12th International Copper Conference

Table of Contents

1. Environmental Control, Safety and Hygiene

   1. Frontmatter

   2. Environmental Challenges of Copper Concentrates Roasting

      Kamal Adham, N. Wong

      Abstract

      Fluidized bed roasters (FBR) have been used on copper concentrates for sulfur, arsenic, and carbon removal. Environmental emissions associated with those operations include SO₂ and As₂O₃ capture and stabilization, as well as dealing with byproducts such as hematite and gypsum. Here those operations and their possible emission mitigations are considered and compared.

   3. Optimizing Furnace Rebuild Efficiency Through Effective Furnace Draining

      Jackey Sjam

      Abstract

      Smelting furnaces for copper and nickel undergo periodic shutdowns for refractory relining, during which residual molten material (slag and matte/metal) solidifies and must be removed. Enhanced furnace draining practices aim to minimize this residual “skull,” thereby simplifying demolition and expediting maintenance. This paper examines how improved draining techniques—such as extended tapping, tilting furnaces, and auxiliary tap-holes—reduce the volume and thickness of leftover slag/metal prior to relining. Using technical specifications of a Brokk 500 remote demolition machine as a base to collect data, we demonstrate that residual material thickness and density strongly affect demolition time: thicker, denser solid slag, or matte can double or triple removal time, whereas thorough draining that leaves only a thin layer can cut demolition durations by more than half. Copper and nickel smelter case studies are presented to quantify the benefits. Data from real operations show that optimized draining and mechanized cleanup have reduced overall shutdown durations by up to 25%, yielded over 18% cost savings in maintenance and lost production, and significantly improved safety by reducing workers’ exposure to hot materials and manual jackhammering. Diagrams illustrate the relationship between skull thickness/density and breakout time, and tables summarize industry examples. The findings underscore that proactive furnace draining, combined with modern demolition technology, can substantially improve smelter maintenance efficiency, economics, and safety. The paper is written for a broad technical audience—from furnace operators to maintenance managers.

   4. Non-conductive Overhead Crane Rope Project—Southside Tankhouse Commercial Trial

      T. Ratnaweera, T. Montoya, P. Joost, S. Sandoval, E. Peru

      Abstract

      This project aimed to eliminate the stray current shock hazard posed by the electrically grounded crane bridge at Freeport-McMoRan Morenci, by replacing the existing metal wire rope with a synthetic fiber rope. The primary challenges were assessing the wear characteristics of the synthetic rope on a retrofitted crane and identifying operational practices that would impact the rope's longevity. Freeport is in process of converting to the synthetic fiber rope at all its tank houses. The evaluation was done as a collaboration between KONECRANES, CERTEX, and Freeport-McMoRan at the Morenci Hydromet Southside G-Crane, with initial pilot testing on the Southside Service Crane. The synthetic rope demonstrated effective mitigation of electrical shock hazard for the operator, while maintaining tensile strength for lifting compared with the metal cable. Relevant OSHA and MSHA standards for overhead crane operation, as well as ASME B30.2 and B30.30 safety standards for overhead cranes and ropes, were reviewed. Commercial testing began in October 2020, with a gradual increase in operational cycles, and concluded in May 2021. The results demonstrated a degradation in rope strength over time, corresponding with increased operational cycles, but maintained a strength ratio of at least 5:1 relative to the maximum carrying capacity of the crane. Electrical conductivity tests indicated the ropes provided effective insulation showing the ropes could be moved into full-scale use. This paper will explore the initial piloting, project planning, overall implementation across Freeport and operational pieces that are still being explored.

   5. Use of ILTEC Technology for Heat Recovery: Calculation Example at a Flash Furnace

      Filzwieser Andreas, Lindthaler Matthias, Martina Hanel

      Abstract

      ILTEC Technology offers an innovative solution for cooling in high-temperature industrial environments, in this case for a flash furnace. Traditional water cooling systems present several risks, including potential explosions upon contact with molten metal. ILTEC eliminates these risks by using ionic liquids, which are non-flammable, non-explosive, and thermally stable up to 200 °C and more. The flash furnace operates continuously, providing a constant heat source that can be used more efficiently with ILTEC Technology. With sufficient piping insulation and optimal design, the heat loss during fluid circulation is minimized. The heat recovery can be used for power generation and/or other industrial processes, thus significantly improving the overall energy efficiency of the plant. When considering heat recovery at a conceptual flash furnace, ILTEC technology enables a stable waste heat recovery at around 200 °C. These high temperature ranges are ideal for integrating heat recovery systems like the Organic Rankine Cycle system that converts waste heat into electrical energy. Based on calculations from a case study at a flash furnace with a heat load of 9.5 MW, the ILTEC system can be used to recover a substantial amount of energy. In the example here forth, ILTEC’s abilities will be shown to not only provide a safer cooling solution for under bath areas but also to enable significant overall energy recovery and corrosion prevention in the uptake shaft area, reducing both operational costs and environmental impact.

   6. Advancements in Understanding Acid Mist Generation and Mitigation in Copper Electrowinning

      Therese Roa, Jinhong Zhang

      Abstract

      During the copper electrowinning (EW) process, oxygen bubbles form on the anode and rupture at the air/solution interface releasing acid mist detrimental to workers’ health and equipment. Anti-mist agents, although effective, are often environmentally unfriendly with poorly understood suppression mechanisms. In the present study, we measured and characterized the physical–chemical properties (density, surface tension, viscosity) of the electrowinning solution, particularly considering the effects of surfactant addition and temperature. Test results show that increasing temperature impacts EW solution by decreasing surface tension, viscosity, and density of EW solution. The addition of FC-1100 decreases surface tension, increases viscosity and increases density. The findings of the present work not only clarify the mechanisms of acid mist formation and suppression but additionally help with the search for and application of an environmentally friendly anti-mist agent for copper electrowinning.

   7. Using Bio-Based Frothers in Froth Flotation to Improve Renewable Carbon Index

      Laura Benavides

      Abstract

      With a large focus recently on growing ESG initiatives, there is a large opportunity for companies to demonstrate “environmentally friendliness” and “sustainable supply.” Integrity Mining and Industrial (IMI) bases the carbon signature of its biopolymer-based products on its renewable carbon index (RCI). RCI readily classifies the origin of carbon in a molecule, i.e., modern vegetative sources or extracted petroleum derivatives. Specifically, it measures the number of carbons derived from renewable sources compared to the total number of carbons in the product. IMI has developed a bio-based frother, TegraFroth that can be used to replace leading synthetics to meet sustainability and environmental regulations. Based on preliminary testing, TegraFroth was evaluated and compared to commodity frothers used in a copper mine, a potash mine, and a gold mine—and in all three cases had no negative effect on the respective mineral recovery or grade when compared to the blank that was evaluated using a standard industry frother. The focus of this presentation will be to discuss the plant trial results of our TegraFroth as compared to alcohol-based furthers, propylene glycol, and other glycol ethers in a copper concentrator in the US, and a potash processing plant in Canada.

   8. Application of Virtual Reality (VR) in Workers Safety Training and Modifying Unsafe Behavior

      Robert Gregorczyk, Tomasz Gąbka

      Abstract

      According to the Central Statistical Office, more than 80% of accidents are caused by human causes. In order to change this situation, it is necessary to take measures related to the optimal preparation of workers for dangerous work. Intense development of VR tools for simulating the real work environment allows to apply virtual reality (VR) to train workers in hazardous works without exposing them to health loss. Analyzing accidents at work in Głogów Smelter and the number of recorded improper behaviors of employees of contractor companies during shutdowns a decision was made to develop software applications for training with the use of VR in hazardous work: Work at height and tap hole opening and plugging. Currently, there is a generational change of staff ongoing at the smelter and training of new employees with use of VR makes it more attractive and efficient.

   9. Managing Stray Current in Cathodic Protection and Electrowinning Plants: Safety and Infrastructure Integrity

      Francis Dakubo

      Abstract

      Stray current interference poses a significant challenge in both cathodic protection (CP) systems and electrowinning (EW) plants, impacting safety, infrastructure longevity, and operational efficacy. In CP systems, stray currents—unintended currents from nearby railways, pipelines, or DC-powered systems—can deviate from their intended paths, creating localized anodic and cathodic sites on protected structures such as pipelines or reinforced concrete. This unintended electrochemical activity accelerates corrosion, leading to structural degradation, increased maintenance costs, and heightened safety risks. Stray current shielding methods such as sacrificial anodes, grounding systems, and insulating barriers are crucial to counter these effects. These measures help divert stray currents from protected assets, particularly in urban environments with multiple DC sources, ensuring CP systems’ integrity and extending critical infrastructure's lifespan. In electrowinning plants, stray currents primarily arise from electrolyte leaks, sulfated insulators, or conductive structural components near cell lines. These currents can lead to galvanic corrosion of metallic infrastructure, increasing the risk of localized corrosion and shock hazards for personnel. Stray currents also pose a unique threat in the high-moisture environments typical of EW operations, where conductive pathways are prevalent, amplifying the risk of electric shock. Effective management practices, including adherence to IEEE Standard 463 and implementing floating ground configurations, are essential to isolate EW cells and reduce shock hazards. Facilities risk compromising safety and asset longevity without regular, stray current audits and proper isolation practices. Therefore, consistent monitoring and mitigating stray currents in CP and EW systems are vital to protect personnel, maintain structural integrity, and adhere to industry standards.

   10. Improving Safety and Efficiency in Copper Mining Training with Virtual Reality Simulation

       Juan Alfonso Reyes López, Alistair Schneider, Juan Carlos Muñoz Di-parodi, Sergio Orlando Silva Muñoz, Victor Eduardo Peñaloza Gaete

       Abstract

       The mining industry faces a growing demand for minerals and a shortage of skilled workers. Traditional training methods struggle to bridge the experience gap for complex operations. Virtual reality (VR) training offers an immersive, scalable solution, accelerating skill acquisition and enhancing safety. This chapter explores how VR can address workforce shortages by providing realistic training scenarios. Behavioral economics, particularly the availability heuristic, explains how VR reshapes risk perception and decision-making. Studies show VR reduces learning time, increases retention, and enhances engagement over traditional methods.