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<p>Hazelett technology produces continuous copper rods from molten copper. Copper rod failure can be controlled by analyzing the impurities as they flow through the conversion process of cathode to rod. Based on the operational data through November 2023 to January 2025 of casting in the refinery plant, Sarcheshmeh Copper Complex, Violation Rules of grade A copper cathode based on London Metal Exchange (LME), and control charts adapted to Nelson rules were proposed to analyze the charge fluctuations in copper cathode, the molten copper from the holding furnace, and the rod analysis. During copper rod production, XRF, SEM, and EDS analyses were used to detect impurities. As a first conclusion, sulfur and silver are the most common impurities associated with the shaft furnace feedstock. In the holding furnace, S, Fe, Ag, Zn, As, Sb, Se, Bi, Te, and Cr were gathered due to the physical entrapment of anodic slime in the cathode and wear of machine parts. As a result of the reducing atmosphere of the holding furnace, as well as the high levels of BaSO<sub>4</sub> and PbSO<sub>4</sub> in the anode sludge, BaS and PbS phases are produced. However, BaS and PbS act as a source of sulfur transfer to the molten copper due to their lower density and thermodynamic stability. As a result of controlling the operational parameters in the holding furnace, copper rod impurities change from S, Fe, Ag, Zn, As, Sb, Se, Bi, Te, Cr <b>to</b> Sb, Cd, Te, Se, Pb, S, Ag, Bi, As, Fe, Zn. When choosing an appropriate strategy, the results can be considered as promising tools, for example, by controlling impurities entry or using engineered flux in the holding furnace.</p>

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Violation Rules of LME and Control Charts Based on Adapted Nelson Rules: A Real Case Study in the Hazelett Technology on the Role of Impurities on 8-mm Copper Rod Failure

  • 期刊论文

  • 发表日期：

    2026年1月30日

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  • Amin Tayari Garkani,
  • Gholam Reza Khayati,
  • Saman Nemat,
  • Ali Reza Hashemi,
  • Ali Manoocheri,
  • Hadi Memarzadeh

摘要

Hazelett technology produces continuous copper rods from molten copper. Copper rod failure can be controlled by analyzing the impurities as they flow through the conversion process of cathode to rod. Based on the operational data through November 2023 to January 2025 of casting in the refinery plant, Sarcheshmeh Copper Complex, Violation Rules of grade A copper cathode based on London Metal Exchange (LME), and control charts adapted to Nelson rules were proposed to analyze the charge fluctuations in copper cathode, the molten copper from the holding furnace, and the rod analysis. During copper rod production, XRF, SEM, and EDS analyses were used to detect impurities. As a first conclusion, sulfur and silver are the most common impurities associated with the shaft furnace feedstock. In the holding furnace, S, Fe, Ag, Zn, As, Sb, Se, Bi, Te, and Cr were gathered due to the physical entrapment of anodic slime in the cathode and wear of machine parts. As a result of the reducing atmosphere of the holding furnace, as well as the high levels of BaSO4 and PbSO4 in the anode sludge, BaS and PbS phases are produced. However, BaS and PbS act as a source of sulfur transfer to the molten copper due to their lower density and thermodynamic stability. As a result of controlling the operational parameters in the holding furnace, copper rod impurities change from S, Fe, Ag, Zn, As, Sb, Se, Bi, Te, Cr to Sb, Cd, Te, Se, Pb, S, Ag, Bi, As, Fe, Zn. When choosing an appropriate strategy, the results can be considered as promising tools, for example, by controlling impurities entry or using engineered flux in the holding furnace.