Recovery Process
The extracted ore is run through a concentrator, where huge grinding mills reduce it to the consistency of face powder. Flotation then separates the gangue from the metalliferous particles, which float off as a 28-percent concentrate of copper along with lesser amounts of silver, gold, lead, molybdenum, platinum and palladium. A selective flotation step separates the molybdenite (molybdenum disulfide) from the chalcopyrite.
The filtered concentrate slurry is piped 17 miles (27 km) to the smelter, where it is dried, and then injected along with oxygen into a flash smelting furnace to oxidize the iron and sulfur. The oxidized iron is skimmed off, while the sulfur dioxide gas is captured and sent to an on-site acid plant for conversion to valuable sulfuric acid - a million tons of it each year.
Left behind is a molten copper sulfide called matte. The 70-percent-copper matte is water-quenched to form a sand-like solid, then injected, with oxygen, into a flash-converting furnace that produces molten, 98.6-percent-pure copper. This copper is then cast into 700-pound (320 kg) anode plates and shipped by rail to the refinery.
At the refinery, the anode plates are pressed flat and interleaved with stainless steel cathode blanks. Automated robotic vehicles place the prepared anodes in cells containing an acidic electrolyte. When the cells are electrified, the anodes slowly dissolve, freeing copper ions that are deposited on the cathode as 99.9-percent-pure copper.
Impurities and precious metals settle to the bottom of the electrolytic cells as "slimes." A chlorination leaching process recovers the gold and silver, which is melted in induction furnaces.
Read more about this topic: Bingham Canyon Mine
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