Copper & its properties

University Of Lahore,Punjab,Pakistan

1. “COPPER AND COPPER ALLOYS” ( PROPERTIES, EXTRACTION, PRODUCTION, USES AND APPLICATIONS)

2. GROUP MEMBERS Zaid Khizar Bajwa BSME 01143071 H Salman Yousaf BSME 01143072 Hamza Saleem BSME 01143075

3. Zaid Khizar Bajwa

4. AREAS OF DISCUSSION: INTRODUCTION TO COPPER (PHYSICAL PROPERTIES, OCCURRENCE, DEPOSITS, ORES, PRODUCTION) INTRODUCTION TO COPPER ALLOYS (CLASSIFICATION, PROPERTIES) IMPORTANT CLASSES OF COPPER ALLOYS (BRASSES, BRONZES, SPECIAL ALLOYS) USES AND APPLICATIONS OF PURE COPPER AND COPPER ALLOYS.

5. COPPER: Copper (Cu) atomic weight 63.546. Its soft , malleable and ductile metal with very high thermal and electrical conductivity. There are 29 isotopes of copper . 63 Cu and 65 Cu are stable & The other isotopes are radioactive.

6. COLOUR Reddish orange in pure form MELTING POINT 1084.62˚C BOILING POINT 2927˚C CRYSTAL STRUCTURE Face centered cubic (F.C.C) SPECIFIC GRAVITY 8.96 g/cm 3

7. ORES OF COPPER: ORES CHEMICAL FORMULA COPPER PYRITE/CHALCOPYRITE CuFeS 2 CHALCOCITE/ COPPER GLANCE Cu 2 S MALACHITE CuCO 3 .Cu(OH) 2 AZURITE Cu 3 (CO 3 ) 2 (OH) 2 BORNITE/PEACOCK ORE 3Cu 2 S.Fe 2 S 3 MELACONITE CuO COVELINE CuS CHALCOSINE Cu 2 S CHRYSCOLLA Cu 2 FeS CUPRITE Cu 2 O

8. OCCURRENCE of copper: Copper is present in the Earth's crust at a concentration of about 50 parts per million (ppm ). The largest mass of elemental copper discovered weighed 420 tonnes and was found in 1857 in Michigan US . In Pakistan large copper deposits are discovered in Reko Diq (Baluchistan) and Saindak town in Chagai District. The total amount of copper on Earth is vast i.e. around 10 14 tons just in the top kilometer of Earth's crust.

9. WORLDWIDE PRODUCTION OF COPPER

10. EXTRACTION TECHNIQUES FOR COPPER Copper ore is mined both underground and on the surface. Large excavations formed by surface mining are called open-pit mines. Most of the copper ores mined today are oxide or sulfide ores . HYDROMETALLURGICAL operations are required for treating very poor grade oxide ores. PYROMETALLURGICAL treatments are given to the sulphide ores for their smelting and roasting. ELECTROMETALLURGICAL techniques are employed for the electro refining of blister copper or copper scrap.

11. EXTRACTION OF COPPER FROM SULPHIDE ORES Copper is extracted usually from the sulphide ore chalcopyrite (CuFeS2) by smelting process. There are following steps for the Pyrometallurgical extraction of copper. CONCENTRATION ROASTING SMELTING BESSEMERIZATION

12. Hafiz Salman Yousaf

13. CONCENTRATION BY FROTH FLOTATION “Crushed ore is suspended in water containing pine oil. The pine oil binds to the copper compounds, but not to the unwanted rocky material. A blast of air is passed through the suspension. The particles of ore get wetted by oil and floats as a froth which is skimmed. The gangue sinks to the bottom .”

14. ROASTING The concentrated ore is roasted in the furnace in the presence of oxygen. Sulphur is oxidized to SO 2 and impurities of arsenic and antimony are removed as volatile oxides. The following reactions take place : 2CuFeS 2 + O 2 Cu 2 S + 2FeS + SO 2 S + O 2 SO 2 4As + 3O 2 2As 2 O 3 4Sb + 3O 2 2Sb 2 O 3 Cu 2 S + O 2 Cu 2 O + SO 2 FeS + O 2 FeO + SO 2

15. SMELTING The roasted ore is mixed with coke and silica sand (SiO 2 ) and is introduced into a blast furnace. The hot air is blasted and FeO is converted into ferrous silicate (FeSiO 3 ) FeO + SiO 2  FeSiO 3   Cu 2 O + FeS    Cu 2 S + FeO FeSiO 3 (slag) floats over the molten matte of copper. The resulting product of smelting is the combination of copper sulfate and iron sulfide called matte (Copper matte).

16. BESSEMERIZATION Copper metal is extracted from molten matte through bessemerization . The matte is introduced in to Bessemer converter which uphold by tuyeres. The air is blown through the molten matte. Blast of air converts Cu 2 S partly into Cu 2 O which reacts with remaining Cu 2 S to give molten copper. 2Cu 2 S + 3O 2   2Cu 2 O + 2SO 2   2Cu 2 O + Cu 2 S  6Cu + SO 2

17. Alloys of Copper

18. CLASSIFICATION OF COPPER AND COPPER ALLOYS

19. Classification of copper alloys There are four different classification of copper alloys 2 )Brasses 1 )Bronze 4 ) Cu-Ni based 3 ) Nickel silver

20. 1 ) Brass: There are two Class of brass The alpha alloys with less than 37% Zinc. These alloys are ductile and can be cold worked. The alpha/beta or duplex alloys with 37-45% Zinc. These alloys have limited cold ductility and are typically harder and stronger.

21. Alloying Element Strength Color Electrical and thermal conductivity Machinability Corrosion resistant Wear resistant

22. Classification Brasses Bronzes Cupronickels (Alloys of Copper & Nickel) Nickel silver (Alloys of copper, Zinc & Nickel)

23. Brasses-General Alpha Brasses (Alloys containing 36 % Zinc) Yellow Alpha Brasses Red Alpha Brasses Alpha + Beta Brasses (54-62% copper).

24. Bronzes Tin Bronzes Al Bronzes Silicon Bronzes Beryllium Bronzes

25. Cupro Nickels Alloys of Cu & Ni , contains upto 30 % Ni It’s a single phase alloys No heat treatment is required It’s high corrosion under sea water. These are widely used in condenser , heat exchanger tubes , coastal power plants Nickel Silver Alloys of Cu-Ni-Zn. If copper is more than 60 % these are single phased ,ductile & easily workable at room temp. These are used For Rivets, screws, Costume jewelry , name plates .

26. Hamza Saleem

27. Copper AND copper alloys applications ELECTRICAL APPLICATIONS Approximately 65% of copper produced is used for electrical applications. Power generation and transmission generators, transformers, motors, busbars and cables provide and efficiently to homes and businesses. Electrical equipment - providing circuitry, wiring and contacts for PCs, TVs and mobile phones.

28. In a microchip because of its good conductivity. These are the wires that connect different sections of the chip together. Cu-Ni 70-30 alloy is used in steam generators, heat exchangers, coolers, condensers, tanks, pipework, valves and fittings.

29. CONSTRUCTION APPLICATIONS 25% of all the copper produced is used in buildings. The skin of STATUE Of LIBERTY is made of 81.3 tones Cu. Cu is used in roofs, flashings, gutters, building & expansion joints.

30. TRANSPORT APPLICATIONS Transport accounts for 7% of copper usage . NUCLEAR WASTE is enclosed in these containers having Cu shell on it.

31. MEDICAL APPLICATIONS Bacteria will not grow on cu surface. Cu doorknobs are used by hospitals to reduce the transfer of diseases . Copper's naturally antimicrobial properties can be exploited in hygienic surfaces for hospitals and healthcare facilities . CuSO4 is used as a fungicides and as algae control in domestic lakes and ponds.

32. KITCHENWARE APPLICATIONS The burnished glow of copper radiates beauty and warmth the kitchen.

33. COMMON applications The remaining 3% is used for coins , sculptures, musical instruments and cookware. Cu-alloy is used in Bullets making. One eurocent coin: 94.35% steel 5.65% copper 10 eurocent coin: 89 % copper 5 % aluminium 5 % zinc 1 % tin PKR 5: Cupro Nikle alloys

34. HEAT EXCHANGERS/RADIATORS: INNER GROOVED COPPER TECHNOLOGY

35. CUTTING BRASS: Hardware : Gears and pinions Industrial : Automatic high speed screw machine parts GILDING METAL (BRONZE): B ullet proof jackets J ewellery E nameled badges

36. THANK YOU FOR PAYING ATTENTION!