US3802871A - Refining of liquid copper - Google Patents
Refining of liquid copper Download PDFInfo
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- US3802871A US3802871A US00143175A US14317571A US3802871A US 3802871 A US3802871 A US 3802871A US 00143175 A US00143175 A US 00143175A US 14317571 A US14317571 A US 14317571A US 3802871 A US3802871 A US 3802871A
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- copper
- fluoride
- metal
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- salt
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/34—Electrolytic production, recovery or refining of metals by electrolysis of melts of metals not provided for in groups C25C3/02 - C25C3/32
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J14/00—Chemical processes in general for reacting liquids with liquids; Apparatus specially adapted therefor
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B15/00—Obtaining copper
- C22B15/0026—Pyrometallurgy
- C22B15/006—Pyrometallurgy working up of molten copper, e.g. refining
Definitions
- a process for refining copper comprises removing an- [58] Field of Search 204/64 R; i nic impurities by electrolytic or chemical reaction 75/72 76 93 followed by removing the remaining impurities by contacting molten copper with a fluorine containing References Cited salt.
- flotation concentrates generally copper-iron sulfides
- precipitate copper obtained by cementation with scrap iron from aqueous solutions produced by leaching of mine waste dumps
- secondary or scrap copper secondary or scrap copper.
- Sources (1) and (2) pass through a wellestablished smelting and converting process, whose end product is an impure grade of metal known as blister copper
- Source (3) may enter the refining process directly, or it may first be smelted in a blast furnace, whose impure product metal is known as black copper.
- Table 1 below gives analyses of a number of samples from various copper sources.
- the first process step is fire refining much as described above, except that the fire refining is carried only far enough to permit casting of economically acceptable anodes.
- Anodes typically have dimensions 36 inch wide X 39 inch long X l inches to 2 inches thick, and weigh between 500 and 800 pounds. Table 11 below gives some representative impurity analyses of copper anodes:
- Fire Refining comprises (1) transferring the crude liquid copper to a refining furnace (or melting it in that furnace should it arrive from the smelting process in solidified form), (2) oxidiaing the molten metal by introduction of air through iro n blowpipes, (3) frequently skimming slag from the surface of the bath, and (4) reducing or poling the metal which consists of inserting green hardwood poles into the molten metal bath that decompose into hydrocarbon gases and carbon.
- the refined copper is then ready for casting into desired shapes.
- Fire refining is capable of removing substantially all of the sulfur, zinc, tin and iron, and partially removing several other impurities.
- the refining of a 300 ton charge of blister copper requires about 20 hours; charging time consumes 2 hours, melting and skimming 14 hours, oxidizing 1% hours and reducing 2% hours. Subsequent casting consumes 3%: hours, so that the entire process operates on a 24-hour cycle.
- Electrolytic Refining is used only where the amount of. precious metals or the character of the impurities Impurity Analyses of Copper Anodes 1n the third process step, the anodes are suspended,-
- electrolytic cells containing sulfuric acid and copper sulfate, and copper is elctrolytically transferred from anode to cathode over a period of 25 to 31 days.
- Impurities dissolve and are carried away in the recirculating electrolyte, or else fall to the bottom of the cells as solid particulate anode mud or slimes.
- Electrolysis cannot be carried to completion because anodes do not dissolve uniformly; 10 to 20 percent of the anode becomes scrap which is recycled to the fire refining furnace. Additionally, about one percent of the anode is converted to anode mud or slimes. This material is treated separately for recovery of Cu, Se, Te and the precious metals.
- the cathodes are melted so that they may be cast into desired commercial shapes.
- Cathode melting should rationally be confined to bringing solid cathodes into the molten state under noncontaminating conditions with provision for elimination of the small amounts of sulfur and occluded gas which may be introduced with the charge.
- melting of cathodes requires essentially the same procedure as for fire-refining of impure copper. It is a batch process and every effort is made to perform the. complete cycle in 24 hours.
- the process of the present invention possesses several advantages over the prior art.
- One of these is that the process is conducted entirely at high temperature upon liquid copper, thereby eliminating the conventional unit operations of casting anodes and melting cathodes.
- Another advantage is that impurities are transferred out of the copper, rather than transferring copper away from the impurities as in conventional electrolytic refining. Since the quantity of impurities in crude copper is ordinarily about one one-hundredth of the total weight, the necessary residence time in the apparatus is therefore very much shortened, as from 32 days to a few minutes.
- Another advantage is that there is no anode scrap, which ordinarly constitutes -20 percent of the copper, and which must be recycled to the anode furnace because it is physically impractical to electrolyze an anode completely.
- anion impurity elements can be removed by contacting impure copper with a molten salt or a mixture of molten salts containing dissolved reactive metal, in a chemical reactor, and removing the anionfree copper to the second process step.
- Metallic impurity removal can also be accomplished by providing copper free of anionic impurity elements from a first process step, and making this copper the anode of an electrolytic cell containing a fused salt electrolyte bearing fluorine-containing compounds, and removing the purified copper from the electrolytic cell.
- the anion impurity elements and the cation or metallic impurities may be simultaneously removed electrochemically in a two compartment electrolytic cell having a common receptacle or container for the impure liquid copper and separate compartments for two electrolytes.
- the anionic impurities are removed by electrolytic or chemical reaction.
- the impure liquid copper is made the cathode of an electrolytic cell containing a fused salt electrolyte and an insoluble anode.
- the electrolyte composition in cathodic refining is not highly critical, but is conveniently rides or mixtures thereof because of their relatively low volatility near the melting point of copper, their chemical stability and their compatibility with graphite and certain other conventional oxide refractories.
- Alkali metal halides may also be added to the electrolyte comosition. The alkali metal halides may comprise from about 0.3 weight percent to about 10 weight percent of the electrolyte.
- the chalcogens or anionic impurity elements for example, oxygen, sulfur, selenium, and tellurium are removed by an electrode reaction taking place at the cathode-electrolyte interface.
- the reaction may be represented as: Cu S (dissolved in metal phase) 2c-2 Cu( 1) S (transferred to the salt phase) where oxygen, selenium and tellurium also act after the manner of sulfur.
- EXAMPLE I 487 grams of impure copper having an initial composition as shown in Table III was melted along with 129 grams of anhydrous barium chloride electrolyte in an alumina crucible.
- the alumina crucible itself was contained in a large graphite crucible, a portion of whose sidewall was in contact with the electrolyte, and which served as the anode.
- the cathode current lead was a graphite rod extending down into the copper pool, and insulated from the electrolyte by an alumina sheath.
- the cell was maintained at 1150 C in an inert atmosphere, and electrolysis, was performed at 3.3 volts 5 with a cathode current density of 1.0 amps. per square centimeter.
- Table III The average analysis of the impurities in the copper before and after electrolysis is shown in Table III.
- a second method for dealing with the contaminated electrolyte depends upon the low solubility of the chalcogenide compounds in the alkaline earth chloride electrolytes.
- a portion of the electrolyte is continuously withdrawn from the electrolytic cell, cooled slightly to precipitate the chalcogenide compounds which are then mechanically separated by high temperature filtration or its equivalent.
- the purified electrolyte is then reheated and returned to the electrolytic cell.
- Another, and the preferred method is to prevent impurity buildup by using a fluoride based electrolyte, in
- a process conducted according to Reaction (1) is simply the desulfidation (or deoxidation, etc.) of copper by barium metal, and the use of the electrolytic cell may be viewed mainly as a convenient way to prepare barium metal and perform a reaction with it. Also, the barium metal will have been produced with less energy expenditure than if pure barium metal had been separately prepared.
- the potential advantages of operating Cathodic Refining according to Reaction (2) rather than Reaction (1) include avoidance of problems of disposal of the chalcogenide compounds (e.g., BaS, BaO, BaSe; BaTe), so that an electrolyte purification circuit is unnecessary; the opportunity to recover Se and Te by condensation of the anode gas, and elimination of chlorine gas recycling (as ,by using it to chlorinate the chalcogenide compounds and regenerate BaCl
- An advantage of using Reaction (1) rather than Reaction (2) is that it can be performed in a chemical reactor without electrodes, as well as in an electrolytic cell. This is because many of the reactive metals are extensively or completely miscible with their halides, forming true liquid solutions at the temperatures where copper is molten.
- the liquid copper can be broken into small droplets and permitted to settle by gravity through a salt-filled vessel or contacting column, so that the reaction surface area of the copper droplets per unit area of plant floor space is much larger and the required plant size appropriately smaller than if an electrolytic cell is employed.
- the reactive metal may be purchased instead of manufactured by the copper refinery, and (2) the optimal values of process parameters for manufacturing reactive metal, should the copper refinery choose to undertake it, will in general be different from those prevailing in the copper refining operation; separation of the two functions may therefore permit each to be performed under its most favorable circumstances.
- reaction products accumulate in the molten salt.
- their solubilities in the molten salt are believed to be quite limited, and they will be precipitated.
- the densities of compounds of reactive metals with chalcogenide elements in general lie between that of the molten salt and that of liquid copper.
- the solid compounds will therefore be trapped by gravity just above the interface between the metal and salt layers and can be removed from the system by gravity through a separate taphole located near the interface.
- the solid compounds will be admixed with salt. It may or may not be useful to separate the admixed salt, depending on whether or not the Se, Te and salt are to be recovered.
- the remaining base impurity elements such as nickel, iron, lead, bismuth, arsenic, antimony, tin, zinc, cadmium, and phosphorus are removed by subjecting the molten copper either to a chemical refining reaction or to an electrochemical refining reaction in which a copper fluoride equivalent is the reactive substance employed.
- CuF is defined for the purposes of this application as a molten solution of stoichiometric cupric fluoride, or CuF which has been saturated with,
- a measure of the ability of CuF, to perform fluorinating reactions is defined by its free energy of dissociation; which is the free energy change of the reaction:
- fluorine potential, or p is another' tion (3): 7* 2 cu) (Pr Z CuF
- a and a are not expected to vary significantly from unity, so that X atm.
- copper fluoride equivalent is defined for the purposes of the application not simply as stoichiometric cupric fluoride having the formula CuF but more broadly as any product or mixture of products having an ability to perform fluorinating reactions upon liquid copper and the impurities contained therein which is controlled or limited by the thermochemical properties of molten CuF
- copper fluoride equivalent is any substance which upon contact with liquid copper provides a fluorine potential m, at least as great as does CuF,.
- copper fluoride equivalent is any fluorine-bearing compound that is thermodynamically less stable than CuF and consequently will act as a fluorinating agent for liquid copper and the impurity elements therein.
- elemental fluorine gas introduced into a molten fluoride salt solution which contains a non-stoichiometric fluorine compound such as CuF or a stoichiometric fluorine compound capable of accepting more fluorine to become a stoichiometric fluorine compound of higher valence, which is in contact with molten copper, the quantity of such fluorine gas being small or limited relative to the amount of molten copper, reacts with the non-stoichiometric fluorine compound or stoichiometric fluorine compound capable of accepting more fluorine to become a stoichiometric fluorine compound of higher valence in the salt to form CuF where x y s 2.
- CuF in turn reacts with molten copper to form more CuF,,.
- the process is thus an indirect fluorination of copper via the salt phase termed copper fluoride equivalent as defined above.
- copper fluoride equivalent a high valency fluorine compound which readily gives up a part of its fluorine content of molten copper, reverting in the process to a fluoride compound of lower valency.
- copper fluoride equivalent a high valency fluorine compound which readily gives up a part of its fluorine content of molten copper, reverting in the process to a fluoride compound of lower valency.
- antimony pentafluoride which may react according to: i
- Stannic fluoride (SnF is another example of a copper fluoride equivalent. Stannic fluoride readily gives up part of its fluorine under the conditions of refining liquid copper to become stannous fluoride (SnF Stannic fluoride is particularly adaptable to the process of this invention since it is a solid at room temperature, and yet sufficiently volatile at liquid copper temperatures so that it does not remain dissolved in the molten copper or the molten salt.
- CuF cuprous fluoride
- Cupric hydroxy fluoride [Cu(OH)F] is thought to be capable of approaching the performance I have observed with the copper fluoride equivalents as described herein. It is believed that under certain process conditions the use of cupric hydroxyfluoride could be considered an adequate substitute for CuF Utilization of a copper fluoride equivalent to refine molten copper by chemical reaction may be brought about in any of a number of ways.
- Copper fluoride as anhydrous CuF may be brought into direct contact with molten copper in the chemical reactor.
- Copper fluoride may be prepared by reacting or burning elemental fluorine gas and anion-free impure copper in a torch or high temperature reactor. The reaction or combustion products copper fluoride equivalent are then brought into contact with molten copper in the chemical reaction vessel.
- Carbon and fluorine gas may be reacted as by contacting fluorine gas with charcoal.
- the reaction gases comprising principally CF.
- C F C l and C F are then passed through the molten copper where the gases decompose and the fluorine combines with copper to form the copper fluoride equivalent.
- reaction products of (3) above comprise cyclic fluorocarbon compounds which are liquid at room temperature, such as Cyclo-C F Cyclo-C F and Cyclo-C F
- This liquid mixture may be vaporized by heating, and then passed through the molten copper where the vapors decompose and the fluorine combines with copper to form the copper fluoride equivalent.
- a copper fluoride equivalent such as antimony pentafluoride or stannic fluoride may be introduced into the molten copper in any convenient manner. This procedure is especially suitable because antimony pen,- tafluoride, antimony trifluoride, stannic fluoride and stannous fluoride are all volatile enough so that they evaporate both from the molten copper and salt phase, and do not accumulate.
- Antimony pentafluoride is a liquid and stannic fluoride is a solid at room temperature and can be conveniently handled.
- the copper fluoride equivalent need not be used at full strength, but may be dissolved in various other stable salt solvents such as alkaline earth fluoride eutectic mixtures. In some cases a salt containing very little dissolved copper fluoride equivalent may be adequate, depending upon which impurities are to be removed and to what concentrations they must be reduced.
- a second advantage is that the use of a diluent material may permit suppression of electronic conductivity thought to exist in copper-saturated liquid copper fluoride, which would greatly reduce current efficiency in electrolytic purification of the impurity laden fused salt.
- a third advantage is that the constituents of the salt phase may be chosen so as to depress the thermodynamic activities of specific impurity fluorides and so drive specific refining reactions further toward completion than otherwise possible. It has been found that as little as 1 mole percent copper fluoride in the electrolyte will be capable of refining liquid copper where the impurity level is low.
- an electrolytic cell In the electrochemical method of performing the fluoride refining reaction an electrolytic cell is used rather than a chemical reactor.
- the major constituents of the electrolyte should be very stable thermodynamically (for example, CaF MgF nonvolatile, and liquid at temperatures substantially below the melting point of copper.
- the electrolyte should also contain a small concentration of copper fluoride.
- In the electrolytic cell there will be an impure liquid copper anode pool and a pure copper cathode pool. Electrolysis is performed with an applied voltage sufficiently small that the major electrolyte constituents do not take part in either electrode reaction and the impurities are not deposited at the cathodes.
- the stoichiometry of the copper fluoride changes as it becomes saturated with copper metal until it attains the composition range of from about CuF to about CuF depending upon the temperature employed.
- the copper fluoride is largely immiscible in the liquid copper, and because of its lower density forms a slag or salt phase above the molten metal.
- the refining reactions occur because of the favorable thermodynamic properties of copper fluoride as compared with the thermodynamic properties of the impurity element fluorides. More specifically the Gibbs free energy of formation is thought to be substantially less negative than forithe formation of the fluorides of the impurity elements.
- the impurities forming the volatile fluorides (a) do not accumulate in the salt phase and thus do not lead to the requirement for a salt repurification process, and (b) tend not to require as negative a free energy of reaction with copper fluoride as impurities forming non-volatile fluorides, because the their evaporation from the salt.
- the solubility of salt in the metal phase is extremely small in the temperature range of interest. For example at 1128" C. the solubility of copper fluoride in molten copper is 522 parts per million by weight. At the monotectic temperature, 1,083C., the solubility of copper fluoride in molten copper is parts per million by weight. Because of the nature of the experimental method in determining these values they are regarded to be the upper limit of solubility so that the true values will be smaller.
- EXAMPLE 7 This is an example of the use of copper fluoride in diluted form. A charge comprising 20 mole percent cop per fluoride, balance CaF -MgF eutectic mixture, was reacted with molten impure copper at 1114 C for 2 TABLE VIII IMPURTY ANALYSES melting point of copper in the choice of operating temlnitial Metal Product Equilibrium Compositions p fg l lhe practical utility of a high temperature metal rempurity Content Metal Phase Salt Phase weight weigh!
- weight fining process such as the one described n th s apphca tron is very much dependent on the availability of suit- Fe 0-049 0-00026 0-046 able materials of construction for containment of g; 3;; :ggggg fig metal, salt, and vapors which arise as products or are Bi .043 .000083 .036 introduced as reactants.
- l have found that graphite and Sb '00025 carbon are excellent materials for containment, and As .045 .00020 .0034
- EXAMPLE 8 TABLE IX IMPURITY ANALYSES Products, Isolated as Liquids
- Initial Metal 16 step of anionic impurity removal should be employed as part of an overall refining process; and (d) the effect of increased temperature is adverse but not unduly so thus permitting a latitude of at least 50 C above the pending on the salt composition present, certain oxide and silicate refractories are considered to be adequate.
- solidified salt may be employed as an insulating and sealing material, by proper engineering design of heat removal from the apparatus, much as frozen cryolite has proven to be the best insulator in aluminum reduction cells.
- a secp I 4 10009 0nd criterion is the provision of a more or less sealed Bi @012 11009 vessel, such that moisture and other hydrogen sources As .045 .0088 .00005 l d d d l Sb .04: .o002s .0005 3P E.
- the process of removing chalcogens from molten copper comprising contacting, in a chemical reactor, chalcogen containing molten copper with a solution of reactive metal dissolved in a molten salt solvent selected from the group consisting of alkaline earth chlorides, alkaline earth fluorides and mixtures thereof and separating chalcogen free copper from the molten salt solvent containing the reaction product of the reactive metal and the chalcogens.
- the process of removing metallic impurities from molten copper comprising the steps of contacting impure molten copper with a copper fluoride equivalent whereby the metallic impurities react with the copper fluoride equivalent to yield copper and impurity metal fluorides and separating metallic impurity free copper from the impurity metal fluorides.
- molten salt is selected from the group consisting of alkaline earth chlorides, alkaline earth fluorides and mixtures thereof.
- the copper fluoride equivalent is selected from the group consisting of cupric fluoride, fluorine gas, fluorocarbon gas mixture, antimony pentafluoride, stannic fluoride and CuF where x is from about 0.90 to about 1.50.
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Abstract
Description
Claims (8)
- 2. The process of claim 1 wherein the molten salt solvent contains from about 0.3 to about 10 weight percent alkali metal halides.
- 3. The process of claim 1 wherein the reactive metal is selected from the group consisting of alkali metals and the alkaline earth metals.
- 4. The process of removing metallic impurities from molten copper comprising the steps of contacting impure molten copper with a copper fluoride equivalent whereby the metallic impurities react with the copper fluoride equivalent to yield copper and impurity metal fluorides and separating metallic impurity free copper from the impurity metal fluorides.
- 5. The process of refining copper comprising the steps of a. reacting liquid copper containing impurities with a solution of a reactive metal dissolved in a molten salt solvent to remove the anionic impurities, b. reacting liquid anionic impurity free copper with a copper fluoride equivalent to remove the metallic impurities and c. separating refined copper from reaction products.
- 6. The process of claim 5 wherein the reactive metal is selected from the group consisting of alkali metals, and alkaline earth metals.
- 7. The process of claim 6 wherein the molten salt is selected from the group consisting of alkaline earth chlorides, alkaline earth fluorides and mixtures thereof.
- 8. The process of claim 5 wherein the copper fluoride equivalent is selected from the group consisting of cupric fluoride, fluorine gas, fluorocarbon gas mixture, antimony pentafluoride, stannic fluoride and CuFx where x is from about 0.90 to about 1.50.
- 9. The process of claim 8 wherein the copper fluoride equivalent is dissolved in a salt solvent selected from the group consisting of alkaline earth fluorides and mixtures thereof.
Priority Applications (1)
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US00143175A US3802871A (en) | 1969-07-14 | 1971-05-13 | Refining of liquid copper |
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US84162969A | 1969-07-14 | 1969-07-14 | |
US00143175A US3802871A (en) | 1969-07-14 | 1971-05-13 | Refining of liquid copper |
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US00143175A Expired - Lifetime US3802871A (en) | 1969-07-14 | 1971-05-13 | Refining of liquid copper |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2341396A (en) * | 1998-09-11 | 2000-03-15 | Toshiba Kk | Molten salt electrolysis of nuclear waste |
GB2352729A (en) * | 1998-09-11 | 2001-02-07 | Toshiba Kk | Molten salt electrolysis of nuclear waste including filtering |
US20100112361A1 (en) * | 2008-11-06 | 2010-05-06 | Tamura Kaken Corporation | Method of removing lead, reclaimed metals and reclaimed products |
WO2020081707A3 (en) * | 2018-10-17 | 2020-06-04 | Kairos Power Llc | Systems and methods for maintaining chemistry in molten salt systems |
-
1971
- 1971-05-13 US US00143175A patent/US3802871A/en not_active Expired - Lifetime
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2341396A (en) * | 1998-09-11 | 2000-03-15 | Toshiba Kk | Molten salt electrolysis of nuclear waste |
GB2352729A (en) * | 1998-09-11 | 2001-02-07 | Toshiba Kk | Molten salt electrolysis of nuclear waste including filtering |
GB2341396B (en) * | 1998-09-11 | 2001-05-23 | Toshiba Kk | Method of treating waste from nuclear fuel handling facility and apparatus for carrying out the same |
US6299748B1 (en) | 1998-09-11 | 2001-10-09 | Kabushiki Kaisha Toshiba | Method and apparatus of treating waste from nuclear fuel handling facility |
GB2352729B (en) * | 1998-09-11 | 2002-04-24 | Toshiba Kk | Method of treating waste from nuclear fuel handling facility and apparatus for carrying out the same |
US6736951B2 (en) | 1998-09-11 | 2004-05-18 | Kabushiki Kaisha Toshiba | Method of treating waste from nuclear fuel handling facility and apparatus for carrying out the same |
US20100112361A1 (en) * | 2008-11-06 | 2010-05-06 | Tamura Kaken Corporation | Method of removing lead, reclaimed metals and reclaimed products |
WO2020081707A3 (en) * | 2018-10-17 | 2020-06-04 | Kairos Power Llc | Systems and methods for maintaining chemistry in molten salt systems |
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Owner name: KENNECOTT CORPORATION, 200 PUBLIC SQUARE, CLEVELAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:KENNECOTT MINING CORPORATION;REEL/FRAME:004815/0063 Effective date: 19870320 Owner name: KENNECOTT MINING CORPORATION Free format text: CHANGE OF NAME;ASSIGNOR:KENNECOTT CORPORATION;REEL/FRAME:004815/0036 Effective date: 19870220 Owner name: KENNECOTT CORPORATION Free format text: CHANGE OF NAME;ASSIGNOR:KENNECOTT COPPER CORPORATION;REEL/FRAME:004815/0016 Effective date: 19800520 |
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