on video Extraction and Manufacture of Copper from the Largest Deposits in the World

 

Copper processing is a complicated process that begins with mining of the ore (less than 1% copper) and ends with sheets of 99.99% pure copper called cathodes, which will ultimately be made into products for everyday use. The most common types of ore, copper oxide and copper sulfide, undergo two different processes, hydrometallurgy and pyrometallurgy, respectively, due to the different chemistries of the ore. Copper oxides are more abundant near the surface, but are considered low-grade ore, with a lower concentration of copper. Although this requires more ore to be extracted and processed, this process is less expensive, so oxides can still be mined at a profit. On the other hand, while copper sulfide ores are less abundant, they contain higher amounts of copper. Although the processing costs are higher, ultimately more copper can be extracted. Since each mine site is unique in its mineral composition, concentration, and quantities, the most economical and profitable processing of ore must be determined by the mine planners. When it is economically feasible, a mine may extract both types of copper minerals; when it is not possible, mines will only process either the copper oxides or the copper sulphides.

The first steps of copper processing are the same for both ores: mining and transporting. Copper mining is usually performed using open-pit mining, in which a series of stepped benches are dug deeper and deeper into the earth over time. To remove the ore, boring machinery is used to drill holes into the hard rock, and explosives are inserted into the drill holes to blast and break the rock. The resulting boulders are then ready for hauling; specialized haul trucks, conveyors, trains, and shuttle cars can all be used to haul the ore from the blasting site to the processing site. The size of the equipment needed to haul the tons and tons of ore is gigantic. Most ores are then sent through a primary crusher, which is typically located very close to or sometimes in the pit. This primary crusher reduces the size of the ore from boulder to golf ball-sized rocks.

A. Processing of Oxide Ore

Oxide ores are generally processed using hydrometallurgy. This process uses aqueous (water-based) solutions to extract and purify copper from copper oxide ores at ordinary temperatures, usually in three steps: heap leaching, solvent extraction, and electrowinning.

 

Copper processing is a complicated process that begins with mining of the ore (less than 1% copper) and ends with sheets of 99.99% pure copper called cathodes, which will ultimately be made into products for everyday use. The most common types of ore, copper oxide and copper sulfide, undergo two different processes, hydrometallurgy and pyrometallurgy, respectively, due to the different chemistries of the ore. Copper oxides are more abundant near the surface, but are considered low-grade ore, with a lower concentration of copper. Although this requires more ore to be extracted and processed, this process is less expensive, so oxides can still be mined at a profit. On the other hand, while copper sulfide ores are less abundant, they contain higher amounts of copper. Although the processing costs are higher, ultimately more copper can be extracted. Since each mine site is unique in its mineral composition, concentration, and quantities, the most economical and profitable processing of ore must be determined by the mine planners. When it is economically feasible, a mine may extract both types of copper minerals; when it is not possible, mines will only process either the copper oxides or the copper sulphides.

The first steps of copper processing are the same for both ores: mining and transporting. Copper mining is usually performed using open-pit mining, in which a series of stepped benches are dug deeper and deeper into the earth over time. To remove the ore, boring machinery is used to drill holes into the hard rock, and explosives are inserted into the drill holes to blast and break the rock. The resulting boulders are then ready for hauling; specialized haul trucks, conveyors, trains, and shuttle cars can all be used to haul the ore from the blasting site to the processing site. The size of the equipment needed to haul the tons and tons of ore is gigantic. Most ores are then sent through a primary crusher, which is typically located very close to or sometimes in the pit. This primary crusher reduces the size of the ore from boulder to golf ball-sized rocks.

A. Processing of Oxide Ore

Oxide ores are generally processed using hydrometallurgy. This process uses aqueous (water-based) solutions to extract and purify copper from copper oxide ores at ordinary temperatures, usually in three steps: heap leaching, solvent extraction, and electrowinning.

 

Copper processing is a complicated process that begins with mining of the ore (less than 1% copper) and ends with sheets of 99.99% pure copper called cathodes, which will ultimately be made into products for everyday use. The most common types of ore, copper oxide and copper sulfide, undergo two different processes, hydrometallurgy and pyrometallurgy, respectively, due to the different chemistries of the ore. Copper oxides are more abundant near the surface, but are considered low-grade ore, with a lower concentration of copper. Although this requires more ore to be extracted and processed, this process is less expensive, so oxides can still be mined at a profit. On the other hand, while copper sulfide ores are less abundant, they contain higher amounts of copper. Although the processing costs are higher, ultimately more copper can be extracted. Since each mine site is unique in its mineral composition, concentration, and quantities, the most economical and profitable processing of ore must be determined by the mine planners. When it is economically feasible, a mine may extract both types of copper minerals; when it is not possible, mines will only process either the copper oxides or the copper sulphides.

The first steps of copper processing are the same for both ores: mining and transporting. Copper mining is usually performed using open-pit mining, in which a series of stepped benches are dug deeper and deeper into the earth over time. To remove the ore, boring machinery is used to drill holes into the hard rock, and explosives are inserted into the drill holes to blast and break the rock. The resulting boulders are then ready for hauling; specialized haul trucks, conveyors, trains, and shuttle cars can all be used to haul the ore from the blasting site to the processing site. The size of the equipment needed to haul the tons and tons of ore is gigantic. Most ores are then sent through a primary crusher, which is typically located very close to or sometimes in the pit. This primary crusher reduces the size of the ore from boulder to golf ball-sized rocks.

A. Processing of Oxide Ore

Oxide ores are generally processed using hydrometallurgy. This process uses aqueous (water-based) solutions to extract and purify copper from copper oxide ores at ordinary temperatures, usually in three steps: heap leaching, solvent extraction, and electrowinning.

 

Copper processing is a complicated process that begins with mining of the ore (less than 1% copper) and ends with sheets of 99.99% pure copper called cathodes, which will ultimately be made into products for everyday use. The most common types of ore, copper oxide and copper sulfide, undergo two different processes, hydrometallurgy and pyrometallurgy, respectively, due to the different chemistries of the ore. Copper oxides are more abundant near the surface, but are considered low-grade ore, with a lower concentration of copper. Although this requires more ore to be extracted and processed, this process is less expensive, so oxides can still be mined at a profit. On the other hand, while copper sulfide ores are less abundant, they contain higher amounts of copper. Although the processing costs are higher, ultimately more copper can be extracted. Since each mine site is unique in its mineral composition, concentration, and quantities, the most economical and profitable processing of ore must be determined by the mine planners. When it is economically feasible, a mine may extract both types of copper minerals; when it is not possible, mines will only process either the copper oxides or the copper sulphides.

The first steps of copper processing are the same for both ores: mining and transporting. Copper mining is usually performed using open-pit mining, in which a series of stepped benches are dug deeper and deeper into the earth over time. To remove the ore, boring machinery is used to drill holes into the hard rock, and explosives are inserted into the drill holes to blast and break the rock. The resulting boulders are then ready for hauling; specialized haul trucks, conveyors, trains, and shuttle cars can all be used to haul the ore from the blasting site to the processing site. The size of the equipment needed to haul the tons and tons of ore is gigantic. Most ores are then sent through a primary crusher, which is typically located very close to or sometimes in the pit. This primary crusher reduces the size of the ore from boulder to golf ball-sized rocks.

A. Processing of Oxide Ore

Oxide ores are generally processed using hydrometallurgy. This process uses aqueous (water-based) solutions to extract and purify copper from copper oxide ores at ordinary temperatures, usually in three steps: heap leaching, solvent extraction, and electrowinning.