New Hydrometallurgical Tech Offers Cleaner, Cheaper Copper Refining
Researchers at the University of Queensland have developed a new hydrometallurgical technology to refine copper, potentially offering a cheaper and cleaner alternative to traditional smelting. This innovation comes as the Mount Isa copper smelter faces a possible closure by 2030, which could impact smaller mines in the region due to increased shipping costs for concentrate.
This groundbreaking technology could redefine copper production, offering a more sustainable and cost-effective solution as the industry navigates significant challenges.
How It Works: A Smelter-Free Approach
The new process, developed by Professor James Vaughan and Leigh Staines of Banksia Minerals, avoids the high heat of conventional smelting. Instead of firing concentrated ore in a 1,200-degree Celsius furnace, it dissolves copper concentrate in highly saline solutions. An electrical current is then used to recover the metal from this solution.
Transformative Benefits
The hydrometallurgical process presents several significant advantages over traditional methods:
- Energy Efficiency: The process is estimated to use roughly half the energy of conventional copper smelting, significantly reducing power costs.
- Environmental Impact: It avoids the gas emissions associated with high-heat smelting, resulting in a lower carbon footprint.
- Processing Capabilities: It can safely process copper deposits with high arsenic levels, which were previously ignored due to contamination risks and air pollution concerns with traditional methods.
- Cost Savings: The technology could be built for approximately half the capital cost of a traditional smelter and offers potential operating cost savings.
- Modularity: The hydrometallurgical process allows for the development of small, modular facilities, potentially enabling multiple plants across a region rather than a single large smelter.
The new process not only halves energy and capital costs but also offers a solution for previously unworkable arsenic-rich copper deposits.
Current Status and Future Outlook
Banksia Minerals is commercializing the technology and received $5 million in federal government funding through the Australian Renewable Energy Agency (ARENA) in February. A pilot plant is expected to be developed by 2028.
Hurdles to Overcome
Initial tests conducted by AIC Mines managing director Aaron Colleran indicated successful extraction of high-quality copper but encountered difficulties with secondary minerals like gold and silver, which constitute a significant revenue stream.
Further research is required to understand the costs, volumes, and treatment methods for the chloride solution used in the process to ensure overall economic viability.