially less than they were then. More significantly, consumers today have very limited holdings compared with stocks they carried in 1974 and 1980. Even if faced with a downturn in their own business, copper consumers will not be able to stay out of the market. To the extent they have any business at all, they will have to buy copper. And on the supply side, there is also a significant difference. The year 1988 has been unusual. US production is up sharply, responding to higher prices. But production is little changed in the rest of the Free World. Indeed, several of the major producing countries have mined less copper this year than in 1987 despite the prices increases. Peru has had labor problems that have cut its output. Zambia and Zaire suffer from shortages of expatriate technicians, not to mention spare parts. They also suffer from the failure to maintain equipment or perform adequate development. In Chile, the two largest mines, Chuquicamata and El Teniente, have not met their production targets. Chuquicamata is struggling with high arsenic content in its ore. And, in late 1987, severe rockbursts hampered operations at El Teniente. In addition, depletion of some mines in Australia and South Africa has offset rising output at other properties. Indeed, when final mine output figures for 1988 become available, it may well be

Jan 1, 1989

By Leons Kovisars

Two-thirds of the world copper produced in 1979 incurred cash costs between $0.35 and $0.89 per lb, averaging $0.62 per lb. North American costs are higher at $0.48, $0.88, and $0.68 per lb, respectively. Variable cash costs are $0.20, $0.58, and $0.39 per lb for the world; $0.29, $0.63, and $0.46 per lb for North America. Cash costs are relevant for comparing existing operations and evaluating market pricing during periods of excess supply. Analysis of full costs of production (cash costs plus income taxes, profit, and non-cash items) becomes relevant in evaluating the incentive price required to develop new production plants. In mid-1979 this cost (incentive price) was about $1.10 per lb; it is expected to approach $2.00 per lb by 1985.

Jan 1, 1979

The observation of lower-than-predicted Fe/Cu ratios in the cementation of copper on iron in tests at elevated temperatures indicated that some other reaction was contributing to the reduction of cupric sulphate in addition to the reduction by elemental iron. Experiments showed that the copper sponge, which initially formed on the iron, subsequently reduced the cupric sulphate giving the products cuprous oxide and sulphuric acid.Tests were undertaken to determine the rate and equilibrium conditions of the reduction reaction with variations in the types of the reducing agent and solution parameters. The reaction first became apparent at temperatures above 50°C and as it ceased at pH 1·8 it was possible to induce further reaction by alkali addition.

Jan 1, 1974