Metso at the Copper 2025 Conference: Driving innovation across extraction, pyrometallurgy and hydrometallurgy

Advancing understanding through joint research with Aalto University

Several of Metso’s papers were developed in partnership with Aalto University, focusing on improving copper smelting efficiency and sustainability.

For one study written together, some experimental data on chemical solubility of copper in slag was evaluated and discussed, comparing it to Direct-to-Blister copper smelting industrial practices. The work also assessed the partitioning behavior of minor elements, providing insight into impurity control and process optimization.

In another collaborative paper, some experimental work is described where a set of various types of biocarbons was characterized in terms of chemical composition and moisture, and their reactivities in copper slag reduction were measured. The characteristics influencing the reactivity of the various biocarbon types were discussed and compared to metallurgical coke as a reference case, as it is widely used in the industry nowadays. 

Metso Metals’ contributions in pyrometallurgy

Metso Metals’ pyrometallurgical experts delivered papers spanning several critical technology areas, ranging from AF steam-gas reduction and copper injection into TSL furnace to describing CAPEX expenditure in a green field project.

One paper explored AF steam–gas reduction as a method of lowering carbon emissions. Life Cycle Assessment (LCA) calculations demonstrated the significant environmental benefits that are achievable through this approach, supporting Metso’s commitment to enabling more sustainable metallurgical operations.

In the Ausmelt paper, it was demonstrated in the pilot scale that it is possible to facilitate an increase in capacity of the existing operations by injecting dried copper concentrates into the bath of an Ausmelt top submerged lance furnace - offering a feasible path to higher throughput without extensive capital modifications.

Furthermore, the magnitude of costs of the different types of work related to a greenfield smelter investment are discussed in the paper CAPEX Structure of a Greenfield Copper Smelter Investment to illustrate the main cost drivers for a successful smelter project.  

The list of papers presented by Metso at the Copper 2025 conference:

• Advancements and Impacts of Expanded FrothSense+™ on Cu Special at Pb/Zn/Cu Mill - A Case of Applied First Principles of Industrial Flotation 

• Evaluation of the suitability of various biocarbon types to copper slag reduction/cleaning 

• Capex Structure of a Greenfield Copper Smelter Investment 

• Flotation Launder Retrofit Impact on Copper Concentrators 

• Injection of Dry Copper Concentrates in the Ausmelt TSL Furnace 

• Integrated circuit trialling and process development of Metso’s novel mesophile-thermophile (MesoTHERMTM) biooxidation technology for a primary (and secondary) copper sulphide concentrate 

• Life-cycle assessment of the improvements achieved using steam-gas reduction system (SGRS) in Anode Furnaces 

• Metallurgical Performance of industrial scale Concorde Cell in improving fines recovery 

• Pressure Leaching of Copper Sulfide Concentrates 

• Slag Chemistry and Partitioning of Trace Elements in Direct-to-Blister Copper Smelting Conditions 

• Tankhouse material handling at Heding Copper 620.000 tpa copper electro refinery 

In addition to presenting and seeing numerous interesting presentations, the conference was an excellent chance to meet valued customers. Positive interactions were made throughout the event, such as in the exhibition at our booth, around in the premises during the coffee breaks, as well as after hours events. Another positive note was that this year, the conference was arranged in conjunction with Ni-Co and Cross-Cutting symposia, so there was a wider audience than previous years.

Metso arranged a cocktail event on Monday night outside the venue, and with more than 140 visitors, it was quite the success. Luckily, the weather was on our side, as the rain hit the scene only after 9 pm - after everyone already had a chance to enjoy the excellent food and drinks with our representatives. At that point, we moved indoors to continue the lively discussions with our friends and customers.

Thank you to all of our customers that came to see us in Phoenix. We are looking forward to seeing you again at the next Flash Smelting congress, as well as in the upcoming Copper conferences.

This article is part of our Smelting Newsletter 2025. Visit the issue front page for all articles and greetings from Jyrki Makkonen - VP, Smelting.