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Garfield Smelters

This page was last updated on October 6, 2013.

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(This is a work in progress; research continues.)

Overview

(interim link: American Smelting & Refining Co. history at Funding Universe)

Timeline

Construction began in August 1905, and operations commenced in the latter part of August 1906 (Salt Lake Mining Review, September 15, 1914, page 14; "The Garfield Plant of the Garfield Smelting Company", article with photographs.)

The Garfield smelter was to start operations "this week". (Salt Lake Mining Review, June 15, 1906, page 32)

News item about the agreement between American Smelting & Refining Company, Utah Copper Company, and Boston Consolidated for the processing of ores at the new Garfield smelter. (Salt Lake Mining Review, August 30, 1906, page 28)

1917
ASARCO began recovering sulphuric acid from the smelter gases at the Garfield smelter.

1946
Utah's three big smelters at Murray, Midvale, and Garfield were closed by a 150-day strike that was settled on June 30, 1946. (Murray Eagle, June 20, 1946)

1953
5,605 tons of concentrate from Magna and Arthur were shipped to Kennecott's smelter in McGill, Nevada due to a one and a half day, and another five day strike at the American Smelting and Refining Company (ASARCO) smelter at Garfield, Utah. (Kennecott Historical Index)

January 1, 1959
Kennecott Copper Corporation purchased the Garfield smelter of American Smelting and Refining Company (ASARCO) (Deseret News, April 25, 1958)

January 1963
Kennecott announced that it was planning a $60 million project to update its Utah facilities, to increase the capacity of milling, smelter and haulage facilities and "thereby restore our copper productions to the approximate level of 10 years ago, 25,000 tons annually." The copper content of the ore had decreased during the past 10 years, from 20 pounds per ton, to 16 pounds per ton, a drop of 20 per cent, with declines expected to continue. The expansion was to raise mine production at the Bingham pit, and use more effective precipitation and milling techniques to recover copper from waste dumps, as well as low grade ore. The present capacity was reported to be 90,000 of ore per day. the expansion was to increase production to 110,000 tons per day. The production of concentrate from precipitation would increase from 1,800 tons per month, to 6,000 tons per month. In addition to improvements mentioned in several other sources, the expansion was to initiate the use of natural gas and anode converters at the smelter, replacing the use of pine logs as fuel. (New York Times, January 30, 1963)

1966
Aa molybdenum oxide production plant was placed in operation at the Garfield smelter. (OnlineUtah.com -- Kennecott History)

November 17, 1974
Kennecott completed the construction of the new smokestack at its Utah smelter. Construction started on August 26, 1974. At 1,115 feet high, the smokestack is the tallest man-made structure in Utah, as well as the tallest free-standing structure west of the Mississippi. The extra height was needed to meet the requirements of the Clean Air Act of 1970, to disperse waste gases according to the new standards. The new smokestack replaced several earlier smokestacks, the tallest of which was 413 feet high. The old smokestacks were demolished upon completion of the new smokestack. (Deseret News, November 15, 2009, upon the 35th anniversary of the completion of the smokestack)

1979
38 million tons of ore mined in 1979 by Utah Copper Division of Kennecott Copper Corporation. 160 million tons of overburden removed. 12 pounds of copper per ton of ore. 206,000 tons of copper produced; 120,000 tons of copper produced in 1978. New smelter went on line in 1977-1978. (Salt Lake Tribune, March 2, 1980)

1992
Plans were also made for the construction of a new $880 million smelter west of Salt Lake City. It was hoped that the new smelter would enable Kennecott to process all of its own concentrate, rather than send 40 percent elsewhere to be refined. (Kennecott History at FundingUniverse.com)

1995
The following comes from a report completed in 1999:

The new Kennecott Utah Copper smelter, started in 1995, was designed to be the cleanest smelter environmentally in the world. The plant is operating at production rates above the original design capacity. Copper concentrate is smelted in an Outokumpu flash smelting furnace. Matte is granulated and processed using Kennecott-Outokumpu flash converting. Copper anodes are processed in a modernized copper refinery using the Kidd Process.

Kennecott Utah Copper Corporation (KUCC) expanded its mine and mill facilities in 1988 increasing the production rate to 773,000 tonnes per year of copper concentrate. A further expansion of the mill in 1992 raised the concentrate production to 1.0 million tonnes per year. The smelter facilities could only process about half this tonnage primarily because of insufficient acid plant capacity to meet increasingly restrictive air emission regulations. The remaining concentrate production was sold.

In 1989, KUCC initiated a study of smelting requirements to process all of the available concentrate resulting from the current expansion of mining and milling facilities and also possible future expansions. As a result of this study, the Outokumpu flash smelting furnace was chosen as the primary smelting vessel, to be coupled with Kennecott-Outokumpu flash converting technology to process solid matte through to blister copper. ("Recent operation and environmental control in the Kennecott Smelter," ca. 1999)

April 1995
Kennecott's 300,000-tons-per-year copper smelter had been completed by mid April 1995 and began its testing phase, with limited production expected to begin in May. When full production starts, in June or July, the old smelter will be demolished. The old smelter used old technology that used open blast furnaces to convert copper concentrate to copper matte, using large overhead cranes and ladels to move the molten copper matte from the furnaces to cast the copper matte into anodes, which were then transported by rail car to the refinery. The new smelter would reduce smelter operating costs by 53 per cent, and changes to the refining process would reduce refining costs by 45 per cent. The resulting copper would be 99 per cent pure. The modernization of the smelter and refinery would allow Kennecott to process all of the copper ore being produced by the Bingham Canyon mine. (Salt Lake Tribune, March 22, 1995; April 16, 1995)

Problems getting the various parts of the new and complex smelting process to work together, forced the smelter to operate at 80 to 85 percent capacity until early 1997. The reduced capacity meant that Kennecott had to sell come of its copper concentrate to other smelters, and to begin stockpiling concentrate pending the smelter's return to full capacity. The new smelter had been commissioned in July 1995. (Salt Lake Tribune, September 13, 1996)

February 1997
The problems with getting the new smelter fully operational drove RTZ profits down 23.9 per cent, from $1.4 billion in 1995, to $1.1 billion in 1996, about half due to falling metals prices, and about half due to delays concerning the new smelter. The new smelter was expected to be fully operational by June 1997. (Salt Lake Tribune, February 28, 1997; Salt Lake Tribune, March 20, 1997)

May 27, 1997
Kennecott's new smelter was re-started after a six-week shutdown. Production was about 100 tons of copper anodes per hour, with each anode weiging 720 pounds, and being 99.5 percent pure copper. The anodes were then transported to the Utah refinery, where the copper was further refined to be 99.99 percent pure. (Salt Lake Tribune, June 12, 1997; Salt Lake Tribune, July 31, 1997)

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