September 24, 2025MetalsOpen Access

Specific Features of Using High-Silica Flux Ore in Copper Smelting Units

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Pilot experiments demonstrate improved metal recovery and slag composition using high-silica flux ore, suggesting energy efficiency gains.

Replacing conventional flux with high-silica ore reduced flux consumption by 19%, showing significant operational savings.
Increasing converter slag temperature from 1124 to 1174 °C improved conditions for metal recovery, enhancing efficiency.
SEM analysis indicated the formation of lead-containing silicate rims which initially hinder settling but facilitate separation at higher temperatures.
These findings support the adoption of high-silica fluxes to optimize processes in copper smelting, potentially transforming industrial practices.

Kenzhaliyev et al. (2025) studied this question.

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Pilot experiments demonstrate improved metal recovery and slag composition using high-silica flux ore, suggesting energy efficiency gains.