Engineering the Future of Copper
In the tapestry of India's industrial growth, copper emerges as a thread weaving through the narrative of development and innovation. Copper's role in India's economic and industrial landscape is historic and pivotal. Known traditionally as 'Tamra' in Sanskrit, copper's legacy in India stretches back millennia, underscoring its importance in ancient and modern contexts.
As the backbone of the electrical and electronics industries, its significance cannot be overstated—powering innovations, supporting infrastructure development and enabling the technological leaps that drive our nation forward. Despite its critical role, India's per capita consumption of copper remains lower than the global average—0.6 Kg in India versus a 3.2 Kg global average, pointing towards a vast growth potential. The burgeoning demand in sectors like clean energy, electric vehicles, and infrastructure projects underscores copper's critical role.
This underlines the urgent need for enhancing our copper production capabilities to not only meet domestic demand but also to contribute significantly towards fulfilling India's vision of Aatmanirbhar Bharat, a self-reliant nation powered by its resources.
In alignment with the Government of India's vision of transforming the nation
into a manufacturing powerhouse, Kutch Copper Limited (KCL), a subsidiary
of Adani Enterprises, is committed to bridging this gap. We're building a
massive 1 million-tonnes-per-year copper complex in Mundra, Gujarat, aiming
to not only reduce reliance on imports but also become a leader in sustainable
and efficient copper production
Our strategic location in Mundra has access to key logistics networks like
waterways, roads, and railways—we are perfectly positioned to transport
copper across India efficiently. This sprawling unit is poised to be the world's
largest single-location copper plant and is a testament to innovation,
sustainability, and operational excellence.
KCL is more than just a copper producer; we're shaping the future of this
critical industry in India. We're committed to reducing reliance on copper
imports by meeting up to of domestic demand, we'll lessen India's
dependence on foreign sources.
Our commitment to producing green copper is
reflected in our state-of-the-art smelting and
refining process, which ensures high productivity,
reduced emissions, and optimal energy
consumption. Here's a glimpse into our
operational excellence:
Copper concentrates are fed into the flash smelting furnace alongside oxygen-enriched air.
Here, the concentrates are instantly oxidized, melting and separating by their reaction heat into
copper matte, with a purity of 60-65%, and slag, comprising iron oxide, silica, and other
compounds.
This cornerstone technology efficiently transforms copper concentrate into molten copper,
underscoring our dedication to reducing emissions and improving energy efficiency.
The matte produced in the flash smelting furnace is transferred to the converter furnace, where oxygen-enriched air further oxidizes the matte, yielding blister copper of approximately 98-99% purity. This critical step purifies the molten copper further, preparing it for anode production.
In the anode furnace, fire refining occurs using fuel oil (FO) or natural gas (NG) as a reductant
to remove oxygen from the blister copper, refining it to approximately 99.5% purity. The refined
blister copper is then cast into moulds on a casting wheel, forming anode plates for electrolytic
refining, each weighing between 380-425 kg.
This process ensures the production of high-quality anodes for electrorefining, reflecting our
commitment to quality and sustainability.
Anode plates (Cu) and stainless-steel cathode plates are set alternately in the electrorefining
cell. A precise level of DC facilitates the electrolytic deposition of dissolved copper from the
anode onto the stainless-steel cathode plate. After 6 - 7 days of electrolysis, the copper
cathode, weighing approximately 110 kg and boasting 99.99% purity, is harvested.
Our advanced electrorefining technology produces superior copper cathodes for various
industrial applications.
Cathodes from the refinery undergo further processing in the CCR, including melting, casting,
and drawing into wires of various sizes according to market demand. The rods drawn must be
exceptionally high quality, enabling ultra-fine wire drawing at high yields. Additionally, the rods
require an excellent surface finish.
We can meet the diverse needs of the electrical and manufacturing industries by producing
essential copper rods.
Gases emitted from the flash smelting and converter furnaces, rich in SO2, undergo heat
recovery via a waste heat recovery boiler. After electrostatic precipitators remove dust, the
gases are sent to the sulphuric acid plant. Here, a catalytic reaction with vanadium oxides
oxidizes SO2 to SO3, which is then absorbed in water to produce concentrated sulphuric acid.
The innovative approach we take exemplifies our commitment to sustainability, transforming by-
products into valuable sulphuric acid for use across various industries.
Slime from the electrolytic refining process, containing precious and rare metals such as gold,
silver, selenium, and tellurium, undergoes recovery at the slime treatment plant. The recovered
silver and gold are melted and cast into ingots.
Our dedication to the principles of the circular economy is evident in our commitment to
recovering valuable metals, further emphasizing our plant's role in sustainable metal production.
Contact us to learn about pricing and procurement.
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