How is copper extracted and processed?:
The step-by-step process of refining copper:
Copper extraction from ore begins with pre-treatment, an important step to reduce material volume and increase copper grade.
Most copper ores contain a small percentage of copper mineral, typically below 0.6%, along with unwanted rock or gangue minerals like silicate or oxide minerals.
After pre-treatment, the ore is screened and oversized particles are sent to the SAG mill. A hammer sampler samples the feed while an overbelt magnet removes any tramp iron before it reaches the SAG mill. Water is added to facilitate slurry transfer to the secondary grinding stage, usually located near or in the mine pit.
A trommel screen removes scats and oversize material that could damage pumps and classification cyclones. Finer particles below the cut point are transferred for primary flotation, while underflow goes to a secondary ball mill and trommel screen for further grinding and classification.
Through froth flotation, copper minerals separate from gangue and rise to the froth layer in flotation cells.
Copper-rich bubbles are then removed or transferred for subsequent stages of flotation. There may be primary, secondary, or even tertiary flotation circuits aimed at maximizing recovery of copper mineral.
After secondary flotation, concentrate is sampled and sent to a thickener where froth bubbles break down and copper minerals settle at the tank bottom. The solid concentrate undergoes filtration to remove excess water.
Tailings from secondary flotation go through regrinding via a mill and trommel screen before being processed again through another round of flotation as slurry.
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