How Copper is made animation | Karthi Explains

Summary

The copper processing journey begins with mining ores, primarily copper sulfide and oxide ores. The extraction methods differ, with sulfide ores processed through pyrometallurgy. The seven key steps include mining, grinding, froth flotation, roasting, smelting, Bessemerisation, and electrolytic refining. In these processes, the ore is crushed, mixed with chemicals to separate copper from waste, heated to remove impurities, and finally refined to produce high-purity copper cathodes. This intricate method highlights the complexity and technology involved in obtaining pure copper, a vital material in various industries.

Takeaways

• 🔍 Copper processing starts with mining copper ores, primarily copper oxide and copper sulfide ores.
• 💧 The extraction methods differ: hydrometallurgy for oxide ores and pyrometallurgy for sulfide ores.
• 🏗️ Sulfide ores, especially chalcopyrite, are the most profitable due to their high copper content.
• ⛏️ Mining involves large open pit mines, using drilling, blasting, and giant dump trucks for transportation.
• 🔨 The grinding process crushes ore in cone crushers and further reduces it in ball mills to create a slurry.
• 🧪 Froth flotation separates copper minerals from waste material using collectors and frothers to make copper hydrophobic.
• 🔥 Roasting involves heating concentrated ore in a reverberatory furnace to remove moisture and volatile impurities.
• ⚗️ Smelting melts copper concentrate with silica flux in a furnace, producing a molten matte with about 60% copper.
• 🚀 Bessemerisation converts molten matte into blister copper by blowing air to remove sulfur and iron impurities.
• ⚡ Electrolytic refining produces pure copper cathodes (99.95% to 99.99%) by depositing copper from anodes onto cathodes.

Q & A

What are the two main types of copper ores mentioned in the script?

The two main types of copper ores are copper oxide ores and copper sulfide ores.

What processing method is typically used for oxide ores?

Oxide ores are generally processed using hydrometallurgy.

Which type of copper ore is usually more profitable and why?

Copper sulfide ores are typically more profitable because they have a higher copper content.

What is the most common sulfide ore, and what are its alternative names?

The most common sulfide ore is chalcopyrite, which is also known as copper pyrite or yellow copper.

Can you list the seven basic steps in the copper processing sequence?

The seven basic steps are: mining the ore, grinding, froth flotation, roasting, smelting, Bessemerisation, and electrolytic refining.

What happens during the grinding stage of copper processing?

In the grinding stage, the ore is crushed using cone crushers and further ground in ball mills, turning it into a slurry mixed with valuable copper and waste rock.

What is the purpose of froth flotation in copper processing?

Froth flotation is used to separate copper minerals from waste material by making copper particles hydrophobic and allowing them to float to the surface.

What occurs during the roasting process?

During roasting, the concentrated ore is heated in a furnace, removing moisture and volatile impurities like sulfur and arsenic.

What role does the flux play in the smelting process?

Flux, such as silica, is added to the ore in the smelting process to help it melt more easily and to combine with impurities to form slag.

Describe the electrolytic refining step and its outcome.

In electrolytic refining, copper anodes are placed in a tank with a cathode and an acidic copper sulfate solution. When electric current is applied, copper is deposited on the cathode, resulting in cathodes that are 99.95% to 99.99% pure.