The considered smelting process includes a continuously functioning flash smelting furnace (FSF) and several Pierce-Smith converters operated in batches. Leaching processes produce residues, while ef-fluent treatment results in sludges, which can be sent for metals recovery. Figure 6 shows the charging procedure. Smelting technology is the world’s leading method for copper and nickel smelting. Copper sulfide and iron oxide can mix, but when sufficient silica is added, a separate slag layer is formed. Copper smelting plants separate elemental copper from copper concentrates through multiple sulphide oxidizing stages. In the furnace, the concentrates are instantly oxidized, after which they melt and separate by their own reaction heat into copper matte with a grade of 65% and slag consisting of iron oxide, silica, and … Pollution Prevention and Control process provides an innovative, high . This is accomplished through a series of several processing steps. The distributions of copper and the other elements among the gas, slag and matte were also investigated. intensity, yet low cost submerged lance smelting process that is easy to operate. The slag forming reaction is: FeO + SiO 2 → FeO.SiO 2 The entire process con-tributes to considerable resource savings as opposed to the process of similar capacity with three converters. Automating scheduling provides advisory information to operators. The copper concentrates are fed through the flash smelting furnace with oxygen-enriched air. Experimental Methods Industrial copper concentrates, matte, slag and flue dust from Chilean smelters were used as test materials. Copper matter is processed to copper blister in two 80 ton Peirce-Smith converters - one in opera-tion and the other under rebricking. 2. Solid feed combined with the high level of oxygen enrichment produces a low volume of offgas, rich in SO2. Adding silica also reduces the melting point (or, more properly, the liquidus temperature) of the slag, meaning that the smelting process can be operated at a lower temperature. copper smelting process. The process is highly energy efficient because it makes full use of the reaction heat of the concentrate, meaning Table 1 shows the example of the chemical compositions of them. The term copper smelting may refer to this melting step in particular or it may refer somewhat less formally to the entire process overall. Smelting is a process of applying heat to ore in order to extract a base metal.It is a form of extractive metallurgy.It is used to extract many metals from their ores, including silver, iron, copper, and other base metals.Smelting uses heat and a chemical reducing agent to decompose the ore, driving off other elements as gases or slag and leaving the metal base behind. contain 0.5–0.7% copper and is frequently used as construction material or for sandblasting. The reverberatory furnace dominated copper matte smelting for much of the 1900s, because it was an excellent process for smelting fine concentrate from flotation. More than half of the world’s primary copper and nickel is produced using Outotec’s proprietary process. It can be used for a range of applications including primary and secondary copper smelting and copper converting, primary and secondary lead smelting, primary nickel smelting and converting, and tin, The smelting process typically produces less than 3 tons of solid waste per ton of copper produced. It is a fossil fuel fired hearth furnace for smelting concentrate and producing copper matte. The process is very easy to operate and is autogenous with combustion air enriched to approximately 30% oxygen. The reverbs began to decline in the This two stage smelting and converting process is being considered for installation at a number of copper smelter sites. 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