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Primary Copper

Several different processes can be used for copper production. The traditional process is based on roasting ores containing copper sulfide, smelting in an electric furnace to produce copper matte (copper-iron sulfide) and blister copper, which is further refined to cathode copper. Another common process, flash smelting, uses the energy released during oxidation of the sulfur in the ore. These flash techniques reduce the energy demand to produce cathode copper. Newer processes such as ISASMELT are replacing roasting and smelting. Peirce-Smith and Hoboken are the most common converters. The matte from the furnace is charged to converters, where the molten material is oxidized in the presence of air to remove the iron and sulfur impurities (as converter slag), forming blister copper. Blister copper is further refined as anode copper (99.5 percent pure copper), which is subsequently used in electrolytic refining.

Refractory solutions are available in a variety of leading brick and castable formulations that combat high temperatures as well as the erosive and corrosive effects of slag. HarbisonWalker International specially engineers products to meet the specific lining demands of primary smelting, converter, and anode furnaces.

HWI offers SUPER NARMAG® FG, NARMAG® FG, SUPER NARMAG® 148 CU, and NARMAG® 60 CU. These products are ideal because they are direct-bonded refractories. Direct bonding improves both high-temperature strength and erosion resistance. Fused-grain magnesite-chrome brick is a good choice for more severe environments. The method of furnace operation determines the type of refractory used.

Products
Primary Copper

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Product SDS
‘SAIRSET A wet, air-setting, fireclay mortar
‘SAIRSET 3000 A high alumina air-setting mortar
60DB® A direct-bonded 60% magnesia, burned brick English
ALADIN® 80 An 80% alumina brick
AUREX® 30 SR An alumina-chrome brick with 30% chrome, designed for thermal shock resistance English
CLIPPER® DP A super duty fireclay brick
GREENKLEEN®-60 PLUS A 60% alumina, andalusite containing low cement castable
GREENTHERM 23 LI A 2300°F rated insulating firebrick
GREENTHERM 26 LI A 2600°F rated insulating firebrick
GREENTHERM 28 LI A 2800°F rated insulating firebrick
HP-CAST ® ULTRA C10 A high purity alumina, 10% chrome containing, ultra-low cement castable English
KALA® A 50% alumina brick
KALA® HPC CHECKERS A 50% alumina brick
KRUZITE®-70 A 70% alumina brick
KX-99® A high fired, super duty fireclay brick
KX-99®-BF A high fired, super duty fireclay brick
NARMAG® 60 CU A mixed-bond magnesia chrome burned brick for the copper industry.
NARMAG® 60 DB A direct-bonded, 65% magnesia, 18% chromia burned brick English
NARMAG® 6260 An 18% chrome-containing, magnesia-chrome burned brick English
NARMAG® 80 DB A 10% chromia-containing, direct-bond, magnesia chrome burned brick English
NARMAG® 95B A 95% magnesia burned brick English
NARMAG® FG A 19% chromia, rebonded fused-grain magnesia-chrome burned brick English
NARMAG® FG CASTABLE An ultra-low cement, magnesia and chrome containing castable
NARMAG® FG FINE MORTAR DRY A magnesia chrome mortar English
NARMAG® FG GUN A magnesia chrome gunning mix English
NARMAG® FG RAM MIX A magnesia chrome ram mix English
NARMAG® FG-HS CASTABLE A magnesia chrome castable
NARMAG® HNF 27 A 27% chrome-containing, magnesia-chrome burned brick English
NARMAG® HNF 31 A burned, magnesia chrome brick English
PLASTECH® RUBY® An alumina-chromium, phosphate bonded refractory plastic
PLASTECH® RUBY® 20 A 20% chrome, phosphate bonded refractory plastic English
RUBY® An alumina-chrome brick with 10% chrome
RUBY® BOND An air-setting alumina chrome mortar English
RUBY® MORTAR An alumina-chrome, phosphate bonded mortar English
RUBY® RAMMING MIX A phosphate-bonded, alumina-chromium ram mix
RUBY® SR An alumina-chrome brick with 10% chrome, designed for thermal shock resistance
SHAMROCK® 391-TR MORTAR An alumina-chrome mortar English
SHAMROCK® 392 DRY MORTAR A dry, phosphate bonded, alumina-chrome mortar
SHAMROCK® 392 MORTAR A chrome alumina mortar
SHAMROCK® 394 DRY MORTAR A dry, heat-setting, alumina-chrome mortar
SHAMROCK® 493 CASTABLE A low-moisture, chromia-alumina castable
SHAMROCK® 885 PLASTIC Chrome-Alumina Plastic
SUPER NARMAG® 142 A 60% magnesia, 20% chrome burned brick
SUPER NARMAG® 145 A 60% magnesia, 20% chrome burned brick English
SUPER NARMAG® 148 CU A semi-rebonded magnesia chrome burned brick designed for the Copper Industry English
SUPER NARMAG® FG A magnesia chrome burned brick English
THERMOLITH® A dry, air-setting, high-temperature, bonding mortar with chrome-ore base

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