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The smelter is a custom copper smelter which uses both copper concentrates and precious metal bearing recyclable materials as its feedstock to produce a 991 copper anode The anode is shipped to the Canadian Copper Refinery CCR in Montreal to be converted into copper cathodes which are sold on world marketsSterlite Copper at a Glance Sterlite Copper represents the Copper Unit of the Sesa Sterlite Limited Sterlite Copper Unit operates a 400 000 Metric Tonnes Per Annum MTPA Copper Smelter with associates facilities such as Refinery and Copper Rod Plant Sulphuric Acid plant of more 12 00 000 MTPA and a Phosphoric Acid of 220 000 MTPA at Thoothukudi Tamil Nadu
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The sulfide concentrates are typically smelted in such furnaces as the Outokumpo or Inco flash furnace or the ISASMELT furnace to produce matte which must be converted and refined to produce anode copper Finally the final refining process is electrolysis For economic and environmental reasons many of the byproducts of extraction are reclaimedBlending can take place at the refinery along the pipelines and tanks that house processed fuel or even at off site locations or on ships or terminals once the fuel has left the refinery gate Additional Resources on the Refining Process Adventures in Energy American Fuel Petrochemical Manufacturers The Refinery Process
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PMR Precious Metals Refinery at Rustenburg Nickel Copper Cobalt Sulphate Sodium Sulphate Gold BMR Base Metals Refinery incl Magnetic Concentration Plant Mortimer Union Chromite Recovery Plant PGM Concentrated Residues Tailings Purchased Concentrate Concentrate Furnace Matte Smelting Ore Anglo Converting Process at Rustenburg A schematic diagram of the conventional process for the production of copper and the SX/EW process can be seen here Conventional Copper Extraction Conventionally copper is recovered by a pyrometallurgical process known as smelting In this process copper ore is mined crushed ground concentrated smelted and refined
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To remove or adjust the levels of these materials the blister copper is first fire refined before it is sent to the final electrorefining process 8 The blister copper is heated in a refining furnace which is similar to a converter described above Air is blown into the molten blister to oxidize some impuritiCopper processing is a complicated process that begins with mining of the ore less than 1 copper and ends with sheets of pure copper called cathodes which will ultimately be made into products for everyday useThe most common types of ore copper oxide and copper sulfide undergo two different processes hydrometallurgy and pyrometallurgy respectively due to the different
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With this plant it is possible to obtain gold with a purity of 999 9/ starting from 900/ with a maximum silver content of 5 Each 35 lt tank produces from 12 to 15 Kg each in 24 hours the electrolyte solution should contain 80gr/lt of gold chloride the plant consists of a single cell divided into two tanks made out of self extiguishing ppl and resting on a safety tray the Refining process of precious metals are described by Northern Refineri We buy refine and assay all forms of gold silver platinum and palladium We provide services to jewelers pawn shops dentists dental laboratories trade shops manufacturers machine shops salvage companies windshield manufacturers fiberglass manufacturers chemical laboratories and the health care industry as
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The smelting and refining of some metals can have special hazards Examples include nickel carbonyl in nickel refining fluorides in aluminium smelting arsenic in copper and lead smelting and refining and mercury and cyanide exposures during gold refining These processes require their own special precautions Other hazardsJun 25 32 Owned and operated by China s largest copper producer Jiangxi Copper Corporation Guixi smelter is located in Jiangxi province Copper cathodes from the smelter are traded via the London Metal Exchange under the Guiye brand Silver and minor metal by products are also extracted from copper ore at the refinery
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Dec 07 32 Process for the Electrolytic Refining of Copper Raw material Blister Copper It is extracted from copper mine in smelting furnace contains 985 copper It is the raw material of electrolytic copper production While the final electrolytic copper product contains copper in itCompared to other metals copper is very ductile meaning that it can be drawn through a tiny hole into very fine wire without breaking Refining improves the ductility of copper so that extremely fine wires can be drawn Impurities increase the chance that the wire will break during the drawing processCopper conducts electricity
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Nov 10 32 Unfortunately the copper refining process doesn t end there and it is here where this story gets interesting As the impure copper from the anodes dissolves into solution and is replated onto the cathode as pure copper the dissolution process is faster than the plating process causing a gradual build up of copper ions in the refinery electrolyteThe details of refinery operations differ from location to location but virtually all refineries share two basic processes for separating crude oil into the various product components Actual refinery operations are very complicated The link below will take you to a 10 minute long video that provides more details on the various refining
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That typically takes place away from the mines themselves at a refining plant or smelter Through copper refining unwanted material is progressively removed and copper is concentrated at up to 99 With this plant it is possible to obtain gold with a purity of 999 9/ starting from 900/ with a maximum silver content of 5 Each 35 lt tank produces from 12 to 15 Kg each in 24 hours the electrolyte solution should contain 80gr/lt of gold chloride the plant consists of a single cell divided into two tanks made out of self extiguishing ppl and resting on a safety tray the
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Clean scrap consisting of pure copper will enter relatively late into the metal refining process possibly only requiring melting and casting Scrap containing alloying constituents can be classified as inter mediate grade scrap and will enter the refining process at some point after the cupola operationsNewer techniques use Chemical processing on some of the fractions to make others in a process called conversion Chemical processing for example can break longer chains into shorter on This allows a refinery to turn diesel fuel into gasoline depending on the demand for gasoline Refineries must treat the fractions to remove impuriti
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Lead Refining Plant Pyrometallurgical techniques The Lead Bullion is fed into a refining kettle Lead bullion contains many other metallic impurities including antimony arsenic copper tin and zinc Refining Process of Lead in Detail a Removal of Copper Copper is the first of This is another article in my series on the smelting of metals this one focusing on the smelting of copper We shall begin by looking at the mining and processing of the copper bearing ore followed by an examination of an established and a modern copper smelting process Mining for Copper
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Electrolytic refining The purest copper is obtained by an electrolytic process undertaken using a slab of impure copper as the anode and a thin sheet of pure copper as the cathode The electrolyte is an acidic solution of copper sulphate By passing electricity through the cell copper is dissolved from the anode and deposited on the cathode Electrolytic Copper Refining Plant Copper electrorefining entails electrochemically dissolving copper from impure copper anodes into an electrolyte containing CuSO4 and H2SO4 and selectively electroplating pure copper from this electrolyte without the anode impuriti
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