A New Paipote Process of Continuous Fire Refining of Copper

A new, continuous fire refining process for copper has been developed and tested at the 5 tph pilot scale. During oxidation, the blister copper flows through a packed bed of crushed refractory bricks counter-current to a hot oxygen containing gas. The resulting desulphurized copper flows then directly into a packed bed of charcoal for deoxidation. By controlling the air to natural gas ratio, both temperature and reducing conditions can be controlled. Based on extensive laboratory scale measurements of the rate of copper oxidation and reduction, the process concept was developed aided by process modeling and simulation. The industrial-pilot scale installation built at the ENAMI Paipote smelter in Chile, consists of two cylindrical, compact reactors, operating in line, with a designed capacity of 5 t/h of blister copper. The results of the industrial-pilot tests confirmed the feasibility of the new process. The blister copper processing capacity was increased to 10 t/h with satisfactory sulphur removal. The degree of oxidation as well the copper temperature was controlled with relative ease. The specially designed siphon block allowed for smooth tapping of the oxidized copper and separation of refining slag. The reduction of oxidized copper in the packed bed of charcoal appeared to be very effective while control of the degree of reduction according to the height of the bed ensured control of the oxygen content in the refined copper at the required level.