CharacteristicsMethods
The concentration of copper in ores averages only 0.6%, and most commercial ores are sulfides, especially chalcopyrite (CuFeS2) and to a lesser extent chalcocite (Cu2S).[24] These minerals are concentrated from crushed ores to the level of 10–15% copper by froth flotation or bioleaching.[25] Heating this material with silica in flash smelting removes much of the iron as slag. The process exploits the greater ease of converting iron sulfides into its oxides, which in turn react with the silica to form the silicate slag, which floats on top of the heated mass. The resulting copper matte consisting of Cu2S is then roasted to convert all sulfides into oxides:[24]
2 Cu2S + 3 O2 → 2 Cu2O + 2 SO2
The cuprous oxide is converted to blister copper upon heating:
2 Cu2O → 4 Cu + O2
The Sudbury matte process converted only half the sulfide to oxide and then used this oxide to remove the rest of the sulfur as oxide. It was then electrolytically refined and the anode mud exploited for the platinum and gold it contained. This step exploits the relatively easy reduction of copper oxides to copper metal. Natural gas is blown across the blister to remove most of the remaining oxygen and electrorefining is performed on the resulting material to produce pure copper:[26]
Cu2+ + 2 e− → Cu