Simplified Process for Making Anode Copper

In conventional copper production, anode copper is produced from concentrate in three furnaces in a process that entails four oxidation steps and one reduction step. Three types of slags are produced that require further treatment to recover copper. Dongying Fangyuan Nonferrous Metals recently developed a simplified process which requires only two custom-designed furnaces instead of the conventional smelting, converting and refining furnaces. The first furnace continuously produces high-grade matte (>75 wt% Cu) that contains little iron (<2 wt% Fe). The liquid matte is continuously fed to the second furnace, which produces anode copper. The new process significantly reduces the capital and operating costs and increases productivity and environmental sustainability. This paper presents fundamental concepts that enable the simplified process to be developed. The detailed operations in Dongying Fangyuan Nonferrous Metals are also described.