Thermodynamics of Converting High-Impurity Copper Matte

As long as the tendency of Chilean copper ores continues to feature high levels of impurities, the smelters face significant challenges in producing high-quality copper. This paper aims to analyze the thermodynamics involved in the conversion of high-impurity copper matte, particularly focusing on the variations in established technologies used for smelting. The methodology includes evaluating thermodynamic data to predict impurity distributions during the slag blow and copper blow processes. The results indicate that for mattes containing up to 66 percent Cu, traditional two-stage conversion processes are applicable, while higher-grade mattes of 70 to 74 percent Cu can be converted in a single blow. The study further highlights the effectiveness of volatilization during slag blowing and the impact of altering flux types and amounts during the copper blow to optimize impurity distribution. As mining companies increasingly process previously uneconomic ores with greater impurity levels, these findings suggest that substantial adjustments in processing technologies will be necessary to maintain operational efficiency and profitability in the copper smelting industry.