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Tables of Contents for Extractive Metallurgy of Copper
Chapter/Section Title
Page #
Page Count
Preface
xiii
Preface to the Third Edition
xv
Preface to the Second Edition
xvii
Preface to the First Edition
xix
Overview
1
16
Introduction
1
1
Extracting Copper from Copper-Iron-Sulfide Ores
1
10
Hydrometallurgical Extraction of Copper
11
2
Melting and Casting Cathode Copper
13
2
Recycle of Copper and Copper-Alloy Scrap
15
1
Summary
15
2
Suggested Reading
16
1
References
16
1
Production and Use
17
14
Locations of Copper Deposits
18
1
Location of Extraction Plants
18
1
Copper Minerals and `Cut-Off' Grades
19
9
Price of Copper
28
1
Summary
29
2
References
29
2
Concentrating Copper Ores
31
26
Concentration Flowsheet
31
2
Crushing and Grinding (Comminution)
33
5
Flotation Feed Particle Size
38
4
Froth Flotation
42
4
Specific Flotation Procedures for Cu Ores
46
3
Flotation Cells
49
1
Sensors, Operation and Control
50
2
The Flotation Product
52
1
Other Flotation Separations
53
1
Summary
53
4
Suggested Reading
54
1
References
54
3
Matte Smelting Fundamentals
57
16
Why Smelting?
57
2
Matte and Slag
59
6
Reactions During Matte Smelting
65
1
The Smelting Process: General Considerations
66
1
Smelting Products: Matte, Slag and Offgas
67
3
Summary
70
3
Suggested Reading
70
1
References
70
3
Flash Smelting -- Outokumpu Process
73
18
Outokumpu Flash Furnace
74
3
Peripheral Equipment
77
5
Furnace Operation
82
1
Control
83
3
Impurity Behavior
86
1
Future Trends
87
1
Summary
87
4
Suggested Reading
88
1
References
88
3
Inco Flash Smelting
91
12
Furnace Details
91
5
Auxiliary Equipment
96
1
Operation
97
1
Control Strategy
98
2
Cu-in-Slag and Molten Converter Slag Recycle
100
1
Inco vs. Outokumpu Flash Smelting
101
1
Summary
101
2
Suggested Reading
101
1
References
102
1
Noranda and Teniente Smelting
103
16
Noranda Process
104
2
Reaction Mechanisms
106
2
Operation and Control
108
1
Production Rate Enhancement
109
1
Noranda Future
110
1
Teniente Smelting
110
1
Process Description
111
1
Operation
111
2
Control
113
1
Impurity Distribution
114
1
Teniente Future
115
1
Discussion
115
1
Summary
116
3
Suggested Reading
117
1
References
117
2
Ausmelt/Isasmelt Matte Smelting
119
12
Basic Operations
119
1
Feed Materials
120
1
The Isasmelt Furnace and Lance
120
5
Smelting Mechanisms
125
1
Startup and Shutdown
126
1
Current Installations
126
1
Other Coppermaking Uses of Ausmelt/Isasmelt Technology
127
1
Summary
127
4
Suggested Reading
128
1
References
129
2
Batch Converting of Cu Matte
131
24
Chemistry
131
6
Industrial Peirce-Smith Converting Operations
137
7
Oxygen Enrichment of Peirce-Smith Converter Blast
144
1
Maximizing Converter Productivity
145
3
Recent Developments in Converting -- Shrouded Blast Injection
148
1
Alternatives to Peirce-Smith Converting
148
2
Summary
150
5
Suggested Reading
151
1
References
151
4
Continuous Converting
155
18
Common Features of Continuous Converting
155
2
Downward Lance Mitsubishi Continuous Converting
157
5
Solid Matte Outokumpu Flash Converting
162
4
Submerged-Tuyere Noranda Continuous Converting
166
4
% Cu-in-Slag
170
1
Summary
170
3
Suggested Reading
171
1
References
171
2
Copper Loss in Slag
173
14
Copper in Slags
173
2
Decreasing Copper in Slag I: Minimizing Slag Generation
175
1
Decreasing Copper in Slag II: Minimizing Cu Concentration in Slag
176
1
Decreasing Copper in Slag III: Pyrometallurgical Slag Settling/Reduction
176
5
Decreasing Copper in Slag IV: Slag Minerals Processing
181
1
Summary
181
6
Suggested Reading
183
1
References
183
4
Direct-To-Copper Flash Smelting
187
12
The Ideal Direct-to-Copper Process
187
1
Industrial Single Furnace Direct-to-Copper Smelting
188
1
Chemistry
189
1
Industrial Details
190
1
Control
190
3
Cu-in-Slag: Comparison with Conventional Matte Smelting/Converting
193
1
Cu-in-Slag Limitation of Direct-to-Copper Smelting
194
1
Direct-to-Copper Impurities
195
1
Summary
195
4
Suggested Reading
196
1
References
196
3
Mitsubishi Continuous Smelting/Converting
199
18
The Mitsubishi Process
201
1
Smelting Furnace Details
201
2
Electric Slag Cleaning Furnace Details
203
1
Converting Furnace Details
203
4
Recent Mitsubishi Process Developments
207
1
Reaction Mechanisms in Mitsubishi Smelting
208
2
Optimum Matte Grade
210
1
Impurity Behavior in Mitsubishi Smelting/Converting
210
1
Process Control in Mitsubishi Smelting/Converting
211
1
Summary
212
5
Suggested Reading
214
1
References
215
2
Capture and Fixation of Sulfur
217
30
Offgases from Smelting and Converting Processes
217
1
Sulfuric Acid Manufacture
218
4
Smelter Offgas Treatment
222
2
Gas Drying
224
3
Acid Plant Chemical Reactions
227
4
Industrial Sulfuric Acid Manufacture
231
9
Recent and Future Developments in Sulfuric Acid Manufacture
240
1
Alternative Sulfur Products
241
1
Future Improvements in Sulfur Capture
241
1
Summary
242
5
Suggested Reading
243
1
References
243
4
Fire Refining and Casting of Anodes: Sulfur and Oxygen Removal
247
18
Industrial Methods of Fire Refining
247
5
Chemistry of Fire Refining
252
1
Choice of Hydrocarbon for Deoxidation
253
1
Casting Anodes
253
3
Continuous Anode Casting
256
4
New Anodes from Rejects and Anode Scrap
260
1
Removal of Impurities During Fire Refining
260
1
Summary
261
4
Suggested Reading
261
1
References
262
3
Electrolytic Refining
265
24
Principles
265
4
Behavior of Anode Impurities During Electrorefining
269
3
Industrial Electrorefining
272
1
Cathodes
273
1
Electrolyte
273
5
Cells and Electrical Connections
278
1
Typical Refining Cycle
279
1
Refining Objectives
280
1
Maximizing Cathode Copper Purity
280
1
Optimum Physical Arrangements
280
1
Optimum Chemical Arrangements
281
1
Optimum Electrical Arrangements
282
1
Minimizing Energy Consumption
283
1
Recent Developments in Electrorefining
283
1
Summary
284
5
Suggested Reading
284
1
References
285
4
Hydrometallurgical Copper Extraction: Introduction and Leaching
289
18
Heap Leaching
289
4
Industrial Heap Leaching
293
6
Steady-State Leaching
299
1
Leaching of Chalcopyrite Concentrates
300
1
Other Leaching Processes
301
1
Future Developments
301
1
Summary
301
6
Suggested Reading
303
1
References
303
4
Solvent Extraction Transfer of Cu from Leach Solution to Electrolyte
307
20
The Solvent Extraction Process
307
2
Chemistry
309
1
Extractants
310
2
Industrial Solvent Extraction Plants
312
5
Quantitative Design of Series Circuit
317
4
Stability of Operation
321
1
`Crud'
322
1
Summary
323
4
Suggested Reading
324
1
References
324
3
Electrowinning
327
14
Electrowinning Reactions
328
1
Electrowinning Tankhouse Practice
329
6
Maximizing Copper Purity
335
1
Maximizing Current Efficiency
335
2
Future Developments
337
1
Summary
337
4
Suggested Reading
338
1
References
338
3
Collection and Processing of Recycled Copper
341
14
The Materials Cycle
341
3
Secondary Copper Grades and Definitions
344
2
Scrap Processing and Beneficiation
346
5
Summary
351
4
Suggested Reading
351
1
References
352
3
Chemical Metallurgy of Copper Recycling
355
12
The Secondary Copper Smelter
355
5
Scrap Processing in Primary Copper Smelters
360
3
Summary
363
4
Suggested Reading
363
1
References
364
3
Melting and Casting
367
18
Product Grades and Quality
367
3
Melting Technology
370
4
Casting Machines
374
6
Summary
380
5
Suggested Reading
381
1
References
381
4
Costs of Copper Production
385
16
Overall Investment Costs: Mine through Refinery
386
3
Overall Direct Operating Costs: Mine through Refinery
389
1
Total Production Costs, Selling Prices, Profitability
389
2
Concentrating Costs
391
2
Smelting Costs
393
2
Electrorefining Costs
395
2
Production of Copper from Scrap
397
1
Leach/Solvent Extraction/Electrowinning Costs
397
1
Profitability
398
1
Summary
399
2
References
399
2
Appendices
401
16
A Stoichiometric Data for Copper Extraction
401
2
B Lesser-Used Smelting Processes
403
10
C Copper Recovery from Anode Slimes
413
2
D Sketch of Series-Parallel Solvent Extraction Circuit
415
1
E Extended List of Chinese Copper Refineries and their Capacities
416
1
Index
417