07-08. Copper Smelting
Zulfiadi Zulhan
Taufiq Hidayat
Imam Santoso
Department of Metallurgical Engineering
Faculty of Mining and Petroleum Engineering
Bandung Institute of Technology
INDONESIA
MG3111 Pyrometallurgy
October 2021
2Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Course Content
1. Introduction
2. Refractory
3. Slag
4. Material Preparation: Aglomeration, Drying, Calcination, Roasting
5. Carbo- / Aluminothermic (Metalothermic)
6. Smelting, Refining
7. Pyrometallurgy of Copper Production I
8. Pyrometallurgy of Copper Production II
9. Mid Exam
10. Pyrometallurgy of Zinc and Lead Productions
11. Pyrometallurgy of Tin Production
12. Pyrometallurgy of Nickel Production I
13. Pyrometallurgy of Nickel Production II
14. Production of Aluminium
15. Production of Magnesium and Titanium
16. Final Exam
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 3
Copper Properties
Why Copper is widely used?29
CuCopper
63.546
https://www.visualcapitalist.com/visualizing-coppers-role-in-the-transition-to-clean-energy/
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 4
Copper Properties
29
CuCopper
63.546
https://www.visualcapitalist.com/how-much-copper-is-in-an-electric-vehicle/
Why Copper is widely used?
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 5
Uses of Copper
Cables for home, office
and industrial usesPrinted copper circuit board
Heat sinks for motherboard Heat exchanger
A. Leibbrandt, “Civilizations and Copper”, 2001
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 6
Uses of Copper
Copper Development Association (2010)
0
5
10
15
20
25
Ap
pli
ca
tio
n (
%)
It’s electrical conductivity, thermal conductivity and
corrosion resistance are its most exploited properties.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 7
Copper Resources & Reserves
ICSG copper market forecast 2015/2016
▪ Resources = Natural occurrence of material in earth’s crust for which there is reasonable
prospect for current or eventual economic extraction
▪ Reserves = Part of a measured or indicated resource for which current economic
extraction has been demonstrated
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 8
Copper Production & Consumption
ICSG copper market forecast 2015/2016
Refined Copper Production
▪ In 2016, world refined copper
production reached 23.2 million ton Cu.
▪ 36.4% was produced in China
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 9
Copper Production & Consumption
ICSG copper market forecast 2015/2016
Refined Copper Consumption
▪ In 2016, world refined copper
consumption was 23.3 Million
ton Cu.
▪ Almost half of the world refined
copper was consumed in China
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 10
Copper in Nature
o The concentration of copper in an ore body is low. Typical copper ores contain
from 0.5% Cu (open pit mines) to 1 or 2% Cu (underground mines).
o Long-running trend shows that the grades of Cu in ores in different mines are
dropping.
https://www.visualcapitalist.com/the-looming-copper-supply-crunch/
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 11
Copper in Nature
o Copper is most commonly present in the earth’s crust as copper-
iron-sulfide and copper sulfide minerals, e.g. chalcopyrite
(CuFeS2), bornite (Cu5FeS4) and chalcocite (Cu2S).
o About 80% of the world’s copper-from-ore originates in Cu-Fe-S
ores.
o Cu-Fe-S minerals are not easily dissolved by aqueous solutions,
so the vast majority of copper extraction from these minerals is
pyrometallurgical.
Cu2S: ChalcociteCuS : Covellite Cu5FeS4:BorniteCuFeS2: Chalcopyrite
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 12
Copper in Nature
o Copper minerals contains impurities, such as:
o Cu12As4S13 : Tennantite
o FeS2 : Pyrite
o FeAsS : Arsenopyrite
o (Fe, Ni)9S8, … : Pentlandite
o SiO2 : Quartz
o Al2O3 : Alumina
o CaO : Lime
o MgO : Periclase
o It can also contains trace elements which can be valuable, such
as: Au and Ag.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 13
Copper Making Principles
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 14
Basic Reactions in Cu Production
CuFeS2
1) Oxidation of S into gas S+O2 → SO2 (gas)
2) oxidation of FeS → FeO / Fe3O4
3) conversion of Cu2S → Cu (liquid)
then to sulphuric acid H2SO4
O2O2
Fluxing with SiO2
Cu2O-FeO-Fe2O3-SiO2 slag
Side reaction – oxidation of Cu into slag: 2Cu(metal/matte)+0.5O2(g) → Cu2O(slag)
Crystal magnetite Fe3O4 barrier
E. Jak, Thermodynamic Principle of Pyrometallurgy of Copper, 2019
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 15
Steps in Cu Production
1. Beneficiation process → to liberate
and increase content of valuable
minerals to produce concentrate (20-
30%Cu).
2. Smelting process → to oxidize S
and Fe from the concentrate to
produce a Cu-enriched molten
sulfide phase (matte) (50-70%Cu).
3. Converting process → to remove
Fe and S from the matte to produce
crude molten copper (99% Cu).
4. Refining process → to remove S
and O from the crude molten copper.
5. Further processes →
Electrorefining, melting, and
fabrication.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 16
Smelting Process
Matte smelting oxidizes and melts flotation concentrate in a
large, hot furnace (~1250°C) .
The objective of the smelting is to oxidize S and Fe from
the Cu-Fe-S concentrate to produce a Cu-enriched molten
sulfide phase (matte). The oxidant is almost always
oxygen-enriched air.
CuFeS2(s) + (0.5+1.5x)O2(g) + ySiO2(s) →
0.5Cu2S–(1-x)FeS(l) + x"FeO"–ySiO2(l) + (0.5+x)SO2(g)
Cu2S(l) + 1.5O2(g) = Cu2O (l) + SO2(g)
Main reaction:
Side reaction:
Exothermic reaction!!
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 17
Smelting Process
Gas/solid, gas/liquid & liquid/liquid contacting mechanisms -
FeS
H2O
SiO2 Al2O3
CuFeS2
BLEND(Concentrate + Flux)
Cu2S
Cu2S-xFeS
MATTE
SO2
O2
N2
GASESH2O
Heat
AIR
(O2 , N2)
Flux
(SiO2 )
OXYGENFeO-ySiO2
Fe3O4
SLAGCu2O, Al2O3
Cu2S
Matte : Sulfide-rich melt
Slag : Oxide-rich melt / Solution of molten oxides
Flux : Additive to control the physico-chemical properties of slag
E. Jak, Thermodynamic Principle of Pyrometallurgy of Copper, 2019
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 18
Smelting Process
CuFeS2(s) + (0.5+1.5x)O2(g) + ySiO2(s) →
0.5Cu2S–(1-x)FeS(l) + x"FeO"–ySiO2(l) + (0.5+x)SO2(g)
Concentrate Blast Flux
Matte Slag Gas
Main reaction:
Gas (S2, O2, SO2)
Liquid Cu-Fe-S matte
Solid
Liquid “FeO”-SiO2 slag
Furnace Lining
Cu2O Al2O3
CaO
MgO
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 19
Smelting Process
Scanning Electron Image of Matte-Slag Mixture
Liquid Matte
Gas
HoleHole
SiO2
SiO2
“Fe3O4”
Matte entrained
in slag
• Cu2O in slag = chemical Cu loss
• Matte entrained in slag =
physical Cu loss
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 20
Smelting Process
Compositions of industrial concentrates, fluxes, mattes, slags and
dusts for various matte-smelting processes, 2001
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 21
Converting Process
Copper converting is oxygen enriched-air or air oxidation of
the molten matte from smelting. It removes Fe and S from the
matte to produce crude (99% Cu) molten copper.
The converting takes place in two sequential stages:
(a) Slag forming stage (FeS elimination) when Fe and S are
oxidized to form FeO, Fe3O4 and SO2. Silica flux is added to
form a liquid slag. The slag-forming stage is finished when the
Fe in the matte has been lowered to about 1%. The principal
product of the slag-forming stage is impure molten Cu2S,
‘white metal’, ~1200°C.
Reaction:
Cu2S–xFeS(l) + ySiO2(s) + 1.5xO2(g) =
Cu2S(l) + x"FeO"–ySiO2(l) + xSO2(g)
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 22
Converting Process
(b) The blister copper forming stage (copper making) when
the sulfur in Cu2S is oxidized to SO2. The blister copper
product of converting is low in both S and O (0.001-0.03%S,
0.1-0.8%O).
Reaction:
Cu2S(l) + O2(g) = 2Cu(l) + SO2(g)
Copper making stage doesn't occur until the matte contains
less than about 1% Fe so that most of the Fe can be removed
from the converter (as slag) before copper production begins.
Significant oxidation of copper does not occur until the sulfur
content of the copper falls below ~0.02%. Blowing is
terminated near this sulfur end point. The resulting molten
'blister' copper (1200°C) is sent to refining.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 23
Converting Process
Reactions:
Gas (S2, O2, SO2)
Liquid Cu2S or Cu
Solid
Liquid Cu2O-“FeO”-SiO2 slag
Furnace Lining
(a) Cu2S–xFeS(l) + ySiO2(s) + 1.5xO2(g) =
Cu2S(l) + x"FeO"–ySiO2(l) + xSO2(g)
(b) Cu2S(l) + O2(g) = 2Cu(l) + SO2(g)
White metal
BlastFlux
Matte
Slag Gas
White metal Blast GasCopper
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 24
Converting Process (Slag Forming Stage)
Scanning Electron Image of White Metal-Copper Mixture
Copper
Copper
White metal
GasSlag
Fe3O4
Fe3O4
Copper
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 25
Converting Process
Compositions of converter raw materials and products, mass%
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 26
Fire Refining Process
The molten blister copper from Peirce-Smith converting
contains ~0.01% S and ~0.5% O. At these levels, the
dissolved sulfur and oxygen would combine during
solidification to form bubbles ('blisters') of SO2 in newly
cast anodes – making them weak and bumpy.
Fire refining removes sulfur and oxygen from liquid blister
copper by:
(a)air-oxidation removal of sulfur as SO2 to ~0.002% S
(b)hydrocarbon-reduction removal of oxygen as CO and
H2O(g) to ~ 0.15%
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 27
Fire Refining Process
(a) Air-oxidation removal of sulfur as SO2
Reaction:
S (in molten copper) + O2(g) = SO2(g)
The equilibrium relationship between gaseous oxygen
entering the bath and S in the bath is:
while oxygen dissolves in the copper by the reaction:
O2(g) = 2O (in molten copper)
K = pSO2 / [mass%S] x pO2
where K is about …. at 1200°C
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 28
Fire Refining Process
(b) Hydrocarbon-reduction removal of oxygen as CO and
H2O(g)
Reaction:
C(s) + O (in molten copper) = CO(g)
CO(g) + O (in molten copper) = CO2(g)
H2(g) + O (in molten copper) = H2O(g)
Removal of most of the oxygen from the molten copper is
carried out using gas or liquid hydrocarbons.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 29
Fire Refining Process
Scanning Electron Image of Blister Copper
Resin
Copper
Cu2O
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 30
Fire Refining Process
Sulphur and Oxygen Contents at Various stages of fire refining
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 31
Key Parameters of Copper Smelting
and Converting processes
- Temperature
- O2 Partial Pressure
- S 2(or SO2) Partial Pressure
- Ratio of Fe/Cu in Concentrate
- Ratio of %Cu in Matte
- Ratio of Fe/SiO2 in Slag
E. Jak, Thermodynamic Principle of Pyrometallurgy of Copper, 2019
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 32
Oxygen Partial Pressure in Copper Smelting
-273
PO2=10-5 atm
PO2=10-12 atm
Target conditions:
T = ~1200 C
Copper in metal: PO2 < 10-5 atm
Iron in slag: PO2 > 10-12 atm
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 33
Gas – Matte – Slag Equilibria
K. Itagaki: Yazawa Intern. Symp., Pyrometallurgy of Copper Short Course, TMS, San Diego (2003)
G. Roghani, Y. Takeda and K. Itagaki, Metallurgical and Materials Transactions, Aug. 2000, Vol. 31B, pp. 705-712
SmeltingConverting
PO2
PS2Change in gas composition
as reaction progresses
CuFeS2(s) + (0.5+1.5x)O2(g) + ySiO2(s) →
0.5Cu2S–(1-x)FeS(l) + x"FeO"–ySiO2(l) + (0.5+x)SO2(g)
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 34
Gas – Matte – Slag Equilibria
Change in activity of
components as reaction
progresses
Yazawa (1974)
Smelting
Converting
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 35
Gas – Matte – Slag Equilibria
Change in chemically
dissolved copper in slag
as reaction progresses
Smelting
Converting
K. Itagaki: Yazawa Intern. Symp., Pyrometallurgy of Copper Short Course, TMS, San Diego (2003)
G. Roghani, Y. Takeda and K. Itagaki, Metallurgical and Materials Transactions, Aug. 2000, Vol. 31B, pp. 705-712
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 36
Matte-Slag Separation
Basic Principle of
Matte-Slag separation
In the ternary FeS-FeO-SiO2 system,
the addition of silica to a homogeneous FeS-
FeO melt tends
to separate into matte and slag.
Similar reaction occur in the presence of Cu
CuFeS2 + O2 + SiO2 =
{Cu-Fe-S} + (FeO-SiO2) + SO2
Slag
FeO:54.8wt%
FeS:17.9wt%
SiO2:27.3wt%
matte
FeO:27.4wt%
FeS:72.4wt%
SiO2:0.16wt%
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 37
Matte Chemistry
Concentrate
Progress of Matte Composition
During smelting, iron sulfide is constantly removed. The progress of the
smelting is showed by Matte Grade (= %Cu in matte).
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 38
Matte Chemistry
Matte specific gravity is higher than that of slag and so matte
settles at the below the slag layer.
Specific gravity
ranges linearly from
3.9 for pure FeS to
5.2 for pure Cu2S. It
decreases slightly
with increasing
temperature.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 39
Slag Chemistry
Slag Compositions of Industrial Operations
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 40
Slag Chemistry
Fayalite slag
Ca-ferrite slag
Fully Liquid at 1300oC
Liquid + “FeO”
Liquid + SiO2
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 41
Slag Chemistry
1300oC
T. Hidayat, H.M. Henao, P.C. Hayes, and E. Jak,
Copper 2010, Hamburg, Germany..
Effect of PO2
on liquidus
Fully Liquid at 1300oC
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 42
Slag Chemistry
Effects of CaO on liquidus
FeO-Fe2O3-SiO2-CaO-(2.2wt%CaO -3.3wt%Al2O3) system at PO2=10-8 atm
H. M. Henao, C. Nexhip, D. P. George-Kennedy, P. Hayes, E. Jak,
Metallurgical and Materials Transactions B, publ. online Apr 2010, vol 38, article 15.
Fully liquid
Liquid + “Fe3O4”
Liquid + SiO2
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 43
Viscosity
Matte viscosities are low ~0.003 kg/m.s vs.
Typical slags viscosities are 0.2–2 poise
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 44
Optimum Condition
Optimum condition for Copper making processes is when:
• As low as possible chemically dissolved Cu in slag
• Both phases in liquid forms with good fluidity
• Sufficient time for both phases to settle into two layers (to
minimize physical Cu entrainment in slag)
Failures to control above conditions
can lead to:
• High loss of Cu into the slag
phase
• Formation of accretion / solid
deposit which can significantly
reduced furnace capacity or
interrupt furnace operationAccretion in Bottom Blown
Copper Smelting FurnaceM.Chen, et.al., International Copper Conference, Copper 2016
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 45
Copper Smelting Reactors
46Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Copper Smelting Reactors
Sohn H.Y. et. al., Treatise on Process Metallurgy: Copper Production, Elsevier, 2014
• The current industrial matte smelting technologies can be groupedinto two general types, Suspension smelting and Bath smelting.
• In the suspension process, finely sized concentrates of <100 mm sizeare injected together with a process gas into a furnace. Example:Outotec flash smelting, INCO process, Kivcet process, etc.
• In the bath smelting process, the process gas is injected into amolten bath to strongly agitate the bath and/or form bubbles.Example: Top submerged lance process, Mitsubishi process, Norandaprocess, Teniente converter process, Vanyukov process, etc.
• In both cases, a large interfacial area or turbulent movement of theliquid is created. This promotes rapid interaction of oxygencontaining gas with the condensed phase to greatly increase the rateof oxidation of iron and sulfur.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 47
Steps in Cu Production
1. Beneficiation process → to liberate
and increase content of valuable
minerals to produce concentrate (20-
30%Cu).
2. Smelting process → to oxidize S
and Fe from the concentrate to
produce a Cu-enriched molten
sulfide phase (matte) (50-70%Cu).
3. Converting process → to remove
Fe and S from the matte to produce
crude molten copper (99% Cu).
4. Refining process → to remove S
and O from the crude molten copper.
5. Further processes →
Electrorefining, melting, and
fabrication.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 48
Copper Smelting Reactors
Flash Furnace50% of world copper production
-Use very little hydrocarbon fuel (Autothermal)
-Efficient capture of strong SO2 gas
-Only accepts solid dry particles of small size
-Off gas contains a high content of dust
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 49
Copper Smelting Reactors
Process Air
Oxygen
Fuel
Molten
Bath
Feed Mix
Offgas
Offgas
System
Molten
Products
25%Cu Conc. Feed
(CuFeS2)
OFF Gas:
SO2, N2, H2O
Air + O2
-Produce high-SO2 gas with small evolution of dust
-Use very little hydrocarbon fuel (Autothermal)
-Accepts pelletized and not dried materials
Molten Products:
Slag: Fe rich (FeO.SiO2)
Matte: (CuS2 + FeS)
Cu rich 50-60% Cu
Gas/liquid
& gas/solid
& liquid/liquid
&liquid/solid
Top Submerged Lance –Isasmelt / Ausmelt
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 50
Copper Smelting Reactors
Gas/liquid
& gas/solid
Gas/liquid
& liquid/liquid
& liquid/solid
Matte
decantation
Noranda Furnace
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 51
Copper Smelting Reactors
Teniente reactor
- Feed can include scrap of different sizes
- Can produce a super high grade matte of 72 to 78% Cu
- The stirring prevents excessive deposition of magnetite
Fluxes, Reverts, Wet Concentrate
matte
Off Gas
Slag
Air + O2 and Dry concentrate injection through tuyeres
Garr gan
Gas/liquid
& liquid/liquid
& liquid/solid
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 52
Copper Smelting Reactors
Gas/liquid
& liquid/liquid
Solid/liquid
& liquid/liquid
Matte
decantation
Fangyuan - oxygen-enriched bottom-blowing smelting process
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 53
Common Features of Matte Smelting
❑ Contacting concentrate particles and silica flux with
air/oxygen.
❑ Heating the melting particles with the energy of Fe and S
oxidation and fossil fuel combustion.
❑ Allowing the partially oxidized droplets and flux to join and
later separate into matte and slag.
❑ Giving the matte droplets sufficient time to settle.
❑ Tapping the matte and slag separately through low and high-set
tap holes.
❑ Sending the matte to the converter.
❑ Sending the slag to a Cu recovery step.E. Jak, Thermodynamic Principle of Pyrometallurgy of Copper, 2019
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 54
Copper Converting Reactors
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 55
Steps in Cu Production
1. Beneficiation process → to liberate
and increase content of valuable
minerals to produce concentrate (20-
30%Cu).
2. Smelting process → to oxidize S
and Fe from the concentrate to
produce a Cu-enriched molten
sulfide phase (matte) (50-70%Cu).
3. Converting process → to remove
Fe and S from the matte to produce
crude molten copper (99% Cu).
4. Refining process → to remove S
and O from the crude molten copper.
5. Further processes →
Electrorefining, melting, and
fabrication.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 56
Copper Converting Reactors
56
Peirce-Smith Copper Converter
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 57
Copper Converting Reactors
Peirce-Smith Copper Converter
- 90% of Cu converters in the world
- Simplicity and high chemical efficiency
- Leaks of SO2 fugitive emissions into the workplace during charging and
relatively dilute SO2 gas
- It operates as a batch process, giving uneven flow of SO2 offgas into the sulfuric
acid plant,
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 58
Copper Converting Reactors
Peirce-Smith Copper Converter
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 59
Copper Converting Reactors
Noranda Continuous Submerged Tuyere Converter
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Copper Converting Reactors
Kennecott – Outotec Flash Converter
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 61
Copper Converting Reactors
ISACONVERT
Process Air
Oxygen
Fuel
Molten
Bath
Feed Mix
Offgas
Offgas
System
Molten
Products
Matte
Molten Products:
Slag: Fe rich (FeO.SiO2)
Cu Blister
OFF Gas: SO2, N2, H2O
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 62
Fire Refining Reactors
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 63
Steps in Cu Production
1. Beneficiation process → to liberate
and increase content of valuable
minerals to produce concentrate (20-
30%Cu).
2. Smelting process → to oxidize S
and Fe from the concentrate to
produce a Cu-enriched molten
sulfide phase (matte) (50-70%Cu).
3. Converting process → to remove
Fe and S from the matte to produce
crude molten copper (99% Cu).
4. Refining process → to remove S
and O from the crude molten copper.
5. Further processes →
Electrorefining, melting, and
fabrication.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 64
Fire Refining Reactors
Anode Furnace
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Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 66
Fire Refining Reactors
Anode Furnace
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 67
Casting Anode
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Rotating Wheel
The final product of fire refining is molten copper, ~0.002% S, 0.15% 0,
1150-1200°C, ready for casting as anodes.
Most copper anodes are cast in open anode-shaped impressions on the
top of flat copper molds. Twenty to thirty such molds are placed on a large
horizontally rotating wheel.
The wheel is rotated to bring a mold under the copper stream from the
anode furnace where it rests while the anode is being poured.
When the anode impression is full, the wheel is rotated to bring a new
mold into casting position and so on. Spillage of copper between the
molds during rotation is avoided by placing one or two tiltable ladles
between the refining furnace and casting wheel.
Most casting wheels operate automatically, but with human supervision.
69Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Rotating Wheel
The newly poured anodes are cooled by spraying water on the tops and
bottoms of the molds while the wheel rotates. They are stripped from their
molds (usually by an automatic raising pin and lifting machine) after a half
rotation.
The empty molds are then sprayed with a barite-water wash to prevent
sticking of the next anode.
Casting rates are 50 to 100 tonnes of anodes per hour. The limitation is
the rate at which heat can be extracted from the solidifying / cooling
anodes. The flow of copper from the refining furnace is adjusted to match
the casting rate by rotating the taphole up or down (rotary furnace) or by
blocking or opening a tapping notch (hearth furnace).
In a few smelters, anodes are cast in pairs to speed up the casting rate.
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Rotating Wheel
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Rotating Wheel
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Continuous Anode Casting (Hazelett Twin Belt)
Continuous casting of anodes in a Hazelett twin-belt type caster is being used
by six smelter/refineries.
The advantages of the Hazelett system over mold-on-wheel casting are
uniformity of anode product and a high degree of mechanization / automation.
In Hazelett casting, the copper is poured at a controlled rate (30-100 tonnes
per hour) from a ladle into the gap between two moving water-cooled low-
carbon steel belts. The product is an anode-thickness continuous strip of
copper moving at 4 to 6 m/minute.
The thickness of the strip is controlled by adjusting the gap between the belts.
The width of the strip is determined by adjusting the distance between bronze
or stainless steel edge blocks which move at the same speed as the steel
belts.
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Electrorefining
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 77
Direct-to-blister Copper Makingand
Continuous Smelting – Converting
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 78
Steps in Cu Production
1. Beneficiation process → to liberate
and increase content of valuable
minerals to produce concentrate (20-
30%Cu).
2. Smelting process → to oxidize S
and Fe from the concentrate to
produce a Cu-enriched molten
sulfide phase (matte) (50-70%Cu).
3. Converting process → to remove
Fe and S from the matte to produce
crude molten copper (99% Cu).
4. Refining process → to remove S
and O from the crude molten copper.
5. Further processes →
Electrorefining, melting, and
fabrication.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 79
Direct-to-blister Copper Making
Cu5FeS4(concentrate) + (0.25x+2.5)O2(g) + ySiO2(s) =
(5-x)Cu(l) + 0.5x“Cu2O”–FeO–ySiO2(slag) + 4SO2(g)
Limited only for processing
concentrate with high Cu
content.
Slag from this process
contains high Cu
concentration (10-30wt%Cu),
thus slag cleaning process is
required.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 80
Continuous Smelting - Converting
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 81
Examples of Copper Plantswith Different Technologies
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 82
Aurubis (Flash Smelter)
Aurubis AG is the largest copper producer in Europe (the second largest in the
world) and the largest copper recycler worldwide. One of its smelters is located in
Hamburg, Germany. Aurubis produces more than 1,000,000 TPY of copper
cathodes and from them a variety of copper products.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 83
Mt Isa (Isa Smelter)
The copper smelter at Mt Isa has a processing capacity of 300,000 TPY. The Mt
Isa operations process approximately 6.5M TPY of ore. The project is Australia's
second-largest copper producer.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 84
Olympic Dam (Direct-to-Blister Process)
The Olympic Dam is an integrated mine, mill, smelter and refinery complex. The
smelter was commissioned in July 1988 with a capacity of 55,000 TPY copper and
90kt/a acid. It was later expanded, raising its capacity to 200,000 TPY of copper
and 4,300 TPY of uranium, plus gold and silver.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 85
PT Smelting (Mitsubishi Process)
PT Smelting was established in February 1996. Currently copper cathode
production level is over 300,000 TPY, with priority of it is sold for Indonesian
market and the rest is exported to Asian market. By-products of sulfuric acid,
granulated slag and gypsum are delivered to local market, and anode slime and
copper telluride are exported to international market.
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 86
Aurubis (Flash Smelter)
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 87
MitsubishiContinuous Smelting – Converting
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 88
Continuous Smelting - Converting
Advantageous:(a) Ability to smelt all concentrates, including CuFeS2
concentrates(b) Elimination of Peirce-Smith converting with its SO2 collection
and air infiltration difficulties(c) Continuous production of high SO2-strength offgas, albeit
from two Sources(d) Relatively simple Cu-from-slag recovery(e) Minimal materials handling.
Major advantage of the process: effectiveness in capturing SO2.two continuous strong SO2 streams (smelting and converting) arecombined to make excellent feed gas for sulfuric acid or liquid SO2
manufacture.
Absence of crane-and-ladle transport of molten material minimizesworkplace emissions.
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Reaktor S-Furnace
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Reaktor S-Furnace
1. The S (smelting) furnace blows oxygenenriched air, dried concentrates, SiO2
flux and recycles into the furnace liquidsvia vertical lances.
2. It oxidizes the Fe and S of theconcentrate to produce 65-68% Cu matteand Fe-silicate slag.
3. Its matte and slag flow together into theelectric slag-cleaning furnace.
Schlesinger M.E., King M.J., Sole K.C., Davenport W.G., Extractive Metallurgy of Copper, Elsevier, 2011
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Reaktor S-Furnace
• Solid fine feed and gas enter through 9 vertical lances.
• Feed and gas react to form matte-slag mixture that continuouslyoverflow into the electric slag-cleaning furnace.
• The offgas from the oxidation reactions is drawn up a large uptaketo waste heat boiler.
Goto M., Hayashi M., The Mitsubishi Continuous Process: Metallurgical Commentary, Mitsubishi Materials Corporation, 1998.Schlesinger M.E., King M.J., Sole K.C., Davenport W.G., Extractive Metallurgy of Copper, Elsevier, 2011
Naoshima Design
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Reaktor CL-Furnace
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Reaktor CL-Furnace
1. The CL (slag-cleaning) furnace separatesthe smelting furnace’s matte and slag.
2. Electrodes and electrical power are usedto keep the slag hot and fluid.
3. Its matte flows continuously to theconverting furnace.
4. Its slag (0.7-0.9% Cu) flows continuouslyto water granulation which then can be soldor stockpiled.
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Reaktor CL-Furnace
Goto M., Hayashi M., The Mitsubishi Continuous Process: Metallurgical Commentary, Mitsubishi Materials Corporation, 1998.Schlesinger M.E., King M.J., Sole K.C., Davenport W.G., Extractive Metallurgy of Copper, Elsevier, 2011
• The electric slag-cleaning furnace (3600 kW) is elliptical with 3 or 6graphite electrodes.
• The slag and matte approach equilibrium due to prolonged residencetimes (1-2 h) and electromagnetic stirring.
• Electricity passes through the slag to ensure that the slag is hotand fluid, and the matte droplets are efficiently settled.
Naoshima Design
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Reaktor C-Furnace
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Reaktor C-Furnace
1. The C (converting) furnace blows oxygen-enriched air, CaCO3 flux, and coolant into thematte via vertical lances.
2. It oxidizes the Fe and S in the matte toproduce molten copper. The coppercontinuously flows into one of anode furnacesfor subsequent fire-refining.
3. The slag (14% Cu) flows continuously into awater-granulation system which is thenrecycled to the smelting furnace.
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Reaktor C-Furnace
Goto M., Hayashi M., The Mitsubishi Continuous Process: Metallurgical Commentary, Mitsubishi Materials Corporation, 1998.Schlesinger M.E., King M.J., Sole K.C., Davenport W.G., Extractive Metallurgy of Copper, Elsevier, 2011
• The oxygen-enriched air and solid enter the furnace through 10lances.
• It also receives converter slag granules and scrap anodes.
• The offgas is drawn up a large uptake to waste heat boiler.
Naoshima Design
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Layout Pabrik Continuous Smelting – Converting
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Layout Umum Pabrik• Naoshima Smelter
2
1
4
6
7
8
109
1112
13
14
16
17 18
19
1. Unload pier 2. Concentrate storage 3. Flux storage 4. Administration office 5. Laboratory
6. Precious metal plant 7. Waste water treatment plant 8. Oxygen plants 9. Technical office
10. Concentrate storage 11. Acid plant-no.3 12. Acid plant-no.2 13. Desulphurization acid plants tail gas
14. Sea water pump 15. Refinery 16. Continuous smelter 17. Power plant 18. Blending yard 19. Stack
Goto M., Hayashi M., The Mitsubishi Continuous Process: Metallurgical Commentary, Mitsubishi Materials Corporation, 1998.
10
00
m
1900 m
15
5 3
Total Map = ~1.9 km2
Plant = ~0.5 km2
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Layout Umum Pabrik• Onsan Smelter
1
1. Office 2. Workshop & warehouse 3. Old smelter (Flash furnace & PS-converter) 4. New smelter
(Mitsubishi continuous smelter) 5. Old refinery 6. New refinery 7. Old acid plant & Utilities
8. New acid plant 9. Concentrate storage 10. Soccer field
2
34
5
6
7 8
10
Lee J.H., Kang S.W., Cho Y.H., Ke J.J., Expansion of Onsan Smelter, Proc. Copper 99 – Cobre 99 Int. Conf., 1999.
9
710 m
65
0 m
~0.47 km2
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Layout Umum Pabrik• Gresik Smelter
1. Raw Materials weighting & sampling 2. Concentrate storage 3. Flux storage 4. Administration office
5. Laboratory 6. Waste water treatment plant 7. Oxygen & power plants 8. Acid plant 9. Refinery
10. Continuous smelter 11. Water reservoir 12. Storm water pond 13. Warehouse 14. Workshop
Ajima S., Konda K., Kanamori K., Igarashi T., Muyo T., Hayashi S., Copper Smelting and Refining in Indonesia, Proc. Copper 99 – Cobre 99 Int. Conf., 1999
37
5 m
830 m
10
7 8
6
1
2 3
12
1
1194
5
13 14
~0.29 km2
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Layout Pabrik Continuous Smelter• Naoshima Smelter
1. Conc. dryer
2. Bag house
3. Flux receiving hopper
4. Flux bins
5. S-furnace feeding tanks
6. S-furnace
7. CL-furnace
8. C-furnace
9. Anode furnace
10. Casting wheel
11,12. Waste heat boilers
13,14. Balloon flues
15. Electrostatic precipitators
16. Discard slag granulation pit
17. Slag bin
18. C-slag granulation pit
19. C-slag dryer
20. Lumpy material conveyor
21. Spent anode conveyor
22. Pressed copper scrap conveyor
23. Control room
24. Compressor room
Mitsubishi Materials Corporation, The Mitsubishi Process Brochure, 1998.
103Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Layout Pabrik Continuous Smelter• Onsan Smelter Lee J.H., Kang S.W., Cho Y.H., Ke J.J., Expansion of Onsan Smelter, Proc. Copper 99 – Cobre 99 Int. Conf., 1999.
104Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Layout Pabrik Continuous Smelter• Gresik Smelter
Prayoga A., Smelting Furnace Melt Zone Wall Modification to Cope Higher Production Rate Operation, Proc. 1st Int. Process Metallurgy Conf., 2016
105Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Copper
concentrate
Aliran Material Pabrik
Offgas
Silica +
Limestone Offgas
Tail Gas
Dilution
Slag + Matte
Matte
C-S
lag
Sulfuric Acid
Enriched air
Offgas
Blister Copper
Limestone Reduction
Gas to
Dryer
Copper
Anode
Air (D-S)CH4 (Reduction)
CH4 (burners)Air (burners)
Ga
s fro
m D
-S
Dryer
Mitsubishi
S-Furnace
W.H.B
+ ESP
W.H.B
+ ESP
Mitsubishi
CL-Furnace
Mitsubishi
C-Furnace
Steam
Dryer
Slag
Granulation
Acid Plant
(double abs.)
Anode
Furnace
Anode scrap
Coolant
Feeding
Facility
Dry
conc.Conc.
StorageWeighing &
Sampling
Ship
Unloading
Storage
Shed
Limestone Silica Coal
Coal
SlagSlag
Granulation
Discard SlagBlower
Oxygen
Plant
Anode
CastingTank
HouseCopper Cathode
Precious
Metal
Plant
Anode
Slime
Dore Bullion
Purchased Slime
NiSO4
Electrolytic Copper
Crude Selenium
Gold
Silver
Pd/Pt Slime
Acid
Storage
Weak Acid Waste
Water
Treatment
Neutralized Sludge
Effluent
to Sea
Desulfurizing
Plant
Offgas
Gypsum
Gypsum
To Fertilizer
Company
ESPOffgas
StackBag
Filter
Pb-rich Slag
By-Product
Plant
EP DustPb Residue
Cd Sludge
Ajima S., et. al., Copper Smelting and Refining in Indonesia, Proc. Copper 99 – Cobre 99 Int. Conf., 1999Ajima S., et. al., The Distribution of Minor Elements at Naoshima, Co-products & Minor Elements in Non-Ferrous Smelting, 1995
Kang Y.C., Song I.H., Two Copper Smelting Processes at Onsan, Yazawa International Symposium, 2003Cooper, W. C. (1990), The Treatment of Copper Refinery Anode Slimes, JOM, 45–49
Leigh, A.H. (1973), Precious Metal Refining Practice, International Symposium on HydrometallurgyLudvigsson, B. M. & Larsson, S.R., (2003), Anode Slimes Treatment: The Boliden Experience, JOM, 41–44
Offgas
to Atmosphere
Note: Solid
Liquid
Gas
Fuel
Hot Air
Copper Telluride
106Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Refraktori Peleburan Tembaga
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Refraktori Peleburan Tembaga
Most of the refractories in the Mitsubishifurnace are fused cast and direct-bondedmagnesite chrome (MgO-Cr2O3)
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Refraktori Peleburan Tembaga
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Refraktori Peleburan Tembaga
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Refraktori Peleburan Tembaga
• There is a trend to apply cooling system on / in the lining systemsto perform ten to fifteen years operation with a minimum repair.
• By inserting water-cooled copper elements in the furnacebrickwork, a frozen slag on the refractory hot face will beformed. This frozen slag protects the bricks from furthererosion/corrosion by the liquid slag.
Heat Input
Slag bathFreeze
liningReactor
wallCooling
medium
Heat removal
CastableCopper fingers
Backing plateCoolant
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Refraktori Peleburan Tembaga
S-Furnace
Prayoga A., Smelting Furnace Melt Zone Wall Modification to Cope Higher Production Rate Operation, Proc. 1st Int. Process Metallurgy Conf., 2016Used initial wall New modified wall Used modified wall
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Refraktori Peleburan Tembaga
CL-Furnace
Newman C.J. Storey A.G., Macfarlane G., Molnar K., The Kidd Creek copper smelter - an update on plant performance, CIM Bulletin, 1992
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Refraktori Peleburan Tembaga
C-Furnace
MacRae A. Wallgren M., Wasmunf B., Lenz J., Majumdar A., Zuliani P., Elvestad P., Converting Furnace Upgrades At The Kidd Metallurgical Division Copper Smelter, Sulfide Smelting ’98, 1998
6 Rows cooler 5 Rows cooler Initial wall
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 114
Future of Copper
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 115
Future of Copper
https://www.visualcapitalist.com/visualizing-coppers-role-in-the-transition-to-clean-energy/
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 116
Future of Copper
https://www.visualcapitalist.com/visualizing-coppers-role-in-the-transition-to-clean-energy/
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 117
Future of Copper
https://www.visualcapitalist.com/visualizing-coppers-role-in-the-transition-to-clean-energy/
Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021 118
Future of Copper
https://www.visualcapitalist.com/visualizing-coppers-role-in-the-transition-to-clean-energy/
119Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
References
• Davenport W.G., Jones D.M., King M.J., Partelpoeg E.H., Flash
Smelting: Analysis, Control and Optimisation, 2nd Edition,
Pergamon Press, 2001.
• Goto M., Hayashi M., The Mitsubishi Continuous Process:
Metallurgical Commentary, Mitsubishi Materials Corporation,
1998.
• Grimsey E., Flash Furnace Model, The Western Australia
School of Mines, Curtin University, 2012.
• Jak E., Pyrometallurgy Course, University of Queensland, 2016.
120Zulfiadi Zulhan / Taufiq Hidayat / Imam Santoso MG3111 Pyrometallurgy 2021
Terima kasih!Program Studi Teknik Metalurgi
Fakultas Teknik Pertambangan dan Perminyakan
Institut Teknologi Bandung
Jl. Ganesa No. 10
Bandung 40132
INDONESIA
www.metallurgy.itb.ac.id
Dr.-Ing. Zulfiadi Zulhan, ST., MT.
Taufiq Hidayat, ST., M.Phil., Ph.D.
D.Sc. (Tech.) Imam Santoso, ST., M.Phil.