Indonesia University

7/28/2019 Indonesia University

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Development of MitsubishiContinuous Process for

Copper ExtractionMoto Goto

President DirectorPT. Smelting


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History of Copper

Copper is one of the oldest metal 6,000-8,000 years ago in the East

Europe and the Middle East

4,000 years ago in China

2,000 years ago in Japan


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DOTAKU Unearthed


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DOTAKU Has a BABY


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DOTAKU


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WADO-KAICHIN


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Buddha in NARA


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Smelting Process in 15thCentury in Japan


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Copper Historyin 16th Century

Mining and smelting wasimproved in Germany and Japan

4-5% grade copper ore

Good quality of wood as fuel

Good quality clay for hearth making

Blasting technology like handbellows and piping


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Copper Historyin 17th-19th Century

Leading countries of copperproduction are Germany, United

Kingdom, Russia and Japan

Copper production was declined

in Japan at the end of 17th

century


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Rapid Increase ofCopper Consumption

Copper consumption in the world Year 1,800 : 10.000 tons

Year 1,900 : 500,000 tons

Year 2,000 : 15,000,000 tons

UK was a leading producer


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Copper Historyin 19th-20th Century

Big copper deposits were found In North America, South America,

and Africa.


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Copper Historyin 20th Century

New copper mines were found inAsia

Indonesia, Philippines, Malaysia,

Papua New Guinea


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Comparison between Steeland Copper Industry

Steel C opper

Production in Japan 80M tons 1.3M tons

M etal content in O re 60% 1%G an gue 2.2 tim es


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Grasberg ConcentrateC onc. C om position

2000 A vg.

A u g/T 30

A g g/T 57

C u % 30.75

F e % 24.59

S % 29.46

Pb % 0.04

Zn % 0.29

SiO 2 % 9.65

A l2O 3 % 2.21

C aO % 0.58

M gO % 0.46

A s % 0.003

Sb % 0.001B i % 0.003


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Outokumpu Flash Furnace


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Key words

% Cu Fe S product ofCopper ore 1 mining

Concentrate 30 25 30 flotation

matte 68 7 21 smelting fceblister 98 1 PS converter

anode 99 anode fce

cathode 99.99 electro- refine


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Peirce-Smith (PS)Converter


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Hood for PS Converter


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Gas Condition

Batchwise Continuous


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Continuous Converting

In 1959 (Pioneer) at Balhashi in Kazakhstan then in

Szekoslovakia

In 1960s Worcra process in Australia

Noranda process in Canada

Mitsubishi process in Japan


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Worcra Process


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Noranda Process


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Mitsubishi Process

Pilot plant of Mitsubishi processby 72T/D in 1968

Basic idea

Smelting and converting in separate

furnace (Two steps)

Transportation through launders

Top blow lances blowing and feeding


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Furnace Arrangement ofFurnace Arrangement of

Mitsubishi ProcessMitsubishi ProcessC Fce CL Fce S

Fce

Anode Fce

Lances

Lances

forconcentrat

e

Hazelett Caster

Matte

LaunderBlister

CL-SlagElectrod

es

Mannesman

Shear

C-Slag


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Cu-Fe-S Phase Diagram


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Difficulties ofDirect Extraction

Long furnace to keep different O2partial pressures in one reacter

(WORCRA)

Insufficient copper recovery fromslag (Noranda)

Poor minor element elimination


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Minor Element Recovery

O ne Step Tw o Steps

D ust Treatm ent Separate Separate

C -Slag T reatm ent Separate Separate

Pb 13% 11%Zn 0% 0%

A s 15% 3%

Sb 31% 14%B i 14% 7%


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Advantage ofTop Blow Lance

Possible to replace duringoperation

Reduce damage of refractory

Campaign life of Mitsubishi

Converting furnace is longer than

that of PS converter


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Cavity and Deep Penetration


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Behavior of gas/solid jet

in Smelting Furnace


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Phase Diagram ofCu2O - CaO System


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Kennecott-OutokumpuFlash Converter

Operation started in 1995 in USA Matte is granulated by water,

piled, reclaimed, ground, dried

and charged to converter

Independent operation of both

furnaces Additional equipment, additional

energy and high dust generation


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Gresik Copper Smelter and RefineryOperation Update and Expansion PlanGresikGresikCopper Smelter and RefineryCopper Smelter and Refinery

Operation Update and Expansion PlanOperation Update and Expansion Plan

Gresik Smelter & Refinery, PT. SmeltingGresik Smelter & Refinery, PT. Smelting

Dr. Moto Goto, Budi Priyo Handogo, M.A.ScDr. Moto Goto, Budi Priyo Handogo, M.A.Sc

Indonesian Mining Conference 2001

Jakarta, Indonesia 7-8 November 2001

Indonesian Mining Conference 2001

Jakarta, Indonesia 7-8 November 2001


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Design CapacityDesign CapacityDesign Capacity

Copper ConcentrateCopper Concentrate 660,000660,000 tpytpy

Copper CathodeCopper Cathode 200,000200,000 tpytpy

Water Granulated SlagWater Granulated Slag 400,000400,000 tpytpySulfuric AcidSulfuric Acid 600,000600,000 tpytpy

Anode SlimeAnode Slime 500500 tpytpy


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Merits of LocationMerits of LocationMerits of Location

Adjacent to a FertilizerAdjacent to a Fertilizer

CompanyCompany

Facing on Sea ShoreFacing on Sea Shore

Close to Good HarborClose to Good Harbor

Having AdequateHaving AdequateInfrastructureInfrastructure


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PT. Smelting OutlookPT.PT.

SmeltingSmelting

OutlookOutlook

SmelterSmelter

RefineryRefinery

Acid PlantAcid Plant

OfficeOffice

OxygenOxygenPowerPower

WaterWater

ReservoirReservoirLaboratoryLaboratory

Conc.Conc.

YardYard


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Flow Sheet of Gresik PlantFlow Sheet ofFlow Sheet ofGresikGresik PlantPlant

Flux & Coal Copper Concentrate Oxygen Enriched Air

SMELTER

GranulatedSlag Copper Anode

SO2 ACID PLANT

Sulfuric Acid

REFINERY Effluent WASTEWATERTREATMENT PLANT

Treated WaterGypsumCopper CathodeAnode Slime

EffluentEffluent


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UnloaderUnloaderUnloader

Furnace Arrangement ofFurnace Arrangement ofFurnace Arrangement of


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Furnace Arrangement of

Mitsubishi Process

Furnace Arrangement ofFurnace Arrangement of

Mitsubishi ProcessMitsubishi Process


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S Furnace OutletS Furnace OutletS Furnace Outlet


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CL slag granulationCL slag granulationCL slag granulation


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Blister Launder TipBlister Launder TipBlister Launder Tip


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Hazelett CasterHazelettHazelett CasterCaster


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Copper AnodeCopper AnodeCopper Anode


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RefineryRefineryRefinery


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Acid PlantAcid PlantAcid Plant


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Wastewater Treatment PlantWastewater Treatment PlantWastewater Treatment Plant

Treated ConcentrateTreated ConcentrateTreated Concentrate


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Treated Concentrate

and Anode Production

Treated Concentrate

and Anode Productionand Anode Production

0

50

100

150

200

250

1st

2nd

3rd

4th

1st

2nd

3rd

4th

1st

2nd

3rd

1999 2000 2001

ConcentrateandAnode(Kiloto

ns)

Concentrate

Anode


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Expansion plan of Gresikcopper productions

Expansion plan ofExpansion plan ofGresikGresikcopper productionscopper productions

From 2003

Nominal production rate of copper cathode

200,000 T/Y 250,000 T/Y

Countries and Consumption ofCountries andCountries and Consumption ofConsumption of


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Cou t es a d Co su pt o o

Gresik copper cathode

pp

GresikGresik copper cathodecopper cathode


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5 S (1)5 S (1)5 S (1)

SEIRI Organization RINGKASSEITON Neatness RAPI

SEISO Cleaning RESIKSEIKETSU Standardization RAWAT

SHITSUKE Discipline RAJIN


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5 S (2)5 S (2)5 S (2)


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ConclusionsConclusionsConclusions

Documents

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