Direct-to-Copper Flash Smelting

This chapter discusses the direct-to-copper flash smelting process as practiced in 2000, highlighting its integrated approach to oxidizing Cu-Fe-S concentrate to produce metallic copper efficiently. The primary objective is to explore the benefits of combining smelting and converting into a single operation that minimizes sulfur dioxide emissions, industrial oxygen, and fuel requirements while reducing costs. The methodology involves analyzing the industrial oxygen and oil requirements for the direct-to-copper flash smelting process, as well as the distribution of copper between metal and slag during this process. Key results indicate that direct-to-copper flash smelting effectively captures sulfur dioxide from a continuous off-gas stream and significantly reduces oxygen and oil consumption, yet it presents a challenge with approximately 114% of copper-in-feed being lost to slag. This dual focus on efficiencies in environmental impact and operational costs underscores the need for advancements in smelting technology to improve copper recovery rates while maintaining environmental compliance.