COPPER METAL [CODE NO.3758]
Copper was a scarce metal with respect to India but recent setting up of copper smelters has entirely changed the scenario of copper production/availability in the country. However, these copper smelters, except that of HCL, are producing copper based on the imported concentrates. In the recent past the country’s status has changed from a net importer to a net exporter
Over the years the use of copper has witnessed growth in electrical, transport, Consumer durables, engineering, construction, telecommunication etc. sectors. In the present survey the demand has been projected up to 2024-25 in the above sectors keeping in view the economic growth in future. The domestic demand works out to be 2.3 million tones. To meet the demand in future the copper industry has already geared up. The supply projection of 2.8 million tons by 2024-25will satisfy the domestic demand in addition to exports demand.
The world scenario vis-à-vis India is necessary to find out the country’s position. The world’s leading producers with their present and future projects are also discussed in the report. The global consumption of copper has been projected at 31 million tons by 2025.
The prices are the dominating economic indicators to control the copper production activity. Enough weightage is given to this aspect by analysing the prices for present and future.
With this background, Indian Bureau of Mines has taken up for the first time a Market Survey Study on metal namely copper. In this study an attempt has been made to study the present and future availability of metal from primary as well as secondary sources and their demand in present and future based on the role in overall development of end-user industry.
COST ESTIMATION
Plant Capacity 30 MT/Day
Land & Building (8000 sq.mt.) Rs. 9.22 Cr
Plant & Machinery Rs. 2.04 Cr
Working Capital for 2 Months Rs. 53.87 Cr
Total Capital Investment Rs. 65.51 Cr
Rate of Return 34%
Break Even Point 36%
INTRODUCTION
TYPES OF COOPER ORE
PROPERTIES OF COPPER
TABLE 1. TYPICAL PROPERTIES OF COPPER POWDER PRODUCED
BY VARIOUS METHODS
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
SIMPLIFIED FLOW CHART LEACH – SOLVENT EXTRACTION – ELECTRO
WINNING PROCESS
PRODUCTION PROCESS OF COOPER
RAW MATERIAL
SULFIDE ORES
OXIDE ORES
COPPER IS EXTRACTED FROM ITS ORES EITHER BY
A) PYROMETALLURGICAL PROCESSES
B) HYDROMETALLURGICAL PROCESSES
LEACH SOLUTIONS
1. ACIDS AND OXIDANTS
2. ALKALIS AND AMMONIA-BASED REAGENTS
3. BACTERIALLY-MEDIATED LEACHING
INFLUENCING FACTORS ON HYDROMETALLURGICAL LEACHING
ADVANTAGES OF HYDROMETALLURGICAL PROCESS
DISADVANTAGES OF HYDROMETALLURGICAL
PROCESSING OF COPPER ORES
(A) COMMINUTION
(I) CRUSHING
(II) GRINDING
(III) SIZING/CLASSIFICATION
(B) LEACHING TECHNOLOGY
LEACHING PROCESS
B) TANK LEACHING
PROCESSES
(C) SOLVENT EXTRACTION
(D) ELECTRO WINNING
WASTE TREATMENTS
ENVIRONMENTAL IMPACTS OF HYDROMETALLURGICAL LEACHING
POLLUTION CONTROL TECHNIQUES
SOURCES OF POLLUTION
CRUSHING AND SIZE REDUCTION
HYDROMETALLURGICAL PROCESSES
LEACHING
HEAP LEACHING
ATMOSPHERIC LEACHING (OPEN TANK)
PRESSURE LEACHING (AUTOCLAVE)
SOLVENT EXTRACTION
ELECTROCHEMICAL PROCESSES
ELECTRO-WINNING
ELECTRO-REFINING
PREVENTION & CONTROLLING METHODS OF ENVIRONMENTAL POLLUTION
USE INDOOR OR COVERED STOCKPILES.
TREATMENT
SULPHUR DIOXIDE TREATMENT
SX/EW SLUDGE
SPENT ELECTROLYTE
SPENT LEACHING SOLUTION
POTENTIAL SOURCES OF CONTAMINATION
(A) RELEASES FROM ACTIVE LEACH UNITS
MARKET SURVEY
COPPER PRODUCTION IN INDIA
MAJOR PLAYERS
COPPER CONSUMPTION GROWTH DRIVERS - INDIA
COPPER INDUSTRY SNAPSHOT
COPPER INDUSTRY SNAPSHOT - INDIA
REFINED COPPER CONSUMPTION - INDIA
POWER SECTOR - INDIA
INDIA REFINED COPPER INDUSTRY - CHALLENGES
RISK OF SUBSTITUTION
SWOT – INDIAN COPPER INDUSTRY
CUSTOM SMELTER VALUE CHAIN
SUPPLIERS OF COPPER CATHODE
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COOPER ORE
SUPPLIERS OF SULFURIC ACID
SUPPLIERS OF NITRIC ACID
SUPPLIERS OF HYDROCLORIC ACID
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF COPPER LEACHING PLANT
SUPPLIERS OF CRUSHING PLANT
SUPPLIERS OF BALL MILL
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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