The Basics of Copper Mining and Processing
Once it’s located within the earth, copper ore goes through eight stages before the consumer sees it in various products that affect everyday life in the home and business. These eight stages include:
- Mining
- Grinding
- Concentrating
- Roasting
- Smelting
- Conversion
- Anode Casting
- Electro-Refining
How is copper mined?
Copper is usually mined in two ways: open-pit mining and underground mining.
Open-pit mining is used for copper deposits closer to the surface. Enormous machines dig up the ground in stair-stepped layers (called “benches”) until the copper is extracted using drilling equipment and explosives. Once each layer is fully extracted, the next one is made until there isn’t enough ore to mine profitably.
Underground mining is more expensive and complex than open-pit mining. It is typically used when the ore deposits are deep beneath the ground, and open-pit mining isn’t safe or viable. Tunnels are created underground until copper ore is found and extracted via drilling and blasting.
How is Copper Processed?
Copper ore must be crushed between extraction and production. Crushing and grinding breaks down the ore from boulder-sized to smaller pieces, making it easier to transport off-site.
After the ore is crushed, it undergoes concentration. This isn’t necessary for some types of ore, such as oxide ores, as crushing and grinding are enough to separate the waste rock from minerals. However, concentration methods such as froth floatation separate the copper minerals from the waste rock for more tricky ores, such as sulfide ores.
The sulfide ore is then roasted or smelted into a purer copper concentrate called a slab. Finally, the copper slab undergoes electrolysis, resulting in 99.99% pure copper cathode slabs.
Where is Copper Found?
Copper deposits naturally occur in sedimentary rocks from hot waters and volcanic activity.
According to the World Economic Forum, Chile is the world’s largest copper producer, supplying about 27% of the global supply in 2021. Two of the largest copper mines in the world are based in Chile. Peru produces the second most, contributing 10% of global copper production. The Democratic Republic of Congo and China are tied for third, each producing 8% of the worldwide supply.
Several other countries, including the United States, Australia, Indonesia, Russia, Canada, and Mexico, contribute to this supply.
The largest copper mine in the United States, as of 2023, is the Morenci Mine in Arizona.
What is Copper Used For?
Copper is a critical mineral because we rely on it to create many everyday items. It is an excellent conductor of electricity and is primarily used to develop electronic components such as wires, circuit boards, motors, and batteries (including EV batteries).
It is also used in various everyday objects, such as:
- Water Pipes
- Coins
- Cookware
- Jewelry
- Ornaments
- Roofing
- Lightning Rods
- Shipbuilding
- Vehicle Construction
- Doorknobs and Other Household Fixtures
The History of Copper Mining
Documentation of the use of copper dates back to ancient times. The laborious task of mining copper ore by hand made obtaining large quantities for production difficult.
During the Industrial Revolution, coal- and steam-powered machinery paved the way for a considerable increase in copper production, with mines smelting between 200 and 300 tons of copper ore per week.
At the beginning of the 20th century, the annual worldwide copper demand was half a million tons. By World War II, this demand had multiplied by more than nine times. Technological advancements have allowed the copper mining industry to meet worldwide demands with efficient and cost-effective mining methods.
The Future of Copper Mining
Advancements in mining equipment, such as those achieved at General Kinematics, along with progress in mining technology, have resulted in growth and production in the copper mining industry.
From primitive, cumbersome mining methods to compact, efficient modern-day equipment, copper mining has become a cost-effective, efficient process.
Additionally, modern mining equipment reduces waste and decreases chemical exposure during all phases of the copper mining process.
General Kinematics’ STM-SCREEN™ was designed to make copper screening and processing more efficient. Contact us to learn more about how GK can help you streamline copper mining.
