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), most of these smelters have been producing copper using imported concentrates. In recent years, India has changed from being a net importer to a net exporter of copper.
Copper consumption has grown across electrical, transport, consumer durables, engineering, construction, and telecommunications sectors. The report projects domestic copper demand at 2.3 million tonnes and supply at 2.8 million tonnes by 2024-25, indicating capacity to meet domestic requirements as well as export demand. Globally, copper consumption is projected at 31 million tonnes by 2025.
The report also examines global copper production and India's position in the international market, including present and future projects of leading producers. Copper prices are considered an important economic indicator influencing production activity. The study undertaken by the Indian Bureau of Mines assesses present and future copper availability from primary and secondary sources and evaluates demand in relation to the development of end-user industries.
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
- 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)
Frequently Asked Questions
Copper is widely used in electrical, transport, construction, engineering, telecommunications, and consumer durable applications. Its electrical and thermal conductivity makes it particularly important for electrical wiring, power equipment, and related infrastructure. Copper is also used in industrial equipment, components, alloys, and various engineering applications. The report highlights the growth of copper use across these end-user sectors and examines how their development influences present and future copper demand.
Copper is generally extracted from ores through pyrometallurgical or hydrometallurgical processes. Pyrometallurgical processing uses thermal treatment, while hydrometallurgical processing uses aqueous solutions to dissolve and recover copper. The report discusses both approaches and covers stages such as crushing, grinding, classification, leaching, solvent extraction, and electro-winning. The appropriate route depends on factors including ore characteristics, mineral composition, process economics, and the desired recovery method.
Hydrometallurgical copper processing recovers copper from ores using aqueous chemical solutions. The process can include ore preparation, leaching, solution treatment, solvent extraction, and electro-winning. Depending on the ore and process design, different acids, oxidants, alkaline or ammonia-based reagents, and biologically mediated methods may be considered. The report also examines heap, atmospheric, and pressure leaching along with environmental impacts, waste treatment, and pollution-control measures associated with hydrometallurgical operations.
Solvent extraction and electro-winning are important stages in many hydrometallurgical copper recovery circuits. Solvent extraction separates and concentrates copper from a leach solution, while electro-winning uses an electrochemical process to recover copper from the purified solution, commonly producing copper cathodes. Their integration allows dissolved copper to be recovered from suitable leach solutions. The report includes the simplified leach–solvent extraction–electro-winning process and discusses the associated environmental and waste-management considerations.
Environmental management in copper hydrometallurgical processing focuses on controlling releases, treating process wastes, and preventing contamination. Potential concerns can arise from leaching operations, spent electrolyte, spent leaching solutions, SX/EW sludge, process emissions, and material handling. The report addresses pollution sources and control techniques, including measures for stockpiles, treatment systems, and active leach units. Proper containment, monitoring, treatment, and process control are important for reducing environmental impacts and maintaining responsible plant operation.
A copper processing plant may require copper ore along with process reagents and supporting utilities, depending on the selected extraction technology. The report specifically covers copper ore, sulfuric acid, nitric acid, and hydrochloric acid among the listed raw-material requirements. Equipment requirements discussed include crushing and leaching plants, ball mills, testing and measuring equipment, cranes, transformers, electrical panels, motors, cooling towers, compressors, material-handling systems, pollution-control equipment, and effluent treatment facilities.
The copper industry in India is influenced by demand from major end-user sectors, domestic production capacity, availability of raw materials, international market conditions, and copper prices. The report examines copper production and consumption in India, growth drivers, the power sector, industry challenges, substitution risks, major players, and the custom smelter value chain. It also considers global production and consumption trends to place India's copper industry within the broader international market context.
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