Copper is one of the most sought-after metals in industry, especially in the electrical sector. Thanks to its high conductivity, it is indispensable for manufacturing busbars, cables, and other power system components. But not all copper is the same—efficient current transmission requires material with minimal resistance.
TETIKA uses high-conductivity copper in its busbars—pure, homogeneous, and meticulously processed. How is it mined, refined, and transformed into a high-tech product? Let’s take a closer look.
Copper Mining: From Ore to Concentrate
Copper rarely occurs in its native form in nature—it is extracted from ore (primarily sulfide (chalcopyrite – CuFeS₂) and oxide compounds) found underground. Major deposits are located in Chile, Peru, Russia (Ural, Norilsk), and Kazakhstan.
How is Copper Extracted?
- Open-pit mining (quarries) – for shallow ore deposits.
- Underground mining (shafts) – for deep deposits.
Key Extraction Stages:
- Exploration & Extraction
Geologists locate deposits, analyze their composition, and assess profitability. Mining then begins—either open-pit or underground. - Ore Enrichment
Raw ore contains only 0.5–2% copper, so it must be concentrated before smelting. This is done via flotation:- Crushed ore is mixed with water and reagents.
- Copper particles attach to air bubbles and rise, forming a concentrate with 25–35% copper content.
Metallurgy: Turning Concentrate into Pure Copper
The enriched copper concentrate undergoes pyrometallurgical or hydrometallurgical processing.
1. Pyrometallurgical Method (Smelting)
Used for sulfide ores. Steps include:
- Roasting – Removing sulfur, converting compounds to oxides.
- Smelting in furnaces – Producing copper matte (~60-70% Cu).
- Conversion – Removing iron/sulfur, yielding blister copper (~98-99% Cu).
- Electrolytic refining – Blister copper anodes are immersed in sulfuric acid electrolyte. 99.99% pure copper deposits on cathodes.
2. Hydrometallurgical Method (Leaching)
Used for oxide ores. The ore is treated with acid solutions to dissolve copper, which is then recovered via cementation or electrolysis. This eco-friendlier method is less common.
Producing High-Conductivity Copper
Standard copper has excellent conductivity, but busbars and high-tech systems demand exceptional purity.
Additional Refining
To minimize impurities (oxygen, sulfur, lead), copper undergoes:
- Vacuum degassing
- Electron beam melting
Oxygen-Free Copper (OFC)
Oxygen compounds reduce conductivity and strength. OFC is produced via:
- Inert atmosphere casting
- Protective gas shielding
Silver Alloying
Small silver additions enhance mechanical strength without sacrificing conductivity.
Forming the Final Product
Refined copper is rolled into busbars, wires, and other components.
Critical Note: Even 0.02% phosphorus degrades conductivity. TETIKA uses only premium OFC copper.
Why Does This Matter for Busbars?
Busbars transmit electricity in industrial, commercial, and infrastructure projects. They must ensure:
- Minimal energy loss (reduced heat generation)
- Stable high-current performance
- Extended equipment lifespan
- Lower overheating/short-circuit risks
TETIKA’s high-conductivity copper busbars deliver reliable, efficient power distribution.
Want to optimize your power systems? Contact us for tailored solutions!
