The product of Sarcheshmeh and Khatoonabad plants is copper anode which is carried to electric refiners to be refined. The above mentioned plant consists of smelting, converting, fire refining and casting sections. The flotation plant product, being mixed with fine silica, fine limestone and revert in correct ratio is carried to the smelting section. Then matte copper which is a valuable product of smelting process is transferred to converting section. Being converted, the blister copper is carried to Anode furnaces to be heat- refined and finally the smelting plant product is cast in to anode form. The approximate weight of each anode is 345 kg and its grade is about 99.6%.
The summary of each division in Smelting factory described in below:
Flux crushing and handling
The run-of-mine silica and limestone are received from outside quarries in trucks. They dumped from the trucks into a receiving hopper over a grizzly. The received silica or limestone is fed to a variable-speed vibrating feeder. Undersize and oversize of silica and limestone are separated. Coarse-sized silica is used as flux during the slag blow of the converter cycle. Some coarse silica maybe added to the reverberatory furnace as fettling material.
Coarse-sized limestone is send to concentrator factory for lime slaking. Fine silica and limestone must be blended with copper concentrate produce a fusible slag in the reverberatory furnaces.
Material blending and handling
This part produce the blended reverberatory furnaces charge that contains concentrate, fine limestone and silica and reverts. This material are drawn from the bins and discharged into conveyor No.28 at one time and by this conveyor (No.28) scaling and transport to reverberatory furnaces charge bins.
In this part, blended charge withdrawn to furnace charge bins, then charged into two furnaces by some charge hoppers. Heat is supplied by burning fuel oil in six burners or gas in oxy-gas burners. Two matte tap hole and one slag skim notch are provided on each side of furnaces. Tap holes are closed with matte tapping machine. Matte and slag are two main production of each furnace. Matte is laundered into ladles and transported to converter by ladle cars and cranes. Slag is laundered into ladle and transported to the slag disposal area (damp). Two uptakes are provided at each furnace to transport the hot furnace gases to two waste heat boilers.
The molten matte from the reverberatory furnace is converted to blister copper in five converters. Matte ladles that received from reverberatory furnaces discharge by two overhead cranes into converters. Reverts
(Cold material) are added to control furnace temperature. Converter's slag is separated and transferred to reverberatory furnaces. The blister copper is the output of these furnaces and for final refining transferred to one of the three anode refining furnaces.
Refining & anode casting
Blister copper from the converters is transferred in ladles by overhead crane to anode furnace that used for copper oxidizing and poling. The objective in the refining furnace is to remove as mush sulfur and iron as possible, and to produce an anode with a flat set. In three refining furnaces at first done the oxidizing stages and impurities are eliminated and then reducing stage have done and finally that is transferred to casting stage. There are two casting wheel, one for anode one and two & another one for anode three. There are number molds (26 for the wheel number one and 16 for second wheel). The overhead crane lifts the anodes from bosh tank and moves these anodes to the inspection area and places them in racks.
Waste heat boilers
Two waste heat boilers are used with each reverberatory furnace for cooling the outgoing Flue gases by generation steam for power generation.
Gas handling system and Electro-filtering
Gas handling system has two parts that this parts located, one after reverberatory furnaces and other after converter furnaces and used for absorb and recovery copper-bearing particles. Furnace gases discharged into a T-shaped balloon flue. Then the gases pass to three electrostatic precipitators in parallel and after the absorb suspension particle are discharged to the furnace stack and then into atmosphere.