188803663 05 electrowinning and electrorefining
DESCRIPTION
-Electrowinning-and-ElectrorefiningTRANSCRIPT
Electrowinning and Electrorefining
SYMPOSIUM: 05 ELECTROWINNIG AND ELECTROREFINING
CODE AUTHOR TITLE ABSTRACT
ER01 Shunsuke Kawai CFD SIMULATION OF COPPER ELECTROREFINING PROCESS AND ANALYSIS FOR THE TANKHOUSE OPERATION AT NAOSHIMA SMELTER AND REFINERY
ER02 Luis Navarro CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO REFINERY
ER06 Jari Aromaa CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER ELECTROREFINING
ER07 Michael Moats, Tim Robinson
GLOBAL SURVEY OF COPPER ELECTROREFINING OPERATIONS AND PRACTICES
ER09 Shuklin, M.A. TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMC'S (URALELECTROMED) NEW COPPER ELECTRO REFINERY
ER10 Guillermo Rios RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT PLANT AT ATLANTIC COPPER
ER11 G. Leuprecht - N. Izatt THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE MODERNIZATION PROJECT
ER14 Ari Rantala USE OF REAL-TIME INFORMATION IN TANKHOUSE OPERATIONAL EFFICIENCY IMPROVEMENT AND QUALITY CONTROL
ER16 Jimmy Bidwell TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE PRECIPITATION
ER17 Hidehiro Sekimoto SOLUBILITY PRODUCT OF ANTIMONY ARESENATE AND BISMUTH ARSENATE
ER18 Takahito Kasuno SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT METALS DURING COPPER ELECTROREFINING
ER19 Masaomi Kanazawa RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY
ER20 Yuuki Watanabe QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSHIMA SMELTER & REFINERY
ER21 Masaaki Kato THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND REFINERY
ER23 A.E. Wraith ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE WORLD`S FIRST COMMERCIAL ELECTROREFINERY
ER24 Michael J Nicol IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR CONTACTS?
ER25 Shijie Wang DETERMINATION OF BISMUTH CONTAMINATION IN COPPER
ER28 Nedelcho Dragoev AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE
ER31 Rodrigo Abel STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)
Electrowinning and Electrorefining
ER33 Stefan Konetschnik COST COMPARISON BETWEEN A CONVENTIONAL ER
TANKHOUSE AND A HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRX-TECHNOLOGY
ER34 Gerardo Cifuentes COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES
ER54 Günter Leuprecht DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS AT AURUBIS, HAMBURG USING EMEW® ELECTROWINNING TECHNOLOGY
ER59 J.P. Ibañez REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS® SYSTEM. LABORATORY INVESTIGATION
ER60 Clyde Wright - Marty Wessman
MOVING COPPER MATERIAL HANDLING FORWARD USING ADVANCED DESIGNS BY BROCHOT COMPANY
ER61 Cristian Cortes E CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC REFINERY OF THE VENTANAS DIVISION
ER62 Michael Stelter PURER CATHODES BY NEW ADDITIVES IN COPPER ELECTROERFINING
ER63 Songlin Zhou COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH CURRENT DENSITY
ER66 Marco Cifuentes A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE EXTRACTION OF ANTIMONY
EW03 Patricio Melani - P.A. Aylwin - N.I. Lagos
SELE MODULAR TECHNOLOGY TO ACHIEVE SUSTAINABLE DEVELOPMENT AND EFFICIENT IN EW PLANTS
EW04 Scott Sandoval OPERATION OF ALTERNATIVE ANODES AT CHINO SXEW
EW05 Tim Johnston HATCH HELM TRACKERTM SYSTEM FOR GUIDING CELL HOUSE PERFORMANCE IMPROVEMENT
EW12 R. Rajasingam ELIMINATION OF ACID MIST IN COPPER ELECTROWINNING
EW15 Luis G. Navarro SMALL COLUMN TESTING OF SUPERLIG® 83 FOR BISMUTH REMOVAL FROM COPPER ELECTRO REFINING ELECTROLYTE
EW22 Robert P. Dufresne CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT SHORT CIRCUITS
EW26 M. Morimitsu A STATE OF THE ART ANODE TECHNOLOGY: SMART ANODE, MSA®, FOR COPPER ELECTROWINNING
EW27 Rob Fraser COMPARISON OF INTERCELL CONTACT BARS FOR ELECTROWINNING PLANTS CONSIDERING THERMAL EFFECTS
EW29 Abbas Mirza OPTIMIZATION OF THE USABLE LIFE OF LEAD ELECTROWINNING ANODES
EW30 Andreas Siegmund ELECTROLYTIC TANKHOUSE ACID MIST CONTROL - MEETING STRINGENT WORKER EXPOSURE LIMITS AND EMISSION TARGETS
EW35 Francisco Sanchez ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL DIVISION
Electrowinning and Electrorefining
EW36 Michael Moats -Tyler
Helsten AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE ROUGHNESS IN COPPER ELECTROWINNING
EW38 Tomas Vargas THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION AND CATHODE QUALITY
EW53 Ricardo Fuentes EXPERIENCIES ON DESIGN, MANUFACTURING AND OPERATION OF HIGH CONTROLLED TRANSFORMER-RECTIFIERS FOR SX-EW COPPER PLANTS
EW55 A. Fiorucci DE NORA'S SOLUTION - PART I, DSA® ANODES FOR CU ELECTROWINNING
EW56 A. Fiorucci DE NORA'S SOLUTION - PART II, ACID MIST ABATEMENT
EW57 Gabriel Zarate MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS
EW58 Michael J Nicol MASS TRANSPORT TO CATHODES IN THE ELECTROWINNING OF COPPER
EW64 A.Lillo EXMAJET®, POTENTIAL FOR IMPROVED ACID MIST CAPTURE AND CATHODE QUALITY AT HIGH CURRENT DELSITY ELECTROWINNING
EW65 P. Los - A. Lukomska - S. Kowalska - M. Masalski -M. Kwartnik
POTENTIAL-CONTROLLED ELECTROLYSIS AS A NEW METHOD OF COPPER ELECTROREFINING AND ELECTROWINNING - DISCUSSION OF SOME BASIC ASPECTS
Electrowinning and Electrorefining
ER01
CFD SIMULATION OF COPPER ELECTROREFINING PROCESS AND
ANALYSIS FOR THE TANKHOUSE OPERATION AT NAOSHIMA SMELTER &
REFINERY
S. Kawai and T. Miyazawa
Computer-Aided Materials Engineering Department, Central Research Institute, Mitsubishi
Materials Corporation
1002-14 Mukohyama, Naka-shi, Ibaraki 311-0102, Japan
ABSTRACT
Copper market has been requesting its smooth appearance on the LME Grade A
Copper in addition to its composition. It is considered that nodular growth on cathode
surfaces is inhibited by preventing the adhesion of anode slime particles to cathodes and
supplying additives optimally to cathodes. The way of circulating electrolyte, such as
“bottom inlet to top outlet”, “side inlet to top outlet” etc., may affect both the slime
behavior and the additive supply to cathodes. The authors have simulated flow patterns in
the cell generated by several different ways of circulating electrolyte and analyzed the
amount of slime particles reaching cathodes and the delivering time of fresh additives to
cathodes using the computational fluid dynamics (CFD) model. The calculation results
have revealed that the electrolyte circulation of “side inlet to top outlet” which Naoshima
Smelter and Refinery has adopted has some advantages, such as inherent flows that
contribute to the reduction of slime particles reaching cathodes, and the uniform time to
deliver additives to every cathode, which can minimize the cell flow rate necessary to keep
smooth appearance of cathodes. Detailed advantages of “side inlet to top outlet” are
discussed in comparison with other conventional ways of electrolyte circulation.
Electrowinning and Electrorefining
ER02
CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO
REFINERY
Luis Navarro1, Tracy Morris
1, Weldon Read
1, Neil E. Izatt
2, Ronald L. Bruening
2, and
Steven R. Izatt2,
1Asarco
7001 State Highway 136
Amarillo, Texas 79106, U.S.A.
2IBC Advanced Technologies, Inc.
856 E. Utah Valley Drive,
American Fork, Utah 84003, U.S.A.
ABSTRACT
An effective removal system for the separation of dissolved bismuth from copper
electrolyte to reach desired bismuth levels has been developed by IBC Advanced
Technologies, Inc (IBC). This system is being operated at ASARCO in Amarillo, Texas to
produce high purity electrolytic copper. Control of bismuth concentration is necessary
because bismuth levels exceeding 2 ppm in the final copper product result in brittleness
making the product unsuitable for wire production. The bismuth removal system is based
on IBC’s Molecular Recognition Technology (MRT) process.
This process employs proprietary non-ion exchange resin materials, termed
SuperLig®, to effect the separation. Key benefits of the MRT process for bismuth removal
include (1) easy control of the bismuth levels in the tank house electrolyte, (2) avoidance of
brittle copper, and (3) flexibility to handle “dirty” copper concentrates as feedstock. This
paper describes the bismuth MRT plant at the Asarco refinery, the operating process, and
the results. Limitations of alternate technologies for bismuth control are discussed,
particularly with respect to their environmental concerns compared to the MRT
process. Benefits of the MRT system to copper refineries where bismuth problems exist
are presented.
Electrowinning and Electrorefining
ER06
CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER
ELECTROREFINING
Jari Aromaa, Antti Kekki, Olof Forsén
Aalto University
Department of Materials Science
PO Box 16200
00076 Aalto
Espoo, FINLAND
ABSTRACT
The AISI 316L type stainless steel is considered corrosion resistant in copper
electrorefining electrolyte, both as permanent cathode blank material and in process
equipment and piping. Damaged cathode blanks show increased surface roughness,
corrosion pits and deeper grain boundaries. The test hypothesis was that too high chloride
concentration and temperature can cause localized corrosion.
A synthetic electrolyte with 180 g/l H2SO4, 45 g/l Cu, 15 g/l Ni and 10 g/l As was
used. Test variables were temperature 50-70 oC and chloride concentrations from 40 ppm to
1000 ppm. Test method was cyclic polarization curve based on ASTM standard G61-86.
No pitting or crevice corrosion was seen in the test series but highest chloride
concentration resulted in wider active peak and higher passive current densities. In
transpassive corrosion tests localized corrosion on grain boundaries and detachment of
grains was seen. Two main possibilities for blank corrosion have been identified. High
chloride concentration can cause active dissolution. The concentration of chlorides has to
be at least 10 times higher than the normal chloride level. Polarization to transpassive
potentials causes corrosion on grain boundaries and detachment of grains. The only
possibility for transpassive dissolution is stray currents.
Electrowinning and Electrorefining
ER07
GLOBAL SURVEY OF COPPER ELECTROWINNING OPERATIONS AND
PRACTICES
Michael Moats
Associate Professor of Metallurgical Engineering,
Materials Research Center
Department of Materials Science and Engineering
Missouri University of Science and Technology
Rolla, MO 65409, U.S.A.
Tim Robinson
Senior Vice President
Republic Alternative Technologies, Inc.
11288 Alameda Dve
Strongsville, OH 44149, U.S.A.
Shijie Wang
Princple Advisor – Process Engineering
Rio Tinto - Kennecott Utah Copper
11500 West 2100 South
Magna, UT 84044, U.S.A.
Andreas Filzwieser
Info
Andreas Siegmund
Senior Vice President
Gas Cleaning Technologies (GCT) LLC
4953 N. O’Connor Road
Irving, TX 75062 U.S.A
William Davenport
Professor Emeritus
Department of Materials Science and Engineering
University of Arizona
Tucson, AZ 85721, U.S.A.
Electrowinning and Electrorefining
ABSTRACT
World copper electrorefining tankhouse operating practices have been surveyed and
reviewed. Previous surveys have been conducted in association with all International
Copper-Cobre conferences. This survey will include detailed analyses of historical and
current data to identify trends and operating correlations. Examples of recent design and
operational choices to increase productivity, improve copper quality and/or decrease
electrical energy consumption will be given.
Electrowinning and Electrorefining
ER09
TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMC’S
(URALELECTROMED) NEW COPPER ELECTRO REFINERY
Shuklin, M.A., Romanov, A.A, Bakhirov, N.Y
JSC Uralelektromed
1 Lenin str., Verkhnyaya Pyshma,
Sverdlovsk region, 624091, Russia
Phone +7 (34368) 4 71 38, 4 61 22
Fax: +7 (34368) 4 60 99, 4 26 26
Larinkari,M., Hukkanen, R.
Outotec (Finland) Oy
Riihitontuntie 7D (P.O Box 84)
02201, Espoo, Finland
Phone +358 20 529 211
Fax: +358 20 529 2200
ABSTRACT
A modern tankhouse relies on high performance material handling, fully automated
process control systems, quality assessment data and consistent operations reporting to
ensure high efficiency of operation and stable quality of final product. In 2012, Outotec’s
and Uralelectromed’s specialists have developed comprehensive tankhouse process
automation solution called Tankhouse Information Management System (TIMS), which has
been implemented at UMMC’s (“Uralelektromed”) new 150 tpa copper electro refinery in
Verkhnyaya Pyshma, Russia.
TIMS collects process data from different systems and material handling equipment
into a central database, providing material tracking and process key performance indicator
calculations. TIMS automates daily production reporting and provides various analytical
views of the process which can be used at higher level in business control systems.
As a result an essential part of the new tankhouse operation information is provided
by TIMS. Systematic and accurate reporting is based on real-time information which
requires minimal manual work by the personnel. Gained benefits are increased visibility
Electrowinning and Electrorefining
and awareness of the process, which has already supported both active supervision and
continuous improvement of tankhouse operations.
Electrowinning and Electrorefining
ER10
RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT
PLANT AT ATLANTIC COPPER
G. Ríos, R. Ramírez, C. Arbizu, I. Ruiz,
Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold)
Av. Francisco Montenegro, s/n
21001 Huelva, Spain
ABSTRACT
Approximately 160 m3/day of electrolyte bleed from the Atlantic Copper Refinery
Tankhouse is sent daily to the Electrolyte Treatment Plant to control the copper content and
impurities (As, Sb and Bi) in the electrolyte. Much of the solution leaving the 3rd stage
liberator circuit is returned to the tankhouse, but a small portion (~28 m3/day) is bled to the
weak acid neutralization plant for minor element control (Fe, Ca). Laboratory and pilot
scale tests have been carried out in order to recover the nickel from this bled solution as
nickel carbonate, using different ion exchange resins technologies. Based on the excellent
results obtained from these tests, Atlantic Copper decided to build a nickel carbonate
production plant, which is expected to be commissioned in February 2013. ECOTEC
Recoflo technology has been chosen for removing the sulphuric acid from the feed
solution.Once the acid is removed, then, through a neutralization process, it is possible first,
to purify the electrolyte and then, to precipitate nickel as nickel carbonate.
Electrowinning and Electrorefining
ER11
THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE
MODERNIZATION PROJECT
G. Leuprecht and R. Behlmer
Aurubis AG
Hovestrasse 50
D-20539 Hamburg, Germany
ABSTRACT
The Hamburg tankhouse of Aurubis was built in 1989 and expanded in 1992. After
more than 20 years of operation, the old lead lined cells had reached the end of their lifes.
During a 3-year program, 1080 old cells have been replaced by polymer concrete cells. The
replacement was executed section by section during normal operation of the tankhouse.
Each turnaround was completed during an anode cycle of 21 days. All steps will be
described in this presentation. In parallel to the replacement program, longer cells with an
increased number of anodes and cathodes were installed.
This fact combined with the full utilization of the rectifier capacity has maintained an
increase of cathode capacity to 416,000 mt per year. Beside the change of the cells, some
modifications into the handling systems were necessary. So the inlet and outlet conveyors
of the stripping machines and the spacing conveyor of the anode preparation machine had
to be adapted to the increased number of electrodes in the cells. Also a special construction
of the crane bale was required for operating old and new cells during the conversion time.
After the retrofit, the modernized tankhouse has increased its productivity and will be
able to achieve the technical and economical demands for the next future.
Electrowinning and Electrorefining
ER14
USE OF REAL-TIME INFORMATION IN TANKHOUSE OPERATIONAL
EFFICIENCY IMPROVEMENT AND QUALITY CONTROL
Ari Rantala
Manager, Advanced Process Control
Outotec (Finland) Oy
ABSTRACT
Optimizing the operations efficiency and cathode quality of a tankhouse requires not
only the efficient use of energy and labor, but also high availability of machinery and the
ability to rapidly observe and react to disturbances. With the use of proven innovative on-
line monitoring and information management systems now available in the market
parameters such as efficiency, productivity and quality can be assessed in real-time mode.
Some of the systems discussed in the paper include systematic surface quality inspection of
anodes and cathodes and permanent cathode condition.
Another system indicates cell performance on-line, facilitating early reaction to
critical events such as short-circuiting, flow blockages, anode passivation or electrolyte
temperature excursion at the cells. Obviously, it is also highly desirable to integrate such
abovementioned information into one overall management system, along with other
important plant information such as that provided by material handling machinery, process
control systems, on-line analysers and laboratory. Such a management system provides
transparency for operations through real-time production efficiency and quality reporting
and material tracking. Practical benefits of utilizing such systems are described and
illustrated with case examples.
Electrowinning and Electrorefining
ER16
TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE
PRECIPITATION
Jimmy Bidwell, Luis G. Navarro, Weldon Read, Tracy Morris
ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108
ABSTRACT
The liberator cells department at Amarillo Copper Refinery has the objective of
reducing metal impurities in the copper electrolyte to achieve high quality cathodes via
electrowining. Insoluble lead anodes are used and the copper is depleted from the
electrolyte and then electrodeposited to copper starter sheets.
After the electrowinning process, the decopperized electrolyte solution is sent to the
Acid Purification Unit (APU®), where sulfuric acid and arsenic are absorbed into the resin
and then desorbed using water which is then returned to the tankhouse to be reused as acid
make up and to increase arsenic concentration in the electrolyte. During this process, the
APU generates a byproduct stream that is high in nickel and other valuable metals that can
be further processed and the metals recovered.
This paper discusses how it is possible to precipitate a Nickel Carbonate product
when the de-acidified electrolyte is treated using sodium carbonate. The pH selective, 2-
step process first recovers copper still present in the solution and transforms it into a
product that can be processed and further recovered at the Hayden Smelter in Arizona.
Electrowinning and Electrorefining
ER17
SOLUBILITY PRODUCT OF ANTIMONY ARSENATE AND BISMUTH
ARSENATE HIDEBIRO SEKIMOTO
Fuyuhiko Miyanaga and Katsunori Yamaguchi
ASBTRACT
The solubility product of compounds consist mainly of the 15 group elements
(arsenic, antimony and bismuth) is essentially important information for understanding the
mechanism of the formation of anode slimes in electrolytic refining process and is useful
for prevention of the formation of floating slimes which are adversely affect the current
density and the quality of copper cathode.
The empirical value of the solubility product of several arsenates has been reported
using the operation data in some copper refineries. However, there is no report on the
solubility product based on the equilibria of dissolved chemical species. In this study, the
solubility product of typical antimony arsenate and bismuth arsenate represented as ShAs04
and BiAs04, respectively, in sulfuric acid solutions were investigated.
The sulfuric acid solution containing arsenic acid was saturated with the arsenates
prepared in our laboratory, and then, the concentration of As, Sb and Bi in the solution was
measured by 1CP-AES. Using the results, the solubility product of SbAs04 and BiAs04
was determined.
Electrowinning and Electrorefining
ER18
SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT
METALS DURING COPPER ELECTROREFINING
Takahito KASUN0,1 Atsushi KITADA,1 Kimihiro SH1MOKAWA,2 and Kuniaki
MURASE1
1 Department of Materials Science and Engineering, Kyoto University, 36-1
Yoshida-hornrnachi, Sakyo-ku, Kyoto 606-8501, Japan 2 PAN PACIFIC COPPER Co.
Ltd., Refinery Manager, 3-3382 Saganoseki, Oita-shi, Oita, 879-2201, Japan
E-mail: [email protected] (Takahito KASLNO)
ABSTRACT
Electrolytic copper contains, on average, 10 ppm silver as impurity, which leads to a
loss of silver as a cash-cow product for copper smelters. Most of silver included in blister
copper anodes passes into anode slime when electrolyzed, keeping the elemental state.
However, once a part of elemental silver oxidatively-dissolves from the anode or from
anode slime for some reason, then silver can co-deposit with electrolytic copper cathode,
since silver is nobler than copper. In the present work, the dissolution behavior of silver
from anode slime was examined using granular silver as a model of the slime.
We have shown that the silver dissolution is caused by dissolved oxygen in the
electrolyte, and that thiourea and/or chloride ions as usual additives play a role to suppress
the silver dissolution approximately to half. Moreover, it was found that the dissolution of
silver was almost perfectly suppressed by galvanic contacting of the granular silver with
less noble metals (Pb or Cu) immersed in the same electrolyte.
Electrowinning and Electrorefining
ER19
RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY
Masaomi Kanazawa, Akira Ueno, Kimihiro Shimokawa
Saganoseki Smelter & Refinery Pan Pacific Copper Co., Ltd. Japan Tel 81-97-575-3555,
Fax 81-97-575-3513 [email protected] Address, postcode: 879-2201, 3-3382
Saganoseki Oita-shi, Oita, Japan
ABSTRACT
Saganoseki Refinery of Pan Pacific Copper Co., Ltd. integrated three existing
tankhouses into two by introducing the Waxless ISA type permanent cathode process in
2006. To achieve the higher current efficiency and better cathode quality at current density
over 300 A/m2, the electrolyte filtering system was introduced to remove the suspended
solids (S.S) in the electrolyte in 2009.
The additives continuous feeding system, jointly developed with Taman° Refinery
of Hibi Kyodo Smelting Co., Ltd., has been installed in 2011, achiving over 97% current
efficiency at 311A/m2 current density. Several improvements were also executed to ensure
the steady operation and to increase the productivity. Owing to the improvements,
Saganoseki Refinery currently continues the stable and efficient operation with maintaining
the adequate cathode quality. This paper describes the outlines of improvements as well as
the current operational status.
Electrowinning and Electrorefining
ER20
QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSLAMA
SMELTER & REFINERY
Yuuki Watanahe, Shigehiro Arakawa
Naoshima Smelter and Refinery Mitsubishi Materials Corporation 4049-1, Naoshima-eho,
Kagawa-gun, Kagawa 761-3110, Japan TEL +81-87-892-3201 FAX +81-87-892-4091
ABSTRACT
Copper tank house in Naoshima Smelter Gr Refinery started with a capacity of
7,500 Um of electrolytic copper in 1969 and subsequently enhanced the capacity to
19,500t/rn until 2006 by expanding the number of tank-house cells and raising the current
density of commercial cells. After the expansion above, the tank-house operation has
focused on obtaining customer satisfaction by improving cathode quality and smoothing
cathode surface. An on-site automatic analysis was introduced to control the chemistry of
electrolyte stringently. Filtration equipments were expanded in the capacity from 10% of
the electrolyte to whole electrolyte.
These modifications have reduced dense nodules and smoothed the cathode surface
much. Integral electro-deposition on the cathode has lowered the frequency of short circuits
between electrodes and resulted in increasing in current efficiency from 96.5% to over
97.5%. Mitsubishi materials corporation naoshima smelter & refinery tank house section
Electrowinning and Electrorefining
ER21
THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE
INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND REFINERY
Masaaki Kato
Manager of Refinery Onahama Smelter & Refinery Onahama Smelting and Refinery Co,
Ltd e-mail: m-katommc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-3951
Masanori Yoshida
Manager of Production Division Onahanna Smelter & Refinery Onahama Smelting and
Refinery Co, Ltd [email protected] TEL: +81-246-54-4841 FAX: +81-246-53-3951
Tetsuro Sakai
Managing Director & General Manager Onahama Smelter & Refinery Onahama Smelting
and Refinery Co, Ltd e-mail: tesakaigmmc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-
3951
ABSTRACT
Since 2007, Onahama Smelter and refinery has operated the 0-SR process which
comprises the S-furnace of the Mitsubishi process is followed by two hearths of
reverberatory furnaces in order to increase the capacity of copper concentrates. Such
enhancement at the smelter requested the tank-houses to increase the productivity more
than 25% coping with impurities load of electrolyte. The productivity has been enhanced by
increasing current density which reinforced rectifiers of No.1 and No.2 tank-houses, and
have supplied and increasing the number of daily operation cells by 25%. Impurities in
electrolyte have been managed by resuming the operation of the secondary liberator cells
and controlling impurities load of the electrolyte. Furthermore,
Electrowinning and Electrorefining
ER23
ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE
WORLD'S FIRST COMMERCIAL ELECTROREFINERY
A.E. Wraith*,
Consultant, Exeter, UK.
P.J. Mackey,
P.J. Mackey Technology Inc., Kirkland QC, Canada.
R. Protheroe Jones,
National Museum of Wales, Swansea, UK.
ABSTRACT
It is well known that the world’s first copper electro-refinery started production in
1869 at Pembrey in South Wales. Built within the Pembrey Copper Smelter which had
commenced operations in 1849, the new refinery was based on principles described in the
British patents issued to J.B. Elkington in 1865 and 1869. Refining principles and practices
pioneered there were key to the foundation of modern electro-refining practice in what is
now a dominant international industry producing 14 Mt of electrical grade copper annually.
This paper explores the background to this pioneering application of the new, early 19th
century, science of “electro-metallurgy” and examines its links to the contemporary
decorative electro-plating industry and to the shortcomings of 19th century fire refining.
The beginnings and early years of the Pembrey electrorefinery are briefly discussed in
relation to the quality, applications and pyrometallurgy of copper at the time. Elkington’s
ideas and the commissioning of the Pembrey refinery can now be recognised as vital
precursors of the modern electrical age.
Electrowinning and Electrorefining
ER24
IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR
CONTACTS?
Michael J Nicol and Justin McGinnity
Murdoch University, Perth, W. Australia
ABSTRACT
Measurements of cell voltages on several copper, zinc and nickel tankhouses have
been made with a view to assessing the reliability of cell voltage as an indicator of shorts or
poor contacts in electrowinning cells. In addition, simulations of current distribution in
contiguous cells have been made using commercial electrical circuit simulation software
adapted to the flow of current in electrowinning cells using the normal Walker
configuration.
The results of both plant measurements and simuations have revealed that the use of
cell voltage as an indicator of the presence of shorts or poor contacts in electrowinning cells
can be ambiguous. Both in the measured cell and in adjacent cells, erroneous conclusions
can be drawn depending on the location of the voltage measurement.
The important factors which determine the variations in measured cell voltages have
been identified. It is recommended that operations make simple voltage measurements in a
number of locations in a number of cells to establish the reliability of such measurements
for their operations.
Electrowinning and Electrorefining
ER25
DETERMINATION OF BISMUTH CONTAMINATION IN COPPER
Daniel Kim, Shijie Wang
Rio Tinto Kennecott Utah Copper
11500 West 2100 South
Magna, UT 84044
ABSTRACT
Bismuth is a most critical impurity to cause copper grain boundary cracks in
wiredrawing. How to control bismuth in copper electrorefining process is an interesting
topic for most copper refineries in the world. From the London Metal Exchange (LME)
and the American Society for Testing and Materials (ASTM), specifications for bismuth
content in copper are 2.0 ppm and 1.0 ppm, respectively. Due to a fact that copper anodes
at KUC contain a significant amount of bismuth, it is a very critical task to determine,
minimize, and control the bismuth contamination in the copper production. This article
presents the methods and techniques used in the study of bismuth contamination. It also
summarizes the contamination mechanism identified in the process control of copper
electrorefining process at KUC.
Electrowinning and Electrorefining
ER28
AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE
Iv. Djurov
D. Kirilov; N. Dragoev; L. Gerov; K. Nedeleva; A. Saraev;
AURUBIS BULGARIA
Industrial zone
Pirdop, Bulgaria 2070
ABSTRACT
ISA 2000 Refinery was put into operation on July 2008 with design capacity of 180
000 tons copper cathodes per year. Refinery includes two electrolyte circulation systems
and Deep electrolyte decopperization section. Final treatment of the bleed electrolyte is
performed in Waste Water Treatment Plant.
As permanent cathodes are used SS blanks. Between both electrolyte circulation
systems there are situated Anode Preparation machine, Full Deposit Stripping machine and
Anode Scrap Washing machine. Control of each machine is made by its own control panel.
The building of the Refinery is divided into two bays. In each bay one completely
automated overhead crane “Single bale – Single lift system” operates.
During past years Refinery’s capacity was increased up to 231 000 tons of cathodes
per year through adjustment and improvement of technological process and its parameters
as a whole, without any investments.
Electrowinning and Electrorefining
ER31
STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)
Rodrigo Abel Fuentes*, Isabel Venegas Fuentes**, Cristian Cortés Egaña***, Luis
Felipe Ramirez****
*Senior Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].
**Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].
***Refinery Superintendent, Ventanas Refinery, Codelco
Chile,[email protected].
**** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS),
ABSTRACT
Most SXEW and Refineries currently use permanent stainless steel cathodes.
However, there are refineries and SxEw operations that use starter sheets/traditional
cathodes technology: In Chile, Ventanas and Salvador Refineries; in Peru, Ilo Refinery and
Cerro Verde’s SxEw plant; several in EEUU and Mexico, ASARCO’s Amarillo Refinery
among them. They require copper starter sheets for their final cathode harvesting.
Stripping starter sheets manually is boring, tiring, unsafe and may produce lower
quality sheets which impacts directly in the quality of commercial cathodes and therefore in
operator revenue.
MIRS designed and developed a Starter Sheet Robotic Stripping Machine (SSRSM)
focusing in improving safety and occupational health and reduce hazards in the process.
The patented method and separation device also improves the quality of starter sheets.
In a standard Layout 4 robotic arms interact in the system: the input robot picks
each cathode from a conveyor and places it in the stripping station; 2 stripping robots strip
each sheet and the output robot picks the empty plate from the stripping station and places
it in the output conveyor. This robot also handles rejects and blank reposition.
One MIRS’ SSRSM was commissioned at Ventanas during 2011. An industrial test
was carried out whose objective was to demonstrate functionality to strip in typical
operating conditions. Test results were: capacity 160 plates per hour and stripping
performance higher than 98%.
Electrowinning and Electrorefining
Now we are incorporating a washing station, and two laser scanners, one for sheets
and another for base plate quality and a starting sheet weighing station to sort them into
different qualities.
Because the SSRSM is robotic, it is more compact, flexible and configurable so it
adapts to existing layout and equipment. It also is capable of using different stripping
strategies according to cathode quality.
Electrowinning and Electrorefining
ER33
COST COMPARISON BETWEEN A CONVENTIONAL ER TANKHOUSE AND A
HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRX-
TECHNOLOGY
Stefan Konetschnik(1)
, Andreas Filzwieser(1)
, Iris Filzwieser(1)
and Andreas Anzinger(2)
(1) METTOP GmbH
Peter-Tunner-Strasse 4
8700 Leoben
Austria
(2) Montanwerke Brixlegg AG
Werkstrasse 1
6230 Brixlegg
Austria
ABSTRACT
In 2011, the first two electrorefining tankhouses using the METTOP-BRX-
Technology went into operation – one producing cathodes out of ore and one out of
secondary raw material. Both tankhouses show the possibility of achieving Grade A
cathodes at a current density of more than 400 A/m² while maintaining a current efficiency
of 97.0 – 98.5 per cent.
After almost two years of operation it is now possible to directly compare the costs
of the two-part tankhouse of Montanwerke Brixlegg AG. While half of the tankhouse is
operated at standard current density, the other half is equipped with the METTOP-BRX-
Technology.
Basis of the technology is an optimized electrolyte feed system in each electrolytic
cell. Even though the higher current density is directly proportional to the consumption of
electrical energy, the overall operational expenditures keep the same due to the lower costs
Electrowinning and Electrorefining
for bound capital. Furthermore, the higher productivity results in a smaller footprint of the
tankhouse.
The present paper gives a detailed insight into the additional costs and economical
benefits when operating a tankhouse at high current densities. It shows the mathematical
background of the calculation, as well as the result – the capital and operational cost
savings when using the METTOP-BRX-Technology.
Electrowinning and Electrorefining
ER34
COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES
Gerardo Cifuentes and Rodolfo Mannheim G2M Ingeniería Ltda., Chile
ABSTRACT
When an electric current flow is present in an electrolysis cell, it follows that the
cell potential, CellE , achieved is equivalent to the voltage difference of the theoretical
thermodynamic equilibrium resulting from the anode and cathode reactions, EqE , plus the
algebraic sum of the terms that reflects the inertia of the reactions involved, normally called
electrode overpotential, ca , plus a resistive term in solution, IRe· , and finally plus the
resistive term due to the external electric circuit, System losses.
Losses in the external electric circuit refer mainly to the Joule effect due to the flow
of current through the conductors. Indeed, intercell bars, also called intercell busbars, work
at an average temperature of 70 to 90 °C, and in short circuit the temperature can go up to
200 °C and higher.
Our CoolBar (WIPO International Patent pending), which has a higher current
conductivity compared to presently used regular intercell bars, will decrease the cell
potential by 2% to 7%, decreasing the specific energy consumption, SEC, by an equivalent
amount. In addition, the Coolbar optimizes the use of thermal energy in the electrolytic
plant by allowing better current flow distribution in the cell, causing a significant drop in
the carbon footprint of the electrolytic process.
Finally, an existing intercell bar can be easily replaced in situ by a Coolbar by just
placing the latter over the cell capping board and making a few small adjustments.
Electrowinning and Electrorefining
ER54
DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS
AT AURUBIS, HAMBURG USING EMEW® ELECTROWINNING TECHNOLOGY
Günter Leuprecht, Peter Stantke (Aurubis);SiddarthGadia (Electrometals);Andreas Siegmund
(GCT)
ABSTRACT
A series of on-site trials were conducted at Aurubis AG, Hamburg refinery using EMEW
electrowinning to remove copper from the liberator solution in high quality form with no arsine
emission. The liberator solution at Aurubis Hamburg works is particularly difficult to process as
it contains high acid concentration of 350-400 g/l and other impurities such as chloride (60ppm)
and arsenic 20 g/l. The results of the test program confirm that harvestable copper cathode can
be produced at copper concentrations below 1 g/l with low arsenic content such that arsenic in air
or solid emissions is eliminated.
The data from the series of trials over a range of copper concentrations from 1-8 g/l and
200-450 A/m2 enables an operating curve to produce solid copper product at various copper
concentrations in solution. Operating current efficiency averaged 93% (DC) which confirms
significant power savings in addition to handling and process cost savings.
Electrowinning and Electrorefining
ER59
REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS®
SYSTEM. LABORATORY INVESTIGATION
J.P. Ibáñez1, S. Cortés
1, P. Suarez
2, A. Labra
2, A. Moyano
3
1 Department of Metallurgical Engineering and Materials -Universidad Técnica Federico
Santa María ([email protected]) 2 Innovaxxion Spa
3 Codelco Chile - División Chuquicamata
ABSTRACT
A new system for reducing the anode scrap in a conventional electro-refining plant
was investigated at laboratory scale. The new system called Earless® is based in the use of
anodes without ears, which are easily mounted in an ad-hoc designed case that provides the
electrical contacts and transportation capability.
Experimental work was carried out to make a critical comparison of the electro-
refining behavior between a typical anode and two types of anodes in the Earless® system.
All the anodes (cathodic copper) and cathodes (stainless steel) were made in a scale of 1:10,
and were processed under the same experimental conditions of current density, anodic
cycle period, electrolyte temperature, electrolyte flow rate and synthetic electrolyte
composition.
The main results indicate that was possible to reach a reduction of the scrap
generation from around 20% (traditional anode) to around 10% (anode in the Earless®
system), all the cathodes obtained having the same quality and furthermore a significant
decrease of the specific energy consumption higher than 20% was observed as well.
Electrowinning and Electrorefining
ER60
MOVING COPPER MATERIAL HANDLING FORWARD USING ADVANCED
DESIGNS BY BROCHOT COMPANY
Clyde Wright
Marty Wessman
ABSTRACT
Our paper will present new material handling developments. The theory is to review
existing copper refinery processes, compare and contrast with the newest scientifically
proven technologies available. The aim is to improve and simplify material handling to
increase reliability thus reducing refineries cost curves.
The paper will develop all new concepts
- Robotic handling of electrodes: We eliminate old style mechanical transferring of
electrodes and replace with state of the art robotics. These robots give variable speed,
accurate control, and yet remain flexible for future process changes. Robotics require less
operator and maintenance intervention therefore enhance personnel plant safety.
- Copper Stripping from stainless steel mother blanks: A new copper stripping system has
been developed to eliminate all hydraulics, prolong mother blank life...
- New Cathode Wash Concept: Conventional copper washing can leave impurities. The
development of a new cathode wash system offers a full face wash using minimal water
consumption.
The paper will present all the Copper Projects
Our company has on going copper projects in Mexico, Peru, Russia, Kazakhstan, and the
Middle East …
Electrowinning and Electrorefining
ER61
CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC
REFINERY OF THE VENTANAS DIVISION
C. Cortés, E. Bahamondes and N. Cornejo
Codelco, Ventanas Division
Carretera F-30 E 58270
Ventanas, Puchuncaví
Chile
[email protected]; [email protected]; [email protected]
ABSTRACT
The Electrolytic Refinery of the Ventanas Division in recent years the Refinery has
focused on improving the productivity of its installation through a series of highly creative
initiatives requiring low-cost investments, in order to reinforce the competitiveness of the
Refinery in an increasingly complex business environment. In this context, during the last
four years, projects such as the "Electrode Optimization in Electrolytic Cells" and the
"High Current Density Stripper Circuits Operation" have been carried out.
The project "Electrode Optimization in Electrolytic Cells Phase II" consisted in
reducing the anode spacing to 100 mm, increasing the number of electrodes per cell and
maintaining the current density at 305 A/m2. The project "Stripper circuit operation with
high current density " consisted of reducing the starting sheet production cycle, operating at
a current density of 330 A/m2. Another prominent change of practices implemented in
2009 was the closure of the electrolyte purification plant, owing to the high cost of the
process, which established new trade opportunities by selling the electrolyte to third parties.
This has resulted in a dramatic change in managing impurities’ control, as well as, in new
improvements. The combination of these projects of improving and changing the practices
resulted in the production of 401,500 t of electrolytic copper in the year 2011.
Electrowinning and Electrorefining
ER62
PURER CATHODES BY NEW ADDITIVES IN COPPER ELECTROERFINING
M. Stelter, H. Bombach, J. Baumbach
Institute for Nonferrous Metallurgy and Purest Materials
TU Bergakademie Freiberg
Leipziger Str. 34
D-09599 Freiberg
ABSTRACT
In copper electrorefining additives are used for a smooth electrodeposition of
copper cathodes. The classical additives glue and thiourea show some disadvantages like
the relatively fast decomposition during electrolysis and the incorporation of sulfur from
thiourea into the cathodes. Only new additive systems avoiding thiourea can help to reduce
the sulfur content in the copper cathodes. Additionally the decomposition of glue and
thiourea forces a continuous dosing of the additives.
Our investigations show that alternative additives can be used in copper
electrorefining indeed. Polyethylene glycols (PEG) act strongly polarizing and can
substitute glue. Current density potential curves show that Bis-(3-sodiumpropyl)disulfide
(SPS), dimethylthiourea, methionin and cystein have a stronger depolarizing effect
compared to thiourea.
Electrolysis experiments with PEG and SPS proceeded without short circuits at a
current density of 500 A/m². However, the cathodes were rough and nodulous. Smoother
cathodes were produced when using glue and thiourea or glue and SPS. In the first case the
sulphur concentration in the cathodes ranged from 4 to 10 µg/g and in the second case only
from 0.3 to 1.5 µg/g. SPS is considerably more stable than thiourea. Thus, there is no need
for continuous addition during electrolysis.
Electrowinning and Electrorefining
ER63
COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH
CURRENT DENSITY
Songlin Zhou
Xiangguang Copper Co., Ltd
No.1 Xiangguang Road
Shifo Town, Yanggu County, 252327, China
ABSTRACT
This paper introduces the Parallel Flow Device (PFD) technology and production
practices for high current density copper electrolytic refining. The technology has been
successfully implemented for the first time on a large industrial scale, enabling the copper
electrolysis current density to reach 420 A/m², thereby substantially increasing copper
electrolytic productivity. Through this technology, a new level in copper electrolytic
refining has been achieved.
Electrowinning and Electrorefining
ER66
A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE
EXTRACTION OF ANTIMONY
Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Zúñiga (3)
(1) codelco chile, división chuquicamata, e-mail: [email protected] .
(2) departamento de ingeniería metalúrgica, facultad de ingeniería, universidad de
santiago de chile, santiago, chile.
(3) departamento de ingeniería química, facultad de ingeniería, universidad de santiago de
chile, santiago, chile.
ABSTRACT
An ion exchange pilot plant, located at the University of Santiago of Chile, was
tested for antimony control in the electrolyte of Chuquicamata Refinery. In the pilot plant
were used three different resins: MX-2, UR-3300S and Duolite C-467. The results showed
that the best behavior for antimony extraction follow the sequence UR3300S >Duolite C
467 > MX 2. A model with the experimental results was used as comparative tools to
increase the knowledge of this process.
Electrowinning and Electrorefining
EW01
CFD SIMULATION OF COPPER ELECTROREFINING PROCESS AND
ANALYSIS FOR THE TANKHOUSE OPERATION AT NAOSHIMA SMELTER &
REFINERY
S. Kawai and T. Miyazawa
Computer-Aided Materials Engineering Department, Central Research Institute, Mitsubishi
Materials Corporation
1002-14 Mukohyama, Naka-shi, Ibaraki 311-0102, Japan
ABSTRACT
Copper market has been requesting its smooth appearance on the LME Grade A
Copper in addition to its composition. It is considered that nodular growth on cathode
surfaces is inhibited by preventing the adhesion of anode slime particles to cathodes and
supplying additives optimally to cathodes. The way of circulating electrolyte, such as
“bottom inlet to top outlet”, “side inlet to top outlet” etc., may affect both the slime
behavior and the additive supply to cathodes. The authors have simulated flow patterns in
the cell generated by several different ways of circulating electrolyte and analyzed the
amount of slime particles reaching cathodes and the delivering time of fresh additives to
cathodes using the computational fluid dynamics (CFD) model. The calculation results
have revealed that the electrolyte circulation of “side inlet to top outlet” which Naoshima
Smelter and Refinery has adopted has some advantages, such as inherent flows that
contribute to the reduction of slime particles reaching cathodes, and the uniform time to
deliver additives to every cathode, which can minimize the cell flow rate necessary to keep
smooth appearance of cathodes. Detailed advantages of “side inlet to top outlet” are
discussed in comparison with other conventional ways of electrolyte circulation.
Electrowinning and Electrorefining
EW02
CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO
REFINERY
Luis Navarro1, Tracy Morris
1, Weldon Read
1, Neil E. Izatt
2, Ronald L. Bruening
2, and
Steven R. Izatt2,
1Asarco
7001 State Highway 136
Amarillo, Texas 79106, U.S.A.
2IBC Advanced Technologies, Inc.
856 E. Utah Valley Drive,
American Fork, Utah 84003, U.S.A.
ABSTRACT
An effective removal system for the separation of dissolved bismuth from copper
electrolyte to reach desired bismuth levels has been developed by IBC Advanced
Technologies, Inc (IBC). This system is being operated at ASARCO in Amarillo, Texas to
produce high purity electrolytic copper. Control of bismuth concentration is necessary
because bismuth levels exceeding 2 ppm in the final copper product result in brittleness
making the product unsuitable for wire production. The bismuth removal system is based
on IBC’s Molecular Recognition Technology (MRT) process.
This process employs proprietary non-ion exchange resin materials, termed
SuperLig®, to effect the separation. Key benefits of the MRT process for bismuth removal
include (1) easy control of the bismuth levels in the tank house electrolyte, (2) avoidance of
brittle copper, and (3) flexibility to handle “dirty” copper concentrates as feedstock. This
paper describes the bismuth MRT plant at the Asarco refinery, the operating process, and
the results. Limitations of alternate technologies for bismuth control are discussed,
particularly with respect to their environmental concerns compared to the MRT
process. Benefits of the MRT system to copper refineries where bismuth problems exist
are presented.
Electrowinning and Electrorefining
EW03
SELE® MODULAR TECHNOLOGY FOR SUSTAINABLE DEVELOPMENT AND
EFFICIENT EW PLANT
P.A. Aylwin and N.I. Lagos
New Tech Copper SpA
3397 Exequiel Fernández
Macul, Santiago, Chile
ABSTRACT
Sustainable development is an evolving concept that emerged in the 1980’s in
response to a growing realisation of the need to balance economic and social progress with
concern for the environment and the stewardship of natural resources. The idea has been
defined as using, conserving and enhancing the community’s resources so that ecological
processes on which life depends, are maintained, and the total quality of life, now and in
the future, can be increased. This paper proposes a framework for sustainability indicators
for EW industry in an attempt to further contribute to this on-going work and it compares
qualitatively the SELE Technology against the conventional technology, showing as an
example on the studies that must carry on in accordance to measure the sustainable
development.
Electrowinning and Electrorefining
EW04
OPERATION OF ALTERNATIVE ANODES AT CHINO SXEW
S. Sandoval, R. Garcia, T. Neff, and N. Schnebly
Freeport-McMoRan Mining Company
4521 U.S. Highway 191
Morenci, USA
ABSTRACT
In 2006, the Freeport-McMoRan Copper & Gold Inc. (FCX) Technology Center in
Safford, Arizona undertook research to develop an alternative anode for copper
electrowinning. An anode development lab was established that included bench-scale
electrowinning cells as well as accelerated life testing cells. In 2008, the Chino
electrowinning plant was fully converted to the new FCX anode becoming the first copper
electrowinning plant in the world to exclusively utilize non-lead anodes. A 15%
electrowinning voltage reduction was achieved. Cleaning of electrowinning cells for lead
sludge and addition of cobalt to the circuit for stabilizing lead anodes were discontinued.
Lead content of copper cathodes measured less than 0.3 ppm.
This paper describes operational results and findings with alternative anodes at Chino
over the ensuing years. Chino has exhibited higher than expected current efficiency,
measuring 93% at 3.8 g/L iron in electrolyte. Chino is operating without heat retention
balls on the cells and achieves low acid mist with only small additions of FC1100. Use of
Cyquest 900, a polyacrylamide, as the cathode smoothing agent has allowed Chino to
operate with over 300 ppm Mn in electrolyte without depositing Mn on the alternative
anode surfaces.
Electrowinning and Electrorefining
EW05
HATCH HELM TRACKERTM
SYSTEM FOR GUIDING CELL HOUSE
PERFORMANCE IMPROVEMENT
Rob Fraser (Hatch)
Tim Johnston (Hatch)
John Yesberg (Hatch)
Ephrem Gebrehiwot (Freeport McMoRan)
Jacklyn Steeples (Freeport McMoRan)
Guang Yeung (Freeport McMoRan)
ABSTRACT
In electrowinning and electrorefining operations, the detection of operational issues
associated with electrode currents has long been a highly labour intensive reactive
operations task. The Hatch HELM tracker™ system makes this proactive and targeted
reducing effort and increasing efficiency. The system measures and records the current
flow of every cathode and anode in real time and presents this information to the operators
through an interactive display clearly indicating the existence of shorts, poor contacts, and
any uneven current distribution. This allows the operators to prioritise and correct current
distribution issues. Expected benefits include increases in current efficiency, and thus
reduction in operating costs and/ or increases in production as well as reduction in electrode
damage due to shorts.
Hatch has been demonstrating the robustness and performance of the HELM
tracker system at commercial copper electrowinning plants including at FCX’s Safford and
Morenci plants with assistance from FMI management and operating personnel. This paper
includes the latest observations and outcomes from these two plants. It also describes the
latest developments for this exciting technology that have been implemented for
electrowinning and electrorefining plant applications.
Electrowinning and Electrorefining
EW06
CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER
ELECTROREFINING
Jari Aromaa, Antti Kekki, Olof Forsén
Aalto University
Department of Materials Science
PO Box 16200
00076 Aalto
Espoo, FINLAND
ABSTRACT
The AISI 316L type stainless steel is considered corrosion resistant in copper
electrorefining electrolyte, both as permanent cathode blank material and in process
equipment and piping. Damaged cathode blanks show increased surface roughness,
corrosion pits and deeper grain boundaries. The test hypothesis was that too high chloride
concentration and temperature can cause localized corrosion.
A synthetic electrolyte with 180 g/l H2SO4, 45 g/l Cu, 15 g/l Ni and 10 g/l As was
used. Test variables were temperature 50-70 oC and chloride concentrations from 40 ppm to
1000 ppm. Test method was cyclic polarization curve based on ASTM standard G61-86.
No pitting or crevice corrosion was seen in the test series but highest chloride
concentration resulted in wider active peak and higher passive current densities. In
transpassive corrosion tests localized corrosion on grain boundaries and detachment of
grains was seen. Two main possibilities for blank corrosion have been identified. High
chloride concentration can cause active dissolution. The concentration of chlorides has to
be at least 10 times higher than the normal chloride level. Polarization to transpassive
potentials causes corrosion on grain boundaries and detachment of grains. The only
possibility for transpassive dissolution is stray currents.
Electrowinning and Electrorefining
EW07
GLOBAL SURVEY OF COPPER ELECTROWINNING OPERATIONS AND
PRACTICES
Michael Moats
Associate Professor of Metallurgical Engineering,
Materials Research Center
Department of Materials Science and Engineering
Missouri University of Science and Technology
Rolla, MO 65409, U.S.A.
Tim Robinson
Senior Vice President
Republic Alternative Technologies, Inc.
11288 Alameda Dve
Strongsville, OH 44149, U.S.A.
Shijie Wang
Princple Advisor – Process Engineering
Rio Tinto - Kennecott Utah Copper
11500 West 2100 South
Magna, UT 84044, U.S.A.
Andreas Filzwieser
Info
Andreas Siegmund
Senior Vice President
Gas Cleaning Technologies (GCT) LLC
4953 N. O’Connor Road
Irving, TX 75062 U.S.A
William Davenport
Professor Emeritus
Department of Materials Science and Engineering
University of Arizona
Tucson, AZ 85721, U.S.A.
Electrowinning and Electrorefining
ABSTRACT
World copper electrorefining tankhouse operating practices have been surveyed and
reviewed. Previous surveys have been conducted in association with all International
Copper-Cobre conferences. This survey will include detailed analyses of historical and
current data to identify trends and operating correlations. Examples of recent design and
operational choices to increase productivity, improve copper quality and/or decrease
electrical energy consumption will be given.
Electrowinning and Electrorefining
EW09
TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMC’S
(URALELECTROMED) NEW COPPER ELECTRO REFINERY
Shuklin, M.A., Romanov, A.A, Bakhirov, N.Y
JSC Uralelektromed
1 Lenin str., Verkhnyaya Pyshma,
Sverdlovsk region, 624091, Russia
Phone +7 (34368) 4 71 38, 4 61 22
Fax: +7 (34368) 4 60 99, 4 26 26
Larinkari,M., Hukkanen, R.
Outotec (Finland) Oy
Riihitontuntie 7D (P.O Box 84)
02201, Espoo, Finland
Phone +358 20 529 211
Fax: +358 20 529 2200
ABSTRACT
A modern tankhouse relies on high performance material handling, fully automated
process control systems, quality assessment data and consistent operations reporting to
ensure high efficiency of operation and stable quality of final product. In 2012, Outotec’s
and Uralelectromed’s specialists have developed comprehensive tankhouse process
automation solution called Tankhouse Information Management System (TIMS), which has
been implemented at UMMC’s (“Uralelektromed”) new 150 tpa copper electro refinery in
Verkhnyaya Pyshma, Russia.
TIMS collects process data from different systems and material handling equipment
into a central database, providing material tracking and process key performance indicator
calculations. TIMS automates daily production reporting and provides various analytical
views of the process which can be used at higher level in business control systems.
As a result an essential part of the new tankhouse operation information is provided
by TIMS. Systematic and accurate reporting is based on real-time information which
requires minimal manual work by the personnel. Gained benefits are increased visibility
Electrowinning and Electrorefining
and awareness of the process, which has already supported both active supervision and
continuous improvement of tankhouse operations.
Electrowinning and Electrorefining
EW10
RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT
PLANT AT ATLANTIC COPPER
G. Ríos, R. Ramírez, C. Arbizu, I. Ruiz,
Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold)
Av. Francisco Montenegro, s/n
21001 Huelva, Spain
ABSTRACT
Approximately 160 m3/day of electrolyte bleed from the Atlantic Copper Refinery
Tankhouse is sent daily to the Electrolyte Treatment Plant to control the copper content and
impurities (As, Sb and Bi) in the electrolyte. Much of the solution leaving the 3rd stage
liberator circuit is returned to the tankhouse, but a small portion (~28 m3/day) is bled to the
weak acid neutralization plant for minor element control (Fe, Ca). Laboratory and pilot
scale tests have been carried out in order to recover the nickel from this bled solution as
nickel carbonate, using different ion exchange resins technologies. Based on the excellent
results obtained from these tests, Atlantic Copper decided to build a nickel carbonate
production plant, which is expected to be commissioned in February 2013. ECOTEC
Recoflo technology has been chosen for removing the sulphuric acid from the feed
solution.Once the acid is removed, then, through a neutralization process, it is possible first,
to purify the electrolyte and then, to precipitate nickel as nickel carbonate.
Electrowinning and Electrorefining
EW11
THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE
MODERNIZATION PROJECT
G. Leuprecht and R. Behlmer
Aurubis AG
Hovestrasse 50
D-20539 Hamburg, Germany
ABSTRACT
The Hamburg tankhouse of Aurubis was built in 1989 and expanded in 1992. After
more than 20 years of operation, the old lead lined cells had reached the end of their lifes.
During a 3-year program, 1080 old cells have been replaced by polymer concrete cells. The
replacement was executed section by section during normal operation of the tankhouse.
Each turnaround was completed during an anode cycle of 21 days. All steps will be
described in this presentation. In parallel to the replacement program, longer cells with an
increased number of anodes and cathodes were installed.
This fact combined with the full utilization of the rectifier capacity has maintained an
increase of cathode capacity to 416,000 mt per year. Beside the change of the cells, some
modifications into the handling systems were necessary. So the inlet and outlet conveyors
of the stripping machines and the spacing conveyor of the anode preparation machine had
to be adapted to the increased number of electrodes in the cells. Also a special construction
of the crane bale was required for operating old and new cells during the conversion time.
After the retrofit, the modernized tankhouse has increased its productivity and will be
able to achieve the technical and economical demands for the next future.
Electrowinning and Electrorefining
EW12
ELIMINATION OF ACID MIST IN COPPER ELECTROWINNING
R. Rajasingam1, W. Yang2, K. Mohanarangam2, B. Tadesse2 and D.J. Robinson1
1CSIRO Minerals Down Under Flagship, CSIRO Process Science and Engineering, PO
Box 7229, Karawara,
Western Australia, 6152
2CSIRO Minerals Down Under Flagship, CSIRO Process Science and Engineering, PO
Box 312, Clayton South,
Victoria, 3169
ABSTRACT
Acid mist is a ubiquitous problem throughout all tank houses of the copper industry.
Various approaches to alleviate the problem have been adopted by companies from
chemical additives to hoods, but all with varying degrees of success. All of these really
have been attempts to treat the symptom (acid mist) rather than the inherent problem and
indeed many of these “band-aids” have proven both expensive and in some cases
ineffectual.
CSIRO has established a full size (width and height) transparent cell capable of
simulating plant operating conditions (across the range currently used) and generating
bubbles under very controlled conditions. With the use of sophisticated diagnostic
analytical tools and in parallel to quantification of acid mist under each condition, we are
now able to study all the operating variables independently for their effect on bubble size,
bubble velocity and consequently acid mist generation. The early results of our
consideration of the underlying factors contributing to acid mist generation will be
presented.
Electrowinning and Electrorefining
EW14
USE OF REAL-TIME INFORMATION IN TANKHOUSE OPERATIONAL
EFFICIENCY IMPROVEMENT AND QUALITY CONTROL
Ari Rantala
Manager, Advanced Process Control
Outotec (Finland) Oy
ABSTRACT
Optimizing the operations efficiency and cathode quality of a tankhouse requires not
only the efficient use of energy and labor, but also high availability of machinery and the
ability to rapidly observe and react to disturbances. With the use of proven innovative on-
line monitoring and information management systems now available in the market
parameters such as efficiency, productivity and quality can be assessed in real-time mode.
Some of the systems discussed in the paper include systematic surface quality inspection of
anodes and cathodes and permanent cathode condition.
Another system indicates cell performance on-line, facilitating early reaction to
critical events such as short-circuiting, flow blockages, anode passivation or electrolyte
temperature excursion at the cells. Obviously, it is also highly desirable to integrate such
abovementioned information into one overall management system, along with other
important plant information such as that provided by material handling machinery, process
control systems, on-line analysers and laboratory. Such a management system provides
transparency for operations through real-time production efficiency and quality reporting
and material tracking. Practical benefits of utilizing such systems are described and
illustrated with case examples.
Electrowinning and Electrorefining
EW15
SMALL COLUMN TESTING OF SUPERLIG® 83 FOR BISMUTH REMOVAL
FROM COPPER ELECTRO REFINING ELECTROLYTE
Luis G. Navarro
1, Weldon Read
1, Tracy Morris
1, Jimmy Bidwell
1, Ronald L. Bruening
2,
Neil E. Izatt2
1ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108
2IBC Advanced Technologies, Inc, 856 E. Utah Valley Drive, American Fork, Utah 84003
ABSTRACT
The removal of Bismuth from Copper electro refining electrolyte using SuperLig ®
83 was studied in a small column with a resin bed volume of 150mL. Several loading and
elution cycles were performed. The research showed that no considerable loading
performance variability was observed between the first loading cycles and a high selectivity
for removing Bismuth was also achieved. The Bismuth elution was sharp and rapid and
accomplished with small bed volumes of 9M Sulfuric Acid.
The Superlig® 83 showed a propensity to amass small amounts of Pb and Sb
making it necessary to perform a 6M HCl wash to elute these elements and regain the initial
capacity of the Superlig® 83 without any considerable detriment.
Electrowinning and Electrorefining
EW16
TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE
PRECIPITATION
Jimmy Bidwell, Luis G. Navarro, Weldon Read, Tracy Morris
ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108
ABSTRACT
The liberator cells department at Amarillo Copper Refinery has the objective of
reducing metal impurities in the copper electrolyte to achieve high quality cathodes via
electrowining. Insoluble lead anodes are used and the copper is depleted from the
electrolyte and then electrodeposited to copper starter sheets.
After the electrowinning process, the decopperized electrolyte solution is sent to the
Acid Purification Unit (APU®), where sulfuric acid and arsenic are absorbed into the resin
and then desorbed using water which is then returned to the tankhouse to be reused as acid
make up and to increase arsenic concentration in the electrolyte. During this process, the
APU generates a byproduct stream that is high in nickel and other valuable metals that can
be further processed and the metals recovered.
This paper discusses how it is possible to precipitate a Nickel Carbonate product
when the de-acidified electrolyte is treated using sodium carbonate. The pH selective, 2-
step process first recovers copper still present in the solution and transforms it into a
product that can be processed and further recovered at the Hayden Smelter in Arizona.
Electrowinning and Electrorefining
EW17
SOLUBILITY PRODUCT OF ANTIMONY ARSENATE AND BISMUTH
ARSENATE HIDEBIRO SEKIMOTO
Fuyuhiko Miyanaga and Katsunori Yamaguchi
ASBTRACT
The solubility product of compounds consist mainly of the 15 group elements
(arsenic, antimony and bismuth) is essentially important information for understanding the
mechanism of the formation of anode slimes in electrolytic refining process and is useful
for prevention of the formation of floating slimes which are adversely affect the current
density and the quality of copper cathode.
The empirical value of the solubility product of several arsenates has been reported
using the operation data in some copper refineries. However, there is no report on the
solubility product based on the equilibria of dissolved chemical species. In this study, the
solubility product of typical antimony arsenate and bismuth arsenate represented as ShAs04
and BiAs04, respectively, in sulfuric acid solutions were investigated.
The sulfuric acid solution containing arsenic acid was saturated with the arsenates
prepared in our laboratory, and then, the concentration of As, Sb and Bi in the solution was
measured by 1CP-AES. Using the results, the solubility product of SbAs04 and BiAs04
was determined.
Electrowinning and Electrorefining
EW18
SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT
METALS DURING COPPER ELECTROREFINING
Takahito KASUN0,1 Atsushi KITADA,1 Kimihiro SH1MOKAWA,2 and Kuniaki
MURASE1
1 Department of Materials Science and Engineering, Kyoto University, 36-1
Yoshida-hornrnachi, Sakyo-ku, Kyoto 606-8501, Japan 2 PAN PACIFIC COPPER Co.
Ltd., Refinery Manager, 3-3382 Saganoseki, Oita-shi, Oita, 879-2201, Japan
E-mail: [email protected] (Takahito KASLNO)
ABSTRACT
Electrolytic copper contains, on average, 10 ppm silver as impurity, which leads to a
loss of silver as a cash-cow product for copper smelters. Most of silver included in blister
copper anodes passes into anode slime when electrolyzed, keeping the elemental state.
However, once a part of elemental silver oxidatively-dissolves from the anode or from
anode slime for some reason, then silver can co-deposit with electrolytic copper cathode,
since silver is nobler than copper. In the present work, the dissolution behavior of silver
from anode slime was examined using granular silver as a model of the slime.
We have shown that the silver dissolution is caused by dissolved oxygen in the
electrolyte, and that thiourea and/or chloride ions as usual additives play a role to suppress
the silver dissolution approximately to half. Moreover, it was found that the dissolution of
silver was almost perfectly suppressed by galvanic contacting of the granular silver with
less noble metals (Pb or Cu) immersed in the same electrolyte.
Electrowinning and Electrorefining
EW19
RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY
Masaomi Kanazawa, Akira Ueno, Kimihiro Shimokawa
Saganoseki Smelter & Refinery Pan Pacific Copper Co., Ltd. Japan Tel 81-97-575-3555,
Fax 81-97-575-3513 [email protected] Address, postcode: 879-2201, 3-3382
Saganoseki Oita-shi, Oita, Japan
ABSTRACT
Saganoseki Refinery of Pan Pacific Copper Co., Ltd. integrated three existing
tankhouses into two by introducing the Waxless ISA type permanent cathode process in
2006. To achieve the higher current efficiency and better cathode quality at current density
over 300 A/m2, the electrolyte filtering system was introduced to remove the suspended
solids (S.S) in the electrolyte in 2009.
The additives continuous feeding system, jointly developed with Taman° Refinery
of Hibi Kyodo Smelting Co., Ltd., has been installed in 2011, achiving over 97% current
efficiency at 311A/m2 current density. Several improvements were also executed to ensure
the steady operation and to increase the productivity. Owing to the improvements,
Saganoseki Refinery currently continues the stable and efficient operation with maintaining
the adequate cathode quality. This paper describes the outlines of improvements as well as
the current operational status.
Electrowinning and Electrorefining
EW20
QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSLAMA
SMELTER & REFINERY
Yuuki Watanahe, Shigehiro Arakawa
Naoshima Smelter and Refinery Mitsubishi Materials Corporation 4049-1, Naoshima-eho,
Kagawa-gun, Kagawa 761-3110, Japan TEL +81-87-892-3201 FAX +81-87-892-4091
ABSTRACT
Copper tank house in Naoshima Smelter Gr Refinery started with a capacity of
7,500 Um of electrolytic copper in 1969 and subsequently enhanced the capacity to
19,500t/rn until 2006 by expanding the number of tank-house cells and raising the current
density of commercial cells. After the expansion above, the tank-house operation has
focused on obtaining customer satisfaction by improving cathode quality and smoothing
cathode surface. An on-site automatic analysis was introduced to control the chemistry of
electrolyte stringently. Filtration equipments were expanded in the capacity from 10% of
the electrolyte to whole electrolyte.
These modifications have reduced dense nodules and smoothed the cathode surface
much. Integral electro-deposition on the cathode has lowered the frequency of short circuits
between electrodes and resulted in increasing in current efficiency from 96.5% to over
97.5%. Mitsubishi materials corporation naoshima smelter & refinery tank house section
Electrowinning and Electrorefining
EW21
THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE
INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND REFINERY
Masaaki Kato
Manager of Refinery Onahama Smelter & Refinery Onahama Smelting and Refinery Co,
Ltd e-mail: m-katommc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-3951
Masanori Yoshida
Manager of Production Division Onahanna Smelter & Refinery Onahama Smelting and
Refinery Co, Ltd [email protected] TEL: +81-246-54-4841 FAX: +81-246-53-3951
Tetsuro Sakai
Managing Director & General Manager Onahama Smelter & Refinery Onahama Smelting
and Refinery Co, Ltd e-mail: tesakaigmmc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-
3951
ABSTRACT
Since 2007, Onahama Smelter and refinery has operated the 0-SR process which
comprises the S-furnace of the Mitsubishi process is followed by two hearths of
reverberatory furnaces in order to increase the capacity of copper concentrates. Such
enhancement at the smelter requested the tank-houses to increase the productivity more
than 25% coping with impurities load of electrolyte. The productivity has been enhanced by
increasing current density which reinforced rectifiers of No.1 and No.2 tank-houses, and
have supplied and increasing the number of daily operation cells by 25%. Impurities in
electrolyte have been managed by resuming the operation of the secondary liberator cells
and controlling impurities load of the electrolyte. Furthermore,
Electrowinning and Electrorefining
EW22
CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT SHORT
CIRCUITS
Robert P. Dufresne
ABSTRACT
It’s now possible to operate entire Electrowinning or Electrorefining processing
plants Without Short Circuits. Research in the design of capping boards and contact system
calculations have been integrated and synchronized to create entire sections of refinery’s
that are devoid of even the possibility of short circuits. This design is adaptable to every
type of contact system in the industry, including symmetrical and non-symmetrical
electrodes and single, double, triple or quadruple contact bars on the same insulator. Our
Without Short Circuit systems’ capping board design guarantees your production rates
during the stripping process are fully maintained. Symmetrical electrode capping boards
have been successfully redesigned into a Single bus bar insulator. Mechanical strength
studies and simulations of electrical fluidity have been performed, using CAD 3D
technology, to optimize efficiency of the electric current within the contact system - which
incorporated into the Without Short Circuit design - reduces resistivity compared to
existing contact systems. Research has yielded a chemical formulation that resists sulphuric
acid concentrations above 80%. Our standard bus bar insulators are considered permanent,
with operational lifetimes of up to 20 years or more with no maintenance and without
increasing sulphatation during refining.
Electrowinning and Electrorefining
EW23
ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE
WORLD'S FIRST COMMERCIAL ELECTROREFINERY
A.E. Wraith*,
Consultant, Exeter, UK.
P.J. Mackey,
P.J. Mackey Technology Inc., Kirkland QC, Canada.
R. Protheroe Jones,
National Museum of Wales, Swansea, UK.
ABSTRACT
It is well known that the world’s first copper electro-refinery started production in
1869 at Pembrey in South Wales. Built within the Pembrey Copper Smelter which had
commenced operations in 1849, the new refinery was based on principles described in the
British patents issued to J.B. Elkington in 1865 and 1869. Refining principles and practices
pioneered there were key to the foundation of modern electro-refining practice in what is
now a dominant international industry producing 14 Mt of electrical grade copper annually.
This paper explores the background to this pioneering application of the new, early 19th
century, science of “electro-metallurgy” and examines its links to the contemporary
decorative electro-plating industry and to the shortcomings of 19th century fire refining.
The beginnings and early years of the Pembrey electrorefinery are briefly discussed in
relation to the quality, applications and pyrometallurgy of copper at the time. Elkington’s
ideas and the commissioning of the Pembrey refinery can now be recognised as vital
precursors of the modern electrical age.
Electrowinning and Electrorefining
EW24
IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR
CONTACTS?
Michael J Nicol and Justin McGinnity
Murdoch University, Perth, W. Australia
ABSTRACT
Measurements of cell voltages on several copper, zinc and nickel tankhouses have
been made with a view to assessing the reliability of cell voltage as an indicator of shorts or
poor contacts in electrowinning cells. In addition, simulations of current distribution in
contiguous cells have been made using commercial electrical circuit simulation software
adapted to the flow of current in electrowinning cells using the normal Walker
configuration.
The results of both plant measurements and simuations have revealed that the use of
cell voltage as an indicator of the presence of shorts or poor contacts in electrowinning cells
can be ambiguous. Both in the measured cell and in adjacent cells, erroneous conclusions
can be drawn depending on the location of the voltage measurement.
The important factors which determine the variations in measured cell voltages have
been identified. It is recommended that operations make simple voltage measurements in a
number of locations in a number of cells to establish the reliability of such measurements
for their operations.
Electrowinning and Electrorefining
EW25
DETERMINATION OF BISMUTH CONTAMINATION IN COPPER
Daniel Kim, Shijie Wang
Rio Tinto Kennecott Utah Copper
11500 West 2100 South
Magna, UT 84044
ABSTRACT
Bismuth is a most critical impurity to cause copper grain boundary cracks in
wiredrawing. How to control bismuth in copper electrorefining process is an interesting
topic for most copper refineries in the world. From the London Metal Exchange (LME)
and the American Society for Testing and Materials (ASTM), specifications for bismuth
content in copper are 2.0 ppm and 1.0 ppm, respectively. Due to a fact that copper anodes
at KUC contain a significant amount of bismuth, it is a very critical task to determine,
minimize, and control the bismuth contamination in the copper production. This article
presents the methods and techniques used in the study of bismuth contamination. It also
summarizes the contamination mechanism identified in the process control of copper
electrorefining process at KUC.
Electrowinning and Electrorefining
EW26
A STATE OF THE ART ANODE TECHNOLOGY: SMART ANODE, MSA®, FOR
COPPER ELECTROWINNING
M. Morimitsu, T. Zhang, Y. Yamada
Department of Environmental Systems Science, Doshisha University, Kyoto, Japan
ABSTRACT
This paper presents the preparation, characterization, and performance of a novel
oxide coated titanium anode for copper electrowinning. The anode consists of a mixture of
RuO2 and Ta2O5 formed on a titanium substrate by thermal decomposition of a precursor
solution containing Ru (III) and Ta (V). The oxide coating comprises 10-20 nm ultra fine
RuO2 particles which are uniformly dispersed in amorphous Ta2O5 matrix; it is like a sea-
island hybrid structure.
This novel anode gives some excellent properties for use in copper electrowinning.
Oxygen evolution on the anode occurs at a low overpotential so that the cell voltage of Cu
EW is much reduced by 700 mV compared to lead alloy anodes and is 100 mV lower than
the oxide coated titanium anodes with amorphous IrO2. Some unwanted side reactions such
as depositions of PbO2 or manganese oxide are suppressed on the anode, which usually
occurs on lead alloy anodes. This smart anode is produced by Republic Alternative Tech.
(Ohio, USA) under the patent licensing from Doshisha University (Kyoto, Japan) and is
under commercialization with the registered trademark, MSA®.
Electrowinning and Electrorefining
EW27
COMPARISON OF INTERCELL CONTACT BARS FOR ELECTROWINNING
PLANTS CONSIDERING THERMAL EFFECTS
Rob Fraser, Chris Boon, Tim Johnston, Peter Allen
ABSTRACT
In normal practice, the design of intercell contact bars (ICCB) for electrowinning
and electrorefining are based on previously used designs or rules of thumb, rather than first
principles. Power consumption is a major operating cost for electrowinning. A significant
portion of the power costs is due to the electrical resistance of the ICCB which comprises
electrode contact resistances and ICCB bulk resistance. Theory suggests that contact
resistance is a function of electrode mass, whilst the bulk resistance is calculated using an
integral function of cross-sectional area.
The electrical resistivity of copper, which is the normal ICCB material, increases
with temperature, resulting in an increase in the resistance through the ICCB electrical
circuit. Electrical resistance also causes heat generation due to the Joule effect. By reducing
the amount of heat that is generated or by allowing rejection of heat, it is possible to
minimise the power consumption associated with the ICCB. This paper uses validated
computational techniques to assess several common ICCB configurations to determine their
thermal performance and hence impact on electrical resistance in both ideal and extreme
short circuit scenarios. The influence of ICCB sizing and cell furniture design is also
examined.
Electrowinning and Electrorefining
EW28
AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE
Iv. Djurov
D. Kirilov; N. Dragoev; L. Gerov; K. Nedeleva; A. Saraev;
AURUBIS BULGARIA
Industrial zone
Pirdop, Bulgaria 2070
ABSTRACT
ISA 2000 Refinery was put into operation on July 2008 with design capacity of 180
000 tons copper cathodes per year. Refinery includes two electrolyte circulation systems
and Deep electrolyte decopperization section. Final treatment of the bleed electrolyte is
performed in Waste Water Treatment Plant.
As permanent cathodes are used SS blanks. Between both electrolyte circulation
systems there are situated Anode Preparation machine, Full Deposit Stripping machine and
Anode Scrap Washing machine. Control of each machine is made by its own control panel.
The building of the Refinery is divided into two bays. In each bay one completely
automated overhead crane “Single bale – Single lift system” operates.
During past years Refinery’s capacity was increased up to 231 000 tons of cathodes
per year through adjustment and improvement of technological process and its parameters
as a whole, without any investments.
Electrowinning and Electrorefining
EW29
OPTIMIZATION OF THE USABLE LIFE OF LEAD ELECTROWINNING
ANODES
Abbas Mirza#, Eben Lombard*, Larry Webb*, Matt Burr# and Timothy Ellis#
RSR Anode Group*and RSR Technologies#
*RSR Anode Group: Quemetco Metals Limited, Castle Lead Works and Le Plomb Francais
ABSTRACT
Lead (Pb) based anodes are the dominant technology for electrowinning process’ in
sulfate based media, e.g. Copper, Nickel, Cobalt, & Manganese. The lifecycle of
electrowinning anodes is very dependent upon tank house operating conditions and
maintenance of the anodes including cleaning and straightening. A presentation is made
which relates optimal operational condition to enhance anode lifecycles. This presentation
will focus on the operational aspects of maximizing the utilization of Pb electrowinning
anodes.
Electrowinning and Electrorefining
EW30
ELECTROLYTIC TANKHOUSE ACID MIST CONTROL - MEETING
STRINGENT WORKER EXPOSURE LIMITS AND EMISSION TARGETS
Dr. Andreas Siegmund and Amandeep Randhawa
Gas Cleaning Technologies LLC,
4953 N. O’Connor Blvd.
Irving, TX 75062
ABSTRACT
SX/EW operations are commonplace due to their lower operating costs. However,
one of the undesirable consequences of this operation is the evolution of acid mist in the
electrowinning step in the process. This acid mist creates a significant worker exposure
hazard, results in corrosion to building and equipment requiring excessive maintenance,
and presents an environmental concern when discharged to the atmosphere. Therefore,
addressing these concerns is key to meeting tighter hygiene and environmental regulations.
This paper presents a summary of the latest process techniques to minimize acid mist
formation, the engineering methods used for evaluation including the use of Computational
Fluid Dynamic (CFD) modeling to optimize tankhouse ventilation systems and cost
effective gas cleaning methods to reduce acid mist discharge to the atmosphere.
Electrowinning and Electrorefining
EW31
STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)
Rodrigo Abel Fuentes*, Isabel Venegas Fuentes**, Cristian Cortés Egaña***, Luis
Felipe Ramirez****
*Senior Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].
**Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].
***Refinery Superintendent, Ventanas Refinery, Codelco
Chile,[email protected].
**** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS),
ABSTRACT
Most SXEW and Refineries currently use permanent stainless steel cathodes.
However, there are refineries and SxEw operations that use starter sheets/traditional
cathodes technology: In Chile, Ventanas and Salvador Refineries; in Peru, Ilo Refinery and
Cerro Verde’s SxEw plant; several in EEUU and Mexico, ASARCO’s Amarillo Refinery
among them. They require copper starter sheets for their final cathode harvesting.
Stripping starter sheets manually is boring, tiring, unsafe and may produce lower
quality sheets which impacts directly in the quality of commercial cathodes and therefore in
operator revenue.
MIRS designed and developed a Starter Sheet Robotic Stripping Machine (SSRSM)
focusing in improving safety and occupational health and reduce hazards in the process.
The patented method and separation device also improves the quality of starter sheets.
In a standard Layout 4 robotic arms interact in the system: the input robot picks
each cathode from a conveyor and places it in the stripping station; 2 stripping robots strip
each sheet and the output robot picks the empty plate from the stripping station and places
it in the output conveyor. This robot also handles rejects and blank reposition.
One MIRS’ SSRSM was commissioned at Ventanas during 2011. An industrial test
was carried out whose objective was to demonstrate functionality to strip in typical
operating conditions. Test results were: capacity 160 plates per hour and stripping
performance higher than 98%.
Electrowinning and Electrorefining
Now we are incorporating a washing station, and two laser scanners, one for sheets
and another for base plate quality and a starting sheet weighing station to sort them into
different qualities.
Because the SSRSM is robotic, it is more compact, flexible and configurable so it
adapts to existing layout and equipment. It also is capable of using different stripping
strategies according to cathode quality.
Electrowinning and Electrorefining
EW33
COST COMPARISON BETWEEN A CONVENTIONAL ER TANKHOUSE AND A
HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRX-
TECHNOLOGY
Stefan Konetschnik(1)
, Andreas Filzwieser(1)
, Iris Filzwieser(1)
and Andreas Anzinger(2)
(1) METTOP GmbH
Peter-Tunner-Strasse 4
8700 Leoben
Austria
(2) Montanwerke Brixlegg AG
Werkstrasse 1
6230 Brixlegg
Austria
ABSTRACT
In 2011, the first two electrorefining tankhouses using the METTOP-BRX-
Technology went into operation – one producing cathodes out of ore and one out of
secondary raw material. Both tankhouses show the possibility of achieving Grade A
cathodes at a current density of more than 400 A/m² while maintaining a current efficiency
of 97.0 – 98.5 per cent.
After almost two years of operation it is now possible to directly compare the costs
of the two-part tankhouse of Montanwerke Brixlegg AG. While half of the tankhouse is
operated at standard current density, the other half is equipped with the METTOP-BRX-
Technology.
Basis of the technology is an optimized electrolyte feed system in each electrolytic
cell. Even though the higher current density is directly proportional to the consumption of
electrical energy, the overall operational expenditures keep the same due to the lower costs
Electrowinning and Electrorefining
for bound capital. Furthermore, the higher productivity results in a smaller footprint of the
tankhouse.
The present paper gives a detailed insight into the additional costs and economical
benefits when operating a tankhouse at high current densities. It shows the mathematical
background of the calculation, as well as the result – the capital and operational cost
savings when using the METTOP-BRX-Technology.
Electrowinning and Electrorefining
EW34
COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES
Gerardo Cifuentes and Rodolfo Mannheim G2M Ingeniería Ltda., Chile
ABSTRACT
When an electric current flow is present in an electrolysis cell, it follows that the
cell potential, CellE , achieved is equivalent to the voltage difference of the theoretical
thermodynamic equilibrium resulting from the anode and cathode reactions, EqE , plus the
algebraic sum of the terms that reflects the inertia of the reactions involved, normally called
electrode overpotential, ca , plus a resistive term in solution, IRe· , and finally plus the
resistive term due to the external electric circuit, System losses.
Losses in the external electric circuit refer mainly to the Joule effect due to the flow
of current through the conductors. Indeed, intercell bars, also called intercell busbars, work
at an average temperature of 70 to 90 °C, and in short circuit the temperature can go up to
200 °C and higher.
Our CoolBar (WIPO International Patent pending), which has a higher current
conductivity compared to presently used regular intercell bars, will decrease the cell
potential by 2% to 7%, decreasing the specific energy consumption, SEC, by an equivalent
amount. In addition, the Coolbar optimizes the use of thermal energy in the electrolytic
plant by allowing better current flow distribution in the cell, causing a significant drop in
the carbon footprint of the electrolytic process.
Finally, an existing intercell bar can be easily replaced in situ by a Coolbar by just
placing the latter over the cell capping board and making a few small adjustments.
Electrowinning and Electrorefining
EW35
ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS
ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL DIVISION
Francisco Sánchez Pino
Codelco Chile, Gabriela Mistral Division, Calama, Chile, Innovation and Technology
Superintendent, 56-55-328576, [email protected].
ASBTRACT
For our objective of promoting continuous improvement of processes, the
application of electrolyte soft aeration technology has been evaluated since 2009, focused
on quality improvement of cathode production; a pilot testing program culminated, after 3
month, with excellent metallurgical results and data that justified the investment to equip
the 504 Electrowining cells in the Tankhouse.
Soft aeration of the electrolyte inside Electrowining cells contributes to uniform
mass transfer, cinematic viscosity and flow velocity across the entire surfaces of the
cathodes, generating homogenous deposits, without preferential growths, and therefore,
virtually exempt of nodules and short circuits, with enhanced physical and chemical quality
of production, and furthermore, optimizing the efficient use of energy by sustaining in time
electric current efficiencies of 94%, specific consumption of 1.750 kWh/TM of fine copper,
with AR elongation test over 40%, and overall grade A quality copper cathodes above 80%.
The technology implemented homogenizes copper concentration in the "permanent
cathode plate-electrolyte" interphase and uniform migration of copper ions throughout the
deposit surfaces, thus diminishing limit layer thickness.
Electrowining process management is enhanced by allowing cell operation at
current densities above 300 A/m2, enabling 100 kg cathodes to be harvested in less than 6
day cycles.
Electrowinning and Electrorefining
EW36
AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND
POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE
ROUGHNESS IN COPPER ELECTROWINNING
Tyler Helsten1 and Michael S. Moats
2
1 – University of Utah
2 - Missouri University of Science and Technology
ABSTRACT
Recently, the use of modified polysaccharides and polyacrylamides has been
reported as smoothing agents in commercial copper electrowinning operations. Very little
published data exist on the fundamental behavior of these compounds in copper
electrodeposition. In this study, the polarization behavior and surface roughness of short
term deposits grown in the presence of a modified polysaccharide, a polyacrylamide or a
50/50 mixture of guar and modified polysaccharide in synthetic copper electrowinning
electrolytes are reported. The polyacrylamide demonstrates classical behavior in that
polarization increases with increasing concentration which correlates to a smoother deposit.
The modified polysaccharide and combination of guar and modified polysaccharide did not
exhibit classical behavior in that increasing concentration did not affect polarization but
result in smoother deposits.
Electrowinning and Electrorefining
EW38
THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING
ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION AND
CATHODE QUALITY.
Tomás Vargas1 and Paz Parra
Department of Chemical Engineering and Biotechnology
Advanced Mining Technology Center (AMTC)
University of Chile, Santiago Chile
ABSTRACT
Dissolved iron present either as ferrous or ferric ions is ubiquitous in electrowining
operations. Its presence arises from undesired incorporation through solvent extraction or
by addition as ferrous ion for reducing purposes. The presence of iron in the electrolyte is
mainly associated to its deleterious effect on current efficiency, which is enhanced if the
electrolyte is somehow stirred. However, the presence of iron in the electrolyte has other
effects which have been somehow overlooked and are not well studied, which could have
some positive influence on the process. The presence of iron as ferric ion helps to
depolarize the cathodic reaction, which can contribute to reduce the voltage drop and
energy consumption in the cell. Also, the presence of dissolved iron interferes with copper
electrocrystallization contributing to reduce the crystal size. The present work analizes
these aspects in detail based on electrochemical studies of the electrokinetics of
ferrous/ferric processes and the electrocrystallization of copper in electrolytes containing
ferrous/ferric ions.
Electrowinning and Electrorefining
EW53
EXPERIENCIES ON DESIGN, MANUFACTURING AND OPERATION OF HIGH
CONTROLLED TRANSFORMER-RECTIFIERS FOR SX-EW COPPER PLANTS
R Fuentes P Lagos J Estrada R Dunner L Neira
[email protected] [email protected] [email protected] [email protected] [email protected]
IDT SA Avda. Las Parcelas 5490, Estación Central,
Santiago, Chile
ABSTRACT
This paper is focused to Chilean experiences on design, manufacturing,
maintenance and operation of high current controlled rectifiers for copper SX-EW and
refinery plant. It concern with new copper or “greenfield” projects and with the
reengineering of existing transformer-rectifiers or “brownfield” projects.
The extended paper deals with parameters for the design, boundary conditions,
current control, protection criteria, harmonics mitigation, maintenance and spare
components, focusing to the most important requirements of this type of equipment:
reliability and high efficiency. Finally, from the authors experience, this paper recommends
technical specification aspects for the future projects.
Electrowinning and Electrorefining
EW54
DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS
AT AURUBIS, HAMBURG USING EMEW® ELECTROWINNING TECHNOLOGY
Günter Leuprecht, Peter Stantke (Aurubis);SiddarthGadia (Electrometals);Andreas Siegmund
(GCT)
ABSTRACT
A series of on-site trials were conducted at Aurubis AG, Hamburg refinery using EMEW
electrowinning to remove copper from the liberator solution in high quality form with no arsine
emission. The liberator solution at Aurubis Hamburg works is particularly difficult to process as
it contains high acid concentration of 350-400 g/l and other impurities such as chloride (60ppm)
and arsenic 20 g/l. The results of the test program confirm that harvestable copper cathode can
be produced at copper concentrations below 1 g/l with low arsenic content such that arsenic in air
or solid emissions is eliminated.
The data from the series of trials over a range of copper concentrations from 1-8 g/l and
200-450 A/m2 enables an operating curve to produce solid copper product at various copper
concentrations in solution. Operating current efficiency averaged 93% (DC) which confirms
significant power savings in addition to handling and process cost savings.
Electrowinning and Electrorefining
EW55
DE NORA’S SOLUTION – PART I, DSA® ANODES FOR CU
ELECTROWINNING
A. Fiorucci, A. Calderara, L. Iacopetti, F. Timpano, G. Faita, C.W. Brown, Jr., M.H.
Barker and F. Prado (Infotrol).
De Nora - Via Bistolfi, 35 Milan, Italy
Infotrol - C. Ramon y Cajal, 7 MONZON, (Huesca) SPAIN
ABSTRACT
The main stay of industrial electrowinning practice today is based on lead alloy
anodes. De Nora’s advanced R&D combined with over 40 years of expertise & experience
in DSA® anodes for chloride based electrowinning has led to the development of “De
Nora’s Solution” for sulfate based Copper Electrowinning (Cu EW).
In addition to the energy saving, elimination of cobalt from the process, improved
tankhouse operation, De Nora’s Solution will bring extra value to the Cu EW tankhouse - a
custom engineered titanium structure with the latest generation catalytic coating,
breakthrough dendrite mitigation system, simultaneous current & voltage monitoring and
an innovative acid mist abatement system.
This paper will describe De Nora’s rigorous process of testing and validation from
laboratory through to Industrial scale; simulating actual and extreme conditions for stable
operation, performance and longevity before introduction into the tankhouse. Results in
terms of dendrite mitigation, energy saving and cathode quality will be discussed. Acid
mist abatement results will be presented in part II.
Electrowinning and Electrorefining
EW56
DE NORA’S SOLUTION – PART II, ACID MIST ABATEMENT
A. Fiorucci, A. Calderara, F. Timpano, G. Faita, C.W. Brown, Jr. and M.H. Barker.
De Nora
Via Bistolfi, 35 Milan, Italy
ABSTRACT
Acid mist is an undesirable and costly by-product of copper electrowinning (Cu
EW), damaging to the health of people working in the tankhouse as well as corrosive and
dangerous for all the metal parts in the plant.
De Nora’s mission is to provide safe and environmentally friendly electrochemical
technology. De Nora’s Solution is built around DSA® anodes, with an integrated anode-
frame structure and a permeable separator envelope which captures the acid mist at the
source. De Nora’s Solution thus allows the plant to operate with an unprecedented low
level of atmospheric acid mist, providing extra added value in safer Cu EW tankhouse
operations.
This paper describes the innovative acid mist containment system - an integral part
of De Nora’s Solution - and the related benefits obtained by confining the oxygen micro-
bubbles in an enclosed space. Significant improvement in operating practice, unexplored
areas for costs savings and environmental benefits generated by De Nora’s Solution will
also be presented.
Electrowinning and Electrorefining
EW57
MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS
Gabriel Zarate,
Anglo American Chile, Santiago, Chile
ABSTRACT
The information on redox potential and its relationship with manganese, iron and
chloride concentrations in the electrolyte has been reviewed for several SX-EW plants and
published elsewhere. The objective was to verify if the published recommendations to
maintain redox potential under control were met, namely:
A minimum Fe:Mn ratio of 8:1 or 10:1.
A minimum 1 g/l of total iron.
A Fe+2
:Mn ratio of 6:1.
It was found that, in general, only one of these recommendations was partially met
and that the redox potential was highly dependent on the combined effect of chloride and
iron concentration in the electrolyte. The highest redox potentials, above 900 mV, are
obtained at chloride concentrations between 35 and 50 ppm when iron concentration is
below 1 g/l. In order to maintain redox potentials below 800 mV, at these chloride
concentrations, the iron concentration should be above 1.5 g/l.
This information has been updated, including the nitrate concentration in the
electrolyte, which effect in the redox potential is even more significant.
The data analysis carried out, as well as the conclusions and recommendations
obtained, are discussed in this paper.
Electrowinning and Electrorefining
EW58
MASS TRANSPORT TO CATHODES IN THE ELECTROWINNING OF COPPER
Michael J Nicol, Suchun Zhang, Allan Kwang, Loon Ang and Alessandro Fiorucci (De
Nora)
Murdoch University, Perth, W. Australia
Industrie De Nora, Milan, Italy
ABSTRACT
Mass transport of copper ions to the cathode during the electrowinning of copper is
important in determining the optimum current density in order to achieve deposits of
acceptable physical and chemical quality. The results of pilot scale tests using full size
cathodes and anodes (both lead-calcium-tin and titanium mixed metal oxide, MMO) will be
described. In these tests, silver ions have been used as a tracer in order to determine local
mass transfer coefficients to 16 sections of each cathode. The results have shown that mass
transfer is slightly higher at the top and bottom of the cathode and that the distribution is
more uniform with MMO anodes than with conventional lead alloy anodes. The results
agree quantitatively with previously published data obtained using half width electrodes.
Measurement of the mass of each section has also been used to establish the current
distribution over the surface of the cathodes.
In addition, the reduced cell voltage obtained with the MMO anodes has been
quantified as have the voltage drops at the contact of the anode header bars with the busbar.
Electrowinning and Electrorefining
EW59
REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS®
SYSTEM. LABORATORY INVESTIGATION
J.P. Ibáñez1, S. Cortés
1, P. Suarez
2, A. Labra
2, A. Moyano
3
1 Department of Metallurgical Engineering and Materials -Universidad Técnica Federico
Santa María ([email protected]) 2 Innovaxxion Spa
3 Codelco Chile - División Chuquicamata
ABSTRACT
A new system for reducing the anode scrap in a conventional electro-refining plant
was investigated at laboratory scale. The new system called Earless® is based in the use of
anodes without ears, which are easily mounted in an ad-hoc designed case that provides the
electrical contacts and transportation capability.
Experimental work was carried out to make a critical comparison of the electro-
refining behavior between a typical anode and two types of anodes in the Earless® system.
All the anodes (cathodic copper) and cathodes (stainless steel) were made in a scale of 1:10,
and were processed under the same experimental conditions of current density, anodic
cycle period, electrolyte temperature, electrolyte flow rate and synthetic electrolyte
composition.
The main results indicate that was possible to reach a reduction of the scrap
generation from around 20% (traditional anode) to around 10% (anode in the Earless®
system), all the cathodes obtained having the same quality and furthermore a significant
decrease of the specific energy consumption higher than 20% was observed as well.
Electrowinning and Electrorefining
EW60
MOVING COPPER MATERIAL HANDLING FORWARD USING ADVANCED
DESIGNS BY BROCHOT COMPANY
Clyde Wright
Marty Wessman
ABSTRACT
Our paper will present new material handling developments. The theory is to review
existing copper refinery processes, compare and contrast with the newest scientifically
proven technologies available. The aim is to improve and simplify material handling to
increase reliability thus reducing refineries cost curves.
The paper will develop all new concepts
- Robotic handling of electrodes: We eliminate old style mechanical transferring of
electrodes and replace with state of the art robotics. These robots give variable speed,
accurate control, and yet remain flexible for future process changes. Robotics require less
operator and maintenance intervention therefore enhance personnel plant safety.
- Copper Stripping from stainless steel mother blanks: A new copper stripping system has
been developed to eliminate all hydraulics, prolong mother blank life...
- New Cathode Wash Concept: Conventional copper washing can leave impurities. The
development of a new cathode wash system offers a full face wash using minimal water
consumption.
The paper will present all the Copper Projects
Our company has on going copper projects in Mexico, Peru, Russia, Kazakhstan, and the
Middle East …
Electrowinning and Electrorefining
EW61
CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC
REFINERY OF THE VENTANAS DIVISION
C. Cortés, E. Bahamondes and N. Cornejo
Codelco, Ventanas Division
Carretera F-30 E 58270
Ventanas, Puchuncaví
Chile
[email protected]; [email protected]; [email protected]
ABSTRACT
The Electrolytic Refinery of the Ventanas Division in recent years the Refinery has
focused on improving the productivity of its installation through a series of highly creative
initiatives requiring low-cost investments, in order to reinforce the competitiveness of the
Refinery in an increasingly complex business environment. In this context, during the last
four years, projects such as the "Electrode Optimization in Electrolytic Cells" and the
"High Current Density Stripper Circuits Operation" have been carried out.
The project "Electrode Optimization in Electrolytic Cells Phase II" consisted in
reducing the anode spacing to 100 mm, increasing the number of electrodes per cell and
maintaining the current density at 305 A/m2. The project "Stripper circuit operation with
high current density " consisted of reducing the starting sheet production cycle, operating at
a current density of 330 A/m2. Another prominent change of practices implemented in
2009 was the closure of the electrolyte purification plant, owing to the high cost of the
process, which established new trade opportunities by selling the electrolyte to third parties.
This has resulted in a dramatic change in managing impurities’ control, as well as, in new
improvements. The combination of these projects of improving and changing the practices
resulted in the production of 401,500 t of electrolytic copper in the year 2011.
Electrowinning and Electrorefining
EW62
PURER CATHODES BY NEW ADDITIVES IN COPPER ELECTROERFINING
M. Stelter, H. Bombach, J. Baumbach
Institute for Nonferrous Metallurgy and Purest Materials
TU Bergakademie Freiberg
Leipziger Str. 34
D-09599 Freiberg
ABSTRACT
In copper electrorefining additives are used for a smooth electrodeposition of
copper cathodes. The classical additives glue and thiourea show some disadvantages like
the relatively fast decomposition during electrolysis and the incorporation of sulfur from
thiourea into the cathodes. Only new additive systems avoiding thiourea can help to reduce
the sulfur content in the copper cathodes. Additionally the decomposition of glue and
thiourea forces a continuous dosing of the additives.
Our investigations show that alternative additives can be used in copper
electrorefining indeed. Polyethylene glycols (PEG) act strongly polarizing and can
substitute glue. Current density potential curves show that Bis-(3-sodiumpropyl)disulfide
(SPS), dimethylthiourea, methionin and cystein have a stronger depolarizing effect
compared to thiourea.
Electrolysis experiments with PEG and SPS proceeded without short circuits at a
current density of 500 A/m². However, the cathodes were rough and nodulous. Smoother
cathodes were produced when using glue and thiourea or glue and SPS. In the first case the
sulphur concentration in the cathodes ranged from 4 to 10 µg/g and in the second case only
from 0.3 to 1.5 µg/g. SPS is considerably more stable than thiourea. Thus, there is no need
for continuous addition during electrolysis.
Electrowinning and Electrorefining
EW63
COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH
CURRENT DENSITY
Songlin Zhou
Xiangguang Copper Co., Ltd
No.1 Xiangguang Road
Shifo Town, Yanggu County, 252327, China
ABSTRACT
This paper introduces the Parallel Flow Device (PFD) technology and production
practices for high current density copper electrolytic refining. The technology has been
successfully implemented for the first time on a large industrial scale, enabling the copper
electrolysis current density to reach 420 A/m², thereby substantially increasing copper
electrolytic productivity. Through this technology, a new level in copper electrolytic
refining has been achieved.
Electrowinning and Electrorefining
EW64
EXMAJET®, POTENTIAL FOR IMPROVED ACID MIST CAPTURE AND
CATHODE QUALITY AT HIGH CURRENT DELSITY ELECTROWINNING
A.Lillo
METALEX
Hernando de Aguirre 162 Oficina 806
Santiago – Chile
ABSTRACT
This paper reviews the technological responses provided by EXMAJET® to the
traditional limitations in obtaining commercial grade copper and reduction of acid mist
at high current density. Integrating concepts of improved hydrodynamics and acid mist
capture with anodic oxygen recirculation into a unique technical solution, EXMAJET®
uses a modified flow distributor which combines electrolyte feed with anodic oxygen
captured at the anode into a close loop. Results indicate that cathode quality is
improved due to the improved homogeneity in copper distribution due to equalization
of the plating conditions between bottom and top of the cathode surface. Also
commercial grade copper cathodes is possible to be produced at high current density,
with acid mist confined to an anodic compartment being recycled directly into the cell
by using a friendly flow distributor. The extension of these results confirm the
feasibility of commercial production of copper at high current density, reduction of the
overall generation of acid mist, elimination of tankhouse hardware such as ducting and
scrubbers and finally improve cell productivity allowing electrode gap to be potentially
reduced.
Electrowinning and Electrorefining
EW65
POTENTIAL-CONTROLLED ELECTROLYSIS AS A NEW METHOD OF
COPPER ELECTROREFINING AND ELECTROWINNING – DISCUSSION OF
SOME BASIC ASPECTS
P. Los and A. Lukomska and S. Kowalska
Industrial Chemistry Research Institute,
ul. Rydygiera 8, 01-793 Warsaw, Poland
M. Masalski
Institute of Biomedical Engineering and Instrumentation,
Wroclaw University of Technology, Wybrzeże Wyspiańskiego27, 50-370 Wroclaw, Poland
Department and Clinic of Otolaryngology Head and Neck Surgery,
Wroclaw Medical University, ul.Borowska 213, 50-556 Wroclaw, Poland
M. Kwartnik.
NANOMETALLURY SA,
Cieszkowskiego 20, 51-604 Wroclaw, Poland
ABSTRACT
Copper electrowinning and electrorefining are very effective methods of industrial
electrochemistry. These processes have been carried out without substantial fundamental
modifications for a pretty long time. For instance industrial copper electrowinning and
electrorefining processes are carried out on industrial scale as current-controlled processes.
Review of literature data shows that the fundamental understanding of copper
electrodeposition processes from industrial electrolytes is not sufficient. Although, the
industrial copper electrodeposition is a very complex multi-ion process realized in
concentrated electrolytes with migration, convection and diffusion as mass transfer modes,
most of the published theoretical and experimental copper electroreduction studies are
carried out in diluted electrolytes of relatively simple compositions and the theoretical
approach of diluted electrolytes is used to analyze the results. Consequently, many
conclusions concerning industrial copper electrorefining and electrowinning processes
which are considered as general are valid only in the case of current-control electrolysis
and/or for diluted electrolytes. Potential is the primary parameter of electrolysis to
determine the electrochemical reactions which might undergo at the electrode. In the
present paper some basic (theoretical and experimental) aspects of patented potential-
controlled electrolysis in copper industrial electrolytes as a new method of copper
electrorefining and electrowinning are presented and discussed.
Electrowinning and Electrorefining
EW66
A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE
EXTRACTION OF ANTIMONY
Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Zúñiga (3)
(1) codelco chile, división chuquicamata, e-mail: [email protected] .
(2) departamento de ingeniería metalúrgica, facultad de ingeniería, universidad de
santiago de chile, santiago, chile.
(3) departamento de ingeniería química, facultad de ingeniería, universidad de santiago de
chile, santiago, chile.
ABSTRACT
An ion exchange pilot plant, located at the University of Santiago of Chile, was
tested for antimony control in the electrolyte of Chuquicamata Refinery. In the pilot plant
were used three different resins: MX-2, UR-3300S and Duolite C-467. The results showed
that the best behavior for antimony extraction follow the sequence UR3300S >Duolite C
467 > MX 2. A model with the experimental results was used as comparative tools to
increase the knowledge of this process.