Specific Features of Using High-Silica Flux Ore in Copper Smelting Units
Kenzhaliyev B. Kvyatkovskiy S. Kozhakhmetov S. Sukurov B. Dyussebekova M. Semenova A.
October 2025Multidisciplinary Digital Publishing Institute (MDPI)
Metals
2025#15Issue 10
This study explores the application of high-silica flux ore in copper smelting and converting processes at the Zhezkazgan Copper Smelting plant. Pilot-scale experiments and SEM analyses were performed to assess its influence on slag composition, temperature regime, and metal recovery. The results demonstrated that replacing conventional flux with high-silica ore reduced flux consumption by 19%, increased converter slag temperature from 1124 to 1174 °C, and decreased copper content in converter slag from 10% to 4.5%. SEM micro-analysis revealed the formation of lead-containing silicate rims around matte inclusions, which hinder their settling at low temperatures. However, when the slag temperature exceeded 1400 °C, these rims were destroyed, facilitating separation and reducing residual copper. These findings highlight the potential of high-silica fluxes (>90% SiO2) to improve both energy efficiency and metal recovery in process of copper matte converting, offering practical recommendations for industrial operations.
converting , copper losses , high-silica flux , magnetite , scanning electron microscopy (SEM) , slag smelting
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JCS Institute of Metallurgy and Ore Beneficiation, Satbayev University, Almaty, 050013, Kazakhstan
JCS Institute of Metallurgy and Ore Beneficiation
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