2026 Cordoba Copper Flash Smelting Partitioning

This study presents a multi-element, industrial-scale evaluation of elemental partitioning in a copper (Cu) flash smelting furnace under varying dust recirculation conditions. Comprehensive chemical characterization of the smelting feed, matte, slag, and dust was performed across three operational scenarios: no recirculation, partial recirculation (60–70%), and full recirculation (100%). Dust recirculation was found to significantly alter the distribution of volatile, semi-volatile, and refractory elements: emissions of Pb, Zn, Sb, Bi, and Mo increased, while Hg retention in the matte improved. Selenium (Se) and cobalt (Co) remained relatively stable, with partitioning largely controlled by redox conditions and speciation. Statistical analysis enabled classification of elements by sensitivity to recirculation: Type I—highly sensitive (Pb, Zn, Sb, Se, Hg); Type II—moderately sensitive (Mo, Ni); and Type III—stable (Co, Te). These findings, validated with industrial process data, provide critical insights for optimizing residue management, minimizing emissions, and supporting circular economy strategies in primary Cu smelting.