Copper Wire Production, Essay Example

Abstract

This research paper will review the process of copper wire production from the extraction process of the ore to the rolling of the wire. The energy resources which are liberated at each process phase will be explored. The perspectives of Arderiu and Properzi (1996), Errington et al. (1997), Gao et al. (2004) Pradenas et al. (2011) and Sachdev and Sachdev (2005) will be reviewed. The optimal furnace type for the most effective processing of the copper into copper wire will be reviewed. Recommendations on the manner by which to optimize profitability of the copper wire production process will be explored. The perspective of the process which had been invented by Properzi- La Farga will be explored as a method of optimizing the profitability of the copper wire production process. This perspective involves a novel method of applying heat in the furnace in order to recover electrical grade copper from 100% scrap metal.

Keywords: copper wire production, energy, optimizing profitability, process

Copper Wire Production                              

The most energy consuming process of ore extraction is conducted in the conversion of copper ore to copper ingots.   In the conventional pyro, hydro and electrowhining process there is a substantial amount of energy which is liberated. The efficiency of the process electrical energy which must be applied in order to produce one tonne of copper is 14.2 x 10³ kWh. The free energy which is produced in the production of one tonne of refined copper is 0.5 X 10³kWh.This yields a process efficiency of 3.7%. The process of copper wire manufacture will be reviewed from the perspective of Arderiu and Properzi (1996), Errington et al. (1997), Gao et al. (2004) Pradenas et al. (2011) and Sachdev and Sachdev (2005).

Efficiency of Copper Extraction from Ore

There is a significant gap in the theoretical energy which is needed for the extraction of copper from its mineral and the real energy which is required for its ores which are available. This is attributed to the premise that the ores possess substantial amounts of gangue. The gangue takes up a lot of energy is the processing phase. There is doubt with regards to the continued feasibility of extracting copper order.   The quality of efficiency in a procedure can possess a diverse number of measures (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

Oneof the evaluations which are of the greatest concern in copper production is the energy efficiency.   This is an assessment which values the electricalpower and fuel which are expended in the process;both are inclusive of the energy which is applied in order to develop the reagents and the fluxes, raw materials and supplies which are applied in the process of production. There are two assessments which possess substantial importance for the metallurgical procedures. The first term is designated as a processing fuel equivalent (PFE) which provides a measure of all of the energy which is consumed in the process of production. The second is designated as the material fuel equivalent, which gives an evaluation of all of the comprehensive energy resources which are applied in order to develop the copper wire from the ore which is underground. The MFE and the PFE are evaluations of the quality of efficiency (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).  The equations which will be applied are the following:

This is considering the following assumptions:

1. Rw is the PFE of the raw copper ore which is applied to begin the process.
2. Bu is the aggregate of the useful extra heat and the PFE of marketable by-products.
3. Sr is the complete amount of fuel resources which are applied in order to produce the important supplies, fluxes and reagents which are consumed by the production process of the copper wire.
4. El is the fossil fuel equivalent of electricity.
5. F is the fuel which is consumed directly in the process of producing copper wire (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

The diesel and steam energized electrical production plants have a variety of distinct efficiencies. Some of the electrical generation plants have a 25% to 40 % complete energy utilization efficiency. This is correlated to a range of 9,000 kJ/ KWh to 14,400 kJ/ kWh for electrical energy which is produced.   It can be presumed that the mean heat rate for the fossil fuel energy of electrical power generation is 11,070 kJ / kWh of electrical energy produced. In order to demonstrate the applications of MFE and PFE, the major stages in the production of copper wire can be reviewed. The sulphide copper ore possess a composition of 0.7% copper (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

This is extracted by an open pit mining method which possesses a ration of waste material to rock of 2.5/ 1. The ore is saturated by a process which is delineated as flotation. In the flotation process over eighty percent of the copper is recovered. Subsequently, 98% of the copper which is contained in the sulphide copper ore is extracted by means of smelting and refining. In order to simplify the process, it can be assumed that there are no other valuable by products which are being extractedfrom the sulphide copper ore (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

Energy Used in Extracting Ore      

Theequivalent in energy for the processes of drilling, blasting and other operations for open pit mining is 46, 520 kJ/ t of sulphide copper ore which is mined. In order to consider a waste to rock proportion of 2.5/ 1, this infers that 3. 5 x 46, 520 = 162,820 kJ per tonne of sulphide copper ore that is mined. In consideration of the copper concentration in the sulphide copper ore being 0.7%, the equivalent energy which is expended is 162,820/0.007 which is equivalent to 23.26 X 10⁶ kJ per tonne of copper is the sulphide copper ore which is mined, the amount of energy which must be expended in order to derive 100,000Kg of copper, the amount is 2.326 X 10⁶ kJ in order to produce 100,000 kg of copper mined ore (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

Energy Used in Converting Copper Ore to Copper Ingots 

As the sulphide copper ore which is underground has a zero equivalent value, MFE= PFE = 2. 326 x10⁶ kJ of copper in minedore. Let it be considered at an 80% recovery rate, the requisite is 1.25 kg of copper in order to develop 1 kg of copper matte. The formula would be 2.326 X1.25 x 10⁶ = 29,075,000 kJ in order to produce 100,000 kg of copper matte. Consequently, MFE =Rw + PFE = 76, 855,000 kJ per 100,000 kg of Copper in copper matte form. The refining and smelting processes for the conversion of copper matte to wire bar has the requirement of energy.   This energy is 46, 520 kJ per kilogram of wire bar.   The crude, raw materialfor the refining and the smelting is derived from the beneficiated ore.   As there is 98% efficiency in the refining and smelting process, 1.02 kg of copper matte would be required in order to produce 1 kg of copper wire bar (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).   1.02 x 76, 855 = Rw= 78,390 kJ/ Kg of copper in wire bar.   Consequently, 12,491,000,000 kJ would be required in order to produce 100,000kg of copper wire bar.   MFE= 4,652,000,000 kJ + 7,839,000,000 kJ or 1.2491 X 10¹⁰ kJ in order to produce 100,000 kg of copper wire bar.

The consideration of the inclusion of the fuel equivalent of the supplies, fluxes and primary reagents which are implemented in the PFE procedure considered the selection of the alternative means of recuperating copper from the dump leach solutions which are diluted. The initial is by the electro winningand extraction of solvents. The second choice is by the cementing process which takes place with iron which is ensued by refining and smelting. The initial selection consumes kerosene and LIX reagents (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

These two methods have the requisite of energy input for their development. The second option has the requisite that copper needs energy for its development in addition to electricity, fluxes and fuel for electro refining sand smelting. The computation of the PFE with the correct amount of fossil fuel with regards to supplies can provide the answer  with respect to which of these two options are more demanding on the limited fuel resourceswhich scarce in their availability (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

The conservative estimates of the energy which is consumed for the primary unit of operations of a hydrologicalmetallurgy flow process for the recovery of sheets of copper from the sulphide substrate.  These assessments are approximately twice as large as the values which are applied for normal refining and smelting. Consequently, many people may erroneously perceive that pyrolurgy consumes more energy than the hydrological aspect of refining copper (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

The majority of the metal extraction procedures were invented in an era when the energy sources which were available were inexpensive andabundant. Many have given little thought to the conversion of energy in these models. Presently, there are abundant opportunities for improving the energy consumption efficiency of these procedures by means of redesigningthem. The recuperation of heat energy which is wasted as entropy is one of the modifications which can be considered in the copper production process.  Notwithstanding, additional contributions will be made from the new designs which are planned from their conception with a perspective of pollution reduction and energy conservation. Presently 65% of the energy used in a furnace is effectively applied to the production of copper ingots (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

Table 1: Energy Utilization for Processing  Ground Copper Ore to Blister Copper

Table 2: Energy Utilization for the Production of 100,000 kg of Copper Wirefrom 100,000 Kg of Copper Ingot

Potential for Energy Savings

The metallurgical industry is an extremely energy intensive industry and represents approximately 10% of the energy consumption in the industrial sector. The metallurgical industry which produces copper wire is accountable for almost 4% of the global energy expenses and approximately 25% of the production expenses.  It has been estimated that less than 25% of the comprehensive energy is actually applied in reducing sulphide copper ore into copper powder.  The comprehensive level of energy which is effectively applied in this process almost never attains the level of 70%; the 70% which is remaining is distributed to the environment in the distinct avenues which are demonstrated in Figures 4-13 in the Appendix (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

Approximately 30% of the energy which is input is lost to radiation from the cooling fluids and gases.  Almost twenty percent is lost to the heat radiation which is absorbed by heated solids.  Almost fifteen percent of the energy is rejected as heat radiation which is emitted from the floors, walls, ceilings and apertures of the copper processing plants and another five percent of the copper material is lost in the transfer processes (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

The potential for diminishing energy consumption is substantial and there is the possibility of decreasing the energy expenses by up to 10%. This can be accomplished by means of enhanced administration of production and maintenance. Increased saving which may attain levels between 10%- 20% may be derived from a fairly inexpensive utilization of recognized technology which incorporate more effective process controls. Additional savings can be derived from making the investment in new copper wire production facilities (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005).

A number of metallurgical processing facilities do not demonstrate adequate concern with regards to the effective administration of energy expenses. Notwithstanding, the administrators of these plants place a far greater amount of attention on the administration of production in order to provide complete or optimalcontinuity during the diverse manufacturing stages. In the event that the copper production plants are not operated at maximum capacity, the trade- offs in efficiency can be substantial (Errington et al., 1997; Gao et al., 2004; Pradenas et al., 2011; Sachdev & Sachdev (2005). There are a variety of implementations which have the capacity of decreasing the expenses which are associated with the energy utilization substantially. Copper reverberating furnaces could be installed instead of the manually administrated systems (Arderiu & Properzi, 1996; Pradenas et al., 2011).

Theapplications of blast furnaces are the optimal manner of increasing the efficiency of the copper wire production plant. The particle sizes which are introduced when the ore is processed could be diminished by 10%.   This would result in s substantial blast furnace productivity increase. The coke which is applied in the blast furnaces is relatively high cost. In a heat injection system where some of the heat which is demonstrated as heat loss in Figure 4- 13 is applied, cheaper fuel sources could be applied in order to supplant some of the expensive coke  (Arderiu & Properzi, 1996; Pradenas et al., 2011).

As demonstrated in Figures 4- 13 in the Appendix, there is a substantial energy loss which occurs in the production of copper wire.  The energy which is lost to entropy could be rechanneled by the application of automatic recuperative furnaces which cause the wasted heated gases to be applied toward the preheating of the air which is in the combustion chamber.  In addition low thermal radiance inserts could be applied along the lining of the furnace walls in order to minimize heat loss and to optimize furnace efficiency at the copper wire production facilities (Arderiu & Properzi, 1996; Pradenas et al., 2011).

Table 3:  Influence of the Productions in Efficient Blast Furnace Operation with Regards to Increased Productivity and Energy Savings

Production of Copper Wire from Scrap Metal

The copper wire producers have long envisioned to the potential of using copper scrap metal which had previously been deemed to be unfeasible for use in copper wire due to the characteristic of impurities.   This has restricted the application of the copper scrap content in the copper wire to be limited to 15% content.   A new thermal process has allowed that the content of scrap metal be increased.   This significantly lowers the cost of producing copper wire and increases theprofitability of the copper wire manufacturingplant.   This has been achieved by means of the Properzi thermal process (Arderiu & Properzi, 1996; Pradenas et al., 2011).

The distinction of the Properzi thermal process with other blastfurnace processes is that the Properzi thermal process applies magnetite cables and bricks. They enable the enduring of the chemical tenacity of the oxides, additive and fumes. These are additional components of the slag and fume process.  As a result, the temperature of the furnaces must be maintained at an elevated level.   The tilting of the furnace is also performed. Tilting of the furnace is conducted in order to assure that fuel air and steam gain access to the copper while it is being processed.The Properzi Thermal process uses a mixture which is ten percent powder and bulk scrap, sixty percent tubing and wiring which is free from other metals and thirty percent first class scrap. The tilted furnace is sustained by two cradles which facilitate motion (Arderiu & Properzi, 1996; Pradenas et al., 2011).

The primary burner which is applied in the Properzi Thermal process is attached to the perimeter of the furnace and can be ignited by the application of fossil fuels which possess a low sulphur composition.   In the more expansive furnaces, a burner which is facilitated with oxygen is applied in order to diminish the melting segment of the copper wire processing. The energizing and melting segments of the process endure for about eight hours. There are potent variable burners which are applied to facilitate fast dissolution and a complete oxidation of the copper wire batch. The uniform homogenization of the copper is attained by the application of elevated temperatures. In the instant that the first slag is extracted from the copper wire batch, the molten copper wire batch is oxidized by the introduction of air under the batch (Arderiu & Properzi, 1996; Pradenas et al., 2011).

This portion of the process normally endures for up to two hours while the furnace is tilted at an angle of twenty degrees. This inclination enables the oxygen content in the molten copper to reach 11,000 parts per million. The impurities which are contained in the molten copper wire batch have a lighter characteristic than the molten copper and rise to the top of the batch in orderto form a slag. The process may need to be repeated in order to extract Nickel which impedes the conductivity of the copper wire (Arderiu & Properzi, 1996; Pradenas et al., 2011).   .

The concluding reduction and refining process is applied in order to remove the final slag and any of the additives which may be contained in the molten bath. Subsequent to skimming, the angle of the furnace is once again inclined to twenty degrees in order to facilitate the introduction of fuel and steam in the molten copper wire batch to decrease the oxygen levels in the batch to less than 500 parts per million.   The molten copper wire batch is transferred from the furnaces to the casting apparatus. The liquid molten batch is transferred into a continuing copper bar. The molten copper is transformedinto a solid by the application of a hydro spray refrigerating system (Arderiu & Properzi, 1996; Pradenas et al., 2011).

TheProperzi ring system enables the copper wire to be introduced into the meld as a circular form and to egress as a solid bar subsequent to being rotated for only one hundred and fifty degrees. The improvements which have been conducted allow the copper wire which is marketed by Properzi-LaFarga to sell at a price which is three hundred and twenty dollars below the market price for copper wire.  The market price for copper wire is established at $US2, 550 per ton. This enables the difference to be passed onto the consumer and the scrap metal processor (Arderiu & Properzi, 1996; Pradenas et al., 2011).

During the time when many metal produces are struggling with elevated raw material expenses, a profit of $200 per metric ton of copper wire is an incredible feat. Notwithstanding, the feasibility of this process of applying scrap metal in order to create copper wire is feasible. Properzi- LaFargais currently operating copper wire production facilities in Saudi Arabia, India, Italy, Korea, Cuba, Uzbekistan and Ukraine (Arderiu & Properzi, 1996; Pradenas et al., 2011).

Conclusion                                                                                                   

In the present climate where economic and environmental challenges are existent, the capacity of being able to recycle materials in every discipline and occupation carries a greater significance in the present day than ever before. There is a particular emphasis which is placed upon the utilization of less energy resources, which are quickly facing exhaustion, in order to enable the future generations and to enhance the activities of environmental conservation. The ability to recycle augments the efforts of global energy conservation and provides a substantial increase in profitability for the final producer of the copper wire.

The characteristic of the quality of the final product which is attained by the recycling of copper metal is effective to the point where eighty percent of the market is accessed. In addition, the copper rod producers are delegated with a substantial opportunity in the competitive metallurgical market. This is a market where financial competitiveness is an outcome of novel efficiency in addition to a social and ecological consciousness.

References

Arderiu, O. G. & Properzi, G. (1996). Continuous copper rod production from 100% scrap. Wire Journal International.

Errington, W. J., Edwards, J. S. & Hawkins, P. (1997). Isasmelt technology- Current status and future development. The Journal of South African Institute of Mining and Metallurgy, July/ August 1997.

Gao, M., Philip, A. & Nigel, A. (2004). Proven technologies from Xstrata and their application for copper smelting and refining in China. Xstrata Technology.

Pradenas, L., Campos, A., Saldañas, J. & Parada, V. (2011). Recent advances in the extraction of copper, nickel and cobalt.Pesquisa Operaciónal, 31(3).

Sachdev, S. & Sachdev, R. (2005). Energy in minerals and metallurgy industries. New Delhi: Allied Publishers Pvt. Ltd.