TOP8 Copper Smelting Furnace equipment

  Congo gold and copper smelting furnace

  Equipment use description:​

  Copper smelting furnace is a kind of key equipment used in copper smelting process. It is heated by electric energy to melt copper bearing charge into crude copper, copper matte or other copper products in the furnace.

  Working principle:

  The working principle of copper smelting electric furnace is based on the electric heating effect. When the current passes through the electrode, there is an arc between the electrode and the charge, and the high temperature of the arc makes the charge melt. At the same time, the resistance of the charge also generates heat, which further facilitates the smelting process. ‌ In the smelting process, the copper element in the charge reacts with other components to form crude copper, matte, slag and other products.

  High efficiency:

  1.Electric furnace copper smelting has the characteristics of high heat utilization rate, can quickly melt the charge.
  2. Environmental protection: Compared with traditional copper smelting methods, the smoke amount of copper smelting in electric furnace is small and the smoke temperature is low, which is conducive to environmental protection.
  3. Flexibility: electric furnace copper smelting can handle a variety of copper bearing charge, including refractory charge, oxide ore, sulfide ore, copper-bearing tailings, copper mud, etc...

  Product process description:

  1. Raw material preparation: ‌ First, prepare the charge containing copper, usually copper concentrate. These concentrates need to be prepared before refining, such as drying, pelleting, etc., to ensure that the moisture content of the furnace material is moderate, ‌ to avoid accidents such as tipping in the smelting process ‌
  2. Ingredients and flux adding: ‌ The prepared copper concentrate is mixed with appropriate amount of flux, the function of flux is to promote the chemical reaction of the charge in the melting process and the separation of impurities
  3. Electric furnace heating and melting: the prepared charge is added to the mineral thermal electric furnace, electric arc and resistance heat are generated through the electrode, so that the charge is melted under the action of electric heating. In the molten pool, the charge will complete various chemical reactions to produce copper matte, slag and other products;
  4. Impurity separation: In the melting process, by controlling the temperature and adding chemicals, various impurities (such as arsenic, iron, sulfur, etc.) in the copper pool float on the surface of the liquid copper pool, and discharge it in an appropriate way to purify the copper liquid;
  5. Cooling and casting: after impurity separation, the obtained crude copper liquid or copper sulfur is cooled, ‌ and then cast into the required copper ingot or copper billet. ‌

  Equipment composition:

  1.Furnace body;

  2.Furnace lining;

  3.Water cooling furnace cover;

  4.Electrode lifting system;

  5.Hydraulic system;

  6.Short network system;

  7.Water tank and water dispenser;

  8.Copper mold;

  9.Electric furnace transformer;

  10.High voltage switch cabinet;

  11.Electric furnace control system.

Key Equipment Components

1. Furnace Body: Lined with high-temperature refractory materials (e.g., magnesia-chrome bricks, alumina) to withstand corrosion from molten slag/matte and thermal shock. It has a charging port, slag tap (upper level), and matte tap (lower level).
2. Fuel/Oxygen Supply System: Delivers fuel (coke, natural gas) and oxygen-enriched air (critical for flash/bath smelting) to maintain reaction temperatures and oxidation efficiency.
3. Off-Gas Treatment System: Captures SO₂-rich off-gas (a byproduct of sulfide smelting) via cyclones, electrostatic precipitators, and acid plants (converting SO₂ to sulfuric acid). Mandatory for environmental compliance.
4. Material Handling System: Includes conveyors for raw materials, feeders for precise charging, and tapping systems for slag/matte (often with ladles or continuous discharge).
5. Control & Monitoring System: Real-time tracks temperature, pressure, oxygen content, and matte/slag composition. Automates charging, oxygen flow, and tapping to optimize smelting conditions and reduce human error.

Advantages of Modern Copper Smelting Furnaces

• High Efficiency: Self-heating via sulfide combustion reduces fuel demand by 30%–50% compared to blast furnaces.
• Environmental Friendliness: SO₂ capture rate exceeds 95% (vs. <70% for blast furnaces), minimizing air pollution; sulfuric acid byproducts create additional economic value.
• High Recovery Rate: Copper recovery from concentrates reaches 97%–99%, reducing waste of valuable resources.
• Flexibility: Adaptable to diverse raw materials, from high-grade concentrates to mixed scrap, supporting circular economy practices.

Core Working Principles

1. Raw Material Preparation: Copper ores/concentrates are crushed, ground, and mixed with fluxes (e.g., silica, limestone) and fuels/reducing agents (e.g., coke, natural gas). Fluxes lower the melting point of gangue (silicate impurities) to form slag, while reducing agents convert copper oxides to elemental copper.
2. High-Temperature Smelting: The mixed charge is fed into the furnace and heated to a molten state. Chemical reactions occur:
   • Oxidation: Sulfide ores (e.g., chalcopyrite, CuFeS₂) react with oxygen to form copper sulfide (Cu₂S), iron oxide (FeO), and sulfur dioxide (SO₂).
   • Phase Separation: Molten copper sulfide combines with other metal sulfides to form matte (a dense alloy of Cu₂S and FeS, with 30%–70% copper content), while gangue and flux form low-density slag (silicates), which floats on top of the matte for separation.
3. Conversion & Initial Refining: Matte is further processed (e.g., in a converter) to remove iron and sulfur, producing blister copper (98%–99.5% purity). Blister copper then undergoes fire refining or electrolysis to reach pure copper (99.95%–99.999%).