Industry Overview
Copper was historically a scarce metal in India, but the establishment of copper smelters has significantly changed the country’s copper production and availability. Except for Hindustan Copper Limited (HCL), these smelters have largely relied on imported concentrates. In the recent past, India’s position has changed from being a net importer to a net exporter of copper.
Over the years, copper consumption has grown across electrical, transport, consumer durables, engineering, construction, telecommunications, and other sectors. The report projects demand through 2024-25, considering anticipated economic growth. Domestic demand is estimated at 2.3 million tonnes, while the projected supply of 2.8 million tonnes by 2024-25 is expected to meet domestic requirements as well as export demand. The copper industry has consequently expanded its capacity and preparedness to address future market requirements.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
Copper is widely used in electrical, transport, engineering, construction, telecommunications, and consumer durable applications. Its electrical and thermal conductivity makes it particularly important for electrical equipment, wiring, power-related applications, and industrial components. Copper is also used in various engineering and construction products because of its useful physical and chemical properties. The report identifies these sectors as important areas contributing to copper consumption and examines their demand in the context of projected economic growth.
Copper is generally extracted from ores using pyrometallurgical or hydrometallurgical processes. Pyrometallurgical processing uses thermal treatment, while hydrometallurgical processing involves operations such as ore preparation, leaching, solvent extraction, and electrowinning. The appropriate process depends on factors including ore characteristics, mineralogy, grade, and economic and environmental considerations. The report discusses both approaches and provides detailed coverage of hydrometallurgical operations used for copper ore processing.
Hydrometallurgical processing extracts copper from ore using aqueous chemical solutions rather than primarily relying on high-temperature treatment. The process can include comminution, leaching, solvent extraction, and electrowinning. Leaching dissolves the desired copper minerals into a solution, after which separation and recovery steps can produce a copper-bearing product. The report covers different leaching approaches, including heap, atmospheric, tank, and pressure leaching, along with the chemical reagents and operating factors relevant to hydrometallurgical copper extraction.
A copper processing plant may require equipment for ore crushing, grinding, sizing, leaching, solvent extraction, electrowinning, material handling, utilities, and environmental control. The report specifically identifies suppliers and equipment categories covering crushing plants, ball mills, copper leaching plants, metal testing machines, precision measuring tools, cranes, transformers, electrical panels, cooling towers, compressors, fire-fighting equipment, and effluent and air pollution control systems. Actual equipment selection depends on the selected process, ore characteristics, plant capacity, and engineering design.
Environmental management in copper hydrometallurgy focuses on controlling releases from ore handling, leaching, solvent extraction, electrochemical operations, and waste treatment. Potential concerns include contaminated solutions, sludge, spent electrolyte, process residues, dust, and other emissions or releases. The report addresses pollution sources and prevention measures, including covered stockpiles and treatment systems. Effective environmental control requires appropriate containment, monitoring, treatment, waste management, and process-specific pollution control measures designed according to applicable requirements.
Copper leaching performance depends on ore characteristics, mineralogy, particle size, reagent selection, solution chemistry, temperature, contact conditions, and other operating parameters. Proper comminution can improve mineral exposure and influence the effectiveness of subsequent leaching. The choice between acids and oxidants, alkaline or ammonia-based reagents, and biologically mediated approaches also depends on the nature of the ore and process objectives. The report examines these influencing factors together with different leaching technologies and their respective advantages and limitations.
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