Copper extraction involves several stages, beginning with mining and culminating in the production of pure copper metal. Depending on the ore nature, either the hydrometallurgy or pyrometallurgy method is chosen. The extracted ore is crushed into small pieces to facilitate further processing. This crushed ore is then ground into a fine powder to increase the surface area for the subsequent chemical reactions.
01
Heap Leaching
Crushed ore is piled onto a leach pad and irrigated with a leach solution (usually sulfuric acid), which percolates through the heap, dissolving copper from the ore.
02
Solvent Extraction
The copper-laden solution (pregnant leach solution) is mixed with an organic solvent that selectively extracts the copper ions.
03
Electrowinning
The copper-rich solution from solvent extraction undergoes electrolysis, where copper ions are plated onto cathodes, producing high-purity copper.
01
Concentration
The ground ore undergoes a concentration process, usually through froth flotation. In this process, the powdered ore is mixed with water and chemicals to create a slurry. Air is then introduced, forming froth that rises to the surface, carrying the copper-containing minerals. The froth is skimmed off, yielding a concentrated ore with higher copper content.
02
Roasting and Smelting
The concentrated ore is subjected to high temperatures in a furnace. During roasting, the ore is heated in the presence of oxygen, converting sulfides into oxides and releasing sulfur dioxide gas. The roasted ore is then smelted, producing a molten mixture of copper matte (a mixture of copper, iron, and sulfur) and slag (a byproduct containing impurities).
03
Converting
The copper matte is transferred to a converter furnace, where it is blown with air or oxygen to remove the remaining iron and sulfur. This process produces blister copper, which is about 98-99% pure.
The blister copper undergoes refining to remove the final impurities. There are two main methods for refining:
Electrolytic Refining
The blister copper is cast into anodes and placed in an electrolyte solution of copper sulfate and sulfuric acid. An electric current passes through the solution, causing copper ions to deposit on a cathode, resulting in 99.99% pure copper.
Fire Refining
This method involves reheating the blister copper in a furnace and adding fluxes to remove impurities. The refined copper is then cast into anodes for electrolytic refining or directly into finished products.
The refined copper is cast into various shapes and sizes, such as rods, bars, and ingots, depending on its intended use.
Knife Gate Valves are crucial in various stages of the copper extraction process, particularly in handling slurry, pulp, and other abrasive materials. Common areas you would find our Knife Gate Valves include:
• Provides reliability in slurry isolation across the entire plant:
o Flotation Cells, Cyclones, Thickeners, etc
o Heap Leach Plants
o SX/EW Plants
o Tailings Distribution Lines & Spigots
• Full body liner protects the valve body from slurry and leach solutions, increasing the life of the valve
• Rotable; easily refurbishable on site as the liner is replaceable
• Gate Options: 316 SS, 2205 Duplex, 2507 Super Duplex, Hastelloy C276, Hastelloy C22, etc
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
• Available in Class #150 and Class #300 ratings
• Meets MSS SP-135 Standards
• Successfully operate in:
o High Density Tailings
o Abrasive and turbulent slurries
• Features identical inlet and outlet seat rings that incorporate a soft primary seat and a hardened secondary seat to improve sealing and service life
o Seat Ring Options: Hardened Steel, Ceramic Lined, other anti-abrasion materials, etc to suit the process conditions
• Rotable; easily refurbishable on site
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
• Available in 10 bar or Class #150 ratings
• Body and Gate Options: 316 SS, DI, CS, 2205 Duplex, 2507 Super Duplex, Hastelloy C276, etc
• Features a soft primary seat and a metal secondary seat to improve sealing and service life
• Rotable; easily refurbishable on site
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
Check out our full range of Knife Gate Valves for Mining Applications.
Gold extraction involves several stages, beginning with mining and culminating in the production of pure gold metal. The extracted ore is crushed into small pieces to facilitate further processing. This crushed ore is then ground into a fine powder to increase the surface area for the subsequent chemical reactions.
01
Uses the density difference between gold and other minerals to separate them. This is done using devices like jigs, spirals, and shaking tables.
02
Involves mixing the ground ore with water and chemicals to create a slurry, which is aerated to form bubbles. Gold-containing minerals attach to the bubbles and rise to the surface, where they can be collected.
03
The ore is treated with a cyanide solution, which dissolves the gold. This process can be conducted in agitated tanks or in heap leaching, where the ore is piled onto a leach pad and irrigated with the cyanide solution.
OR 04
Alternative to cyanidation, especially for ores that are resistant to cyanide. This process uses a thiosulfate solution to dissolve the gold.
The gold-bearing (pregnant) solution is then processed to extract the gold. This is typically done using activated carbon or resin
01
Carbon-in-Pulp (CIP)
Activated carbon is added to the gold-laden slurry, which adsorbs the gold.
02
Carbon-in-Leach (CIL)
Similar to CIP but the carbon is added directly to the leach tanks.
03
Carbon-in-Column (CIC)
Used for heap leaching operations where the gold-laden solution passes through columns packed with activated carbon.
The gold adsorbed on the carbon or resin is then stripped off and recovered
01
Desorption
The gold is desorbed (removed) from the carbon or resin using a hot caustic solution.
02
Electrowinning
The desorbed gold solution is subjected to electrolysis, where gold is plated onto cathodes.
The recovered gold is then refined to achieve high purity
01
Smelting
The gold is melted and poured into molds to form bars or ingots. Impurities are removed during this process.
02
Electrolytic Refining
The gold is further purified by dissolving it in an electrolyte solution and using electrolysis to produce high-purity gold.
Knife Gate Valves are crucial in various stages of the gold extraction process, particularly in handling slurry, pulp, and other abrasive materials. Common areas you would find our Knife Gate Valves include:
• Provides reliability in slurry isolation across the entire plant:
o Flotation Cells, Cyclones, Thickeners, etc
o Heap Leach Plants / CIL / CIP
o Elution Column Circuits
o SX/EW Plants
o Tailings Distribution Lines & Spigots
• Full body liner protects the valve body from slurry, leach solutions and electrolyte solutions, increasing the life of the valve
• Rotable; easily refurbishable on site as the liner is replaceable
• Gate Options: 316 SS, 2205 Duplex, 2507 Super Duplex, Hastelloy C276, Hastelloy C22,etc
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
• Available in Class #150 and Class #300 ratings
• Meets MSS SP-135 Standards
• Successfully operate in:
o High Density Tailings
o Abrasive and turbulent slurries
• Features identical inlet and outlet seat rings that incorporate a soft primary seat and a hardened secondary seat to improve sealing and service life
o Seat Ring Options: Hardened Steel, Ceramic Lined, other anti-abrasion materials, etc to suit the process conditions
• Rotable; easily refurbishable on site
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
• Available in 10 bar or Class #150 ratings
• Body and Gate Options: 316 SS, DI, CS, 2205 Duplex, 2507 Super Duplex, Hastelloy C276, etc
• Features a soft primary seat and a metal secondary seat to improve sealing and service life
• Rotable; easily refurbishable on site
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
View our complete range of high performance valves for slurry applications.
We understand the need to offer choices for our customers and offer a range of valves, price points and services.
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