05 Electrowinning and Electrorefining

Electrowinning and Electrorefining
SYMPOSIUM: 05 ELECTROWINNIG AND ELECTROREFINING

CODE AUTHOR ER01 Shunsuke Kawai TITLE ABSTRACT CFD SIMULATION OF COPPER ELECTROREFINING PROCESS AND ANALYSIS FOR THE TANKHOUSE OPERATION AT NAOSHIMA SMELTER AND REFINERY CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO REFINERY CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER ELECTROREFINING GLOBAL SURVEY OF COPPER ELECTROREFINING OPERATIONS AND PRACTICES TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMC'S (URALELECTROMED) NEW COPPER ELECTRO REFINERY RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT PLANT AT ATLANTIC COPPER THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE MODERNIZATION PROJECT USE OF REAL-TIME INFORMATION IN TANKHOUSE OPERATIONAL EFFICIENCY IMPROVEMENT AND QUALITY CONTROL TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE PRECIPITATION SOLUBILITY PRODUCT OF ANTIMONY ARESENATE AND BISMUTH ARSENATE SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT METALS DURING COPPER ELECTROREFINING RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSHIMA SMELTER & REFINERY THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND REFINERY ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE WORLD`S FIRST COMMERCIAL ELECTROREFINERY IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR CONTACTS? DETERMINATION OF BISMUTH CONTAMINATION IN COPPER AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)
ER02 Luis Navarro ER06 Jari Aromaa ER07 Michael Moats, Tim Robinson ER09 Shuklin, M.A. ER10 Guillermo Rios ER11 G. Leuprecht - N. Izatt ER14 Ari Rantala
ER16 Jimmy Bidwell ER17 Hidehiro Sekimoto ER18 Takahito Kasuno ER19 Masaomi Kanazawa ER20 Yuuki Watanabe ER21 Masaaki Kato
ER23 A.E. Wraith ER24 Michael J Nicol ER25 Shijie Wang ER28 Nedelcho Dragoev ER31 Rodrigo Abel
ER33 Stefan Konetschnik
ER34 Gerardo Cifuentes ER54 Gnter Leuprecht
ER59 J.P. Ibaez ER60 Clyde Wright - Marty Wessman ER61 Cristian Cortes E ER62 Michael Stelter ER63 Songlin Zhou ER66 Marco Cifuentes EW03 Patricio Melani - P.A. Aylwin - N.I. Lagos EW04 Scott Sandoval EW05 Tim Johnston EW12 R. Rajasingam EW15 Luis G. Navarro EW22 Robert P. Dufresne EW26 M. Morimitsu EW27 Rob Fraser EW29 Abbas Mirza EW30 Andreas Siegmund
COST COMPARISON BETWEEN A CONVENTIONAL ER TANKHOUSE AND A HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRX-TECHNOLOGY COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS AT AURUBIS, HAMBURG USING EMEW ELECTROWINNING TECHNOLOGY REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS SYSTEM. LABORATORY INVESTIGATION MOVING COPPER MATERIAL HANDLING FORWARD USING ADVANCED DESIGNS BY BROCHOT COMPANY CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC REFINERY OF THE VENTANAS DIVISION PURER CATHODES BY NEW ADDITIVES IN COPPER ELECTROERFINING COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH CURRENT DENSITY A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE EXTRACTION OF ANTIMONY SELE MODULAR TECHNOLOGY TO ACHIEVE SUSTAINABLE DEVELOPMENT AND EFFICIENT IN EW PLANTS OPERATION OF ALTERNATIVE ANODES AT CHINO SXEW HATCH HELM TRACKERTM SYSTEM FOR GUIDING CELL HOUSE PERFORMANCE IMPROVEMENT ELIMINATION OF ACID MIST IN COPPER ELECTROWINNING SMALL COLUMN TESTING OF SUPERLIG 83 FOR BISMUTH REMOVAL FROM COPPER ELECTRO REFINING ELECTROLYTE CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT SHORT CIRCUITS A STATE OF THE ART ANODE TECHNOLOGY: SMART ANODE, MSA, FOR COPPER ELECTROWINNING COMPARISON OF INTERCELL CONTACT BARS FOR ELECTROWINNING PLANTS CONSIDERING THERMAL EFFECTS OPTIMIZATION OF THE USABLE LIFE OF LEAD ELECTROWINNING ANODES ELECTROLYTIC TANKHOUSE ACID MIST CONTROL - MEETING STRINGENT WORKER EXPOSURE LIMITS AND EMISSION TARGETS ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL DIVISION
EW35 Francisco Sanchez
EW36 Michael Moats -Tyler Helsten EW38 Tomas Vargas
AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE ROUGHNESS IN COPPER ELECTROWINNING THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION AND CATHODE QUALITY EXPERIENCIES ON DESIGN, MANUFACTURING AND OPERATION OF HIGH CONTROLLED TRANSFORMERRECTIFIERS FOR SX-EW COPPER PLANTS DE NORA'S SOLUTION - PART I, DSA ANODES FOR CU ELECTROWINNING DE NORA'S SOLUTION - PART II, ACID MIST ABATEMENT MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS MASS TRANSPORT TO CATHODES IN THE ELECTROWINNING OF COPPER EXMAJET, POTENTIAL FOR IMPROVED ACID MIST CAPTURE AND CATHODE QUALITY AT HIGH CURRENT DELSITY ELECTROWINNING POTENTIAL-CONTROLLED ELECTROLYSIS AS A NEW METHOD OF COPPER ELECTROREFINING AND ELECTROWINNING DISCUSSION OF SOME BASIC ASPECTS
EW53 Ricardo Fuentes
EW55 A. Fiorucci EW56 A. Fiorucci EW57 Gabriel Zarate EW58 Michael J Nicol EW64 A.Lillo
EW65 P. Los - A. Lukomska - S. Kowalska - M. Masalski M. Kwartnik
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 skawai@mmc.co.jp
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.
ER02
CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO REFINERY
Luis Navarro1, Tracy Morris1, Weldon Read1, Neil E. Izatt2, Ronald L. Bruening2, and Steven R. Izatt2, Asarco 7001 State Highway 136 Amarillo, Texas 79106, U.S.A. IBC Advanced Technologies, Inc. 856 E. Utah Valley Drive, American Fork, Utah 84003, U.S.A.
2 1
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 IBCs 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.
ER06
CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER ELECTROREFINING
Jari Aromaa, Antti Kekki, Olof Forsn 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.
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. moatsm@mst.edu Tim Robinson Senior Vice President Republic Alternative Technologies, Inc. 11288 Alameda Dve Strongsville, OH 44149, U.S.A. trobinson@republicgreentech.com Shijie Wang Princple Advisor Process Engineering Rio Tinto - Kennecott Utah Copper 11500 West 2100 South Magna, UT 84044, U.S.A. shijie.wang@riotinto.com Andreas Filzwieser Info Andreas Siegmund Senior Vice President Gas Cleaning Technologies (GCT) LLC 4953 N. OConnor Road Irving, TX 75062 U.S.A siegmund@gcteng.com William Davenport Professor Emeritus Department of Materials Science and Engineering University of Arizona Tucson, AZ 85721, U.S.A. billdavenport@live.com
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.
ER09
TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMCS (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, Outotecs and Uralelectromeds specialists have developed comprehensive tankhouse process automation solution called Tankhouse Information Management System (TIMS), which has been implemented at UMMCs (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
and awareness of the process, which has already supported both active supervision and continuous improvement of tankhouse operations.
ER10
RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT PLANT AT ATLANTIC COPPER
G. Ros, R. Ramrez, 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.
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 g.leuprecht@aurubis.com
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.
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 online 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.
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, 2step 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.
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.
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: kasuno.takahito.53w@st.kyoto-u.ac.jp (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.
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 kanazawa@ppcu.co.jp 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.
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
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 rnyoshida@nunc.co.jp 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: +81-246-533951
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,
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 worlds 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. Elkingtons ideas and the commissioning of the Pembrey refinery can now be recognised as vital precursors of the modern electrical age.
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.
ER25
DETERMINATION OF BISMUTH CONTAMINATION IN COPPER
Daniel Kim, Shijie Wang Rio Tinto Kennecott Utah Copper 11500 West 2100 South Magna, UT 84044 wangs@kennecott.com
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.
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 i.djurov@aurubis.com
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 Refinerys 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.
ER31
STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)
Rodrigo Abel Fuentes*, Isabel Venegas Fuentes**, Cristian Corts Egaa***, Luis Felipe Ramirez**** *Senior Process Engineer, Ventanas Refinery, Codelco Chile, rabel@codelco.cl. **Process Engineer, Ventanas Refinery, Codelco Chile, ivene001@codelco.cl. ***Refinery Superintendent, Ventanas Refinery, Codelco Chile,ccort002@codelco.cl. **** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS), framirez@mirs.cl
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 Verdes SxEw plant; several in EEUU and Mexico, ASARCOs 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%.
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.
ER33
COST COMPARISON BETWEEN A CONVENTIONAL ER TANKHOUSE AND A HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRXTECHNOLOGY
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-BRXTechnology 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/m 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-BRXTechnology. 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
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.
ER34
COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES
Gerardo Cifuentes and Rodolfo Mannheim G2M Ingeniera Ltda., Chile gerardocifuentes@yahoo.es
ABSTRACT When an electric current flow is present in an electrolysis cell, it follows that the cell potential, ECell , achieved is equivalent to the voltage difference of the theoretical thermodynamic equilibrium resulting from the anode and cathode reactions, EEq , plus the algebraic sum of the terms that reflects the inertia of the reactions involved, normally called electrode overpotential, a c , plus a resistive term in solution, ReI , 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.
ER54
DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS AT AURUBIS, HAMBURG USING EMEW ELECTROWINNING TECHNOLOGY
Gnter 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.
ER59
REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS SYSTEM. LABORATORY INVESTIGATION
J.P. Ibez1, S. Corts1, P. Suarez2, A. Labra2, A. Moyano3 Department of Metallurgical Engineering and Materials -Universidad Tcnica Federico Santa Mara (juan.ibanez@usm.cl) 2 Innovaxxion Spa 3 Codelco Chile - Divisin 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 electrorefining 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.
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
ER61
CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC REFINERY OF THE VENTANAS DIVISION
C. Corts, E. Bahamondes and N. Cornejo Codelco, Ventanas Division Carretera F-30 E 58270 Ventanas, Puchuncav Chile ccort002@codelco.cl; ebaha005@codelco.cl; ncornejo@codelco.cl
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.
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 stelter@inemet.tu-freiberg.de
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/m. 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 g/g and in the second case only from 0.3 to 1.5 g/g. SPS is considerably more stable than thiourea. Thus, there is no need for continuous addition during electrolysis.
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/m, thereby substantially increasing copper electrolytic productivity. Through this technology, a new level in copper electrolytic refining has been achieved.
ER66
A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE EXTRACTION OF ANTIMONY
Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Ziga (3) (1) codelco chile, divisin chuquicamata, e-mail: mcifuent@codelco.cl . (2) departamento de ingeniera metalrgica, facultad de ingeniera, universidad de santiago de chile, santiago, chile. (3) departamento de ingeniera qumica, facultad de ingeniera, 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.
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 skawai@mmc.co.jp
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.
EW02
CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO REFINERY
Luis Navarro1, Tracy Morris1, Weldon Read1, Neil E. Izatt2, Ronald L. Bruening2, and Steven R. Izatt2, Asarco 7001 State Highway 136 Amarillo, Texas 79106, U.S.A. IBC Advanced Technologies, Inc. 856 E. Utah Valley Drive, American Fork, Utah 84003, U.S.A.
2 1
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 IBCs 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.
EW03
SELE MODULAR TECHNOLOGY FOR SUSTAINABLE DEVELOPMENT AND EFFICIENT EW PLANT
P.A. Aylwin and N.I. Lagos New Tech Copper SpA 3397 Exequiel Fernndez Macul, Santiago, Chile paylwin@ntc.cl
ABSTRACT Sustainable development is an evolving concept that emerged in the 1980s 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 communitys 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.
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.
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 FCXs 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.
EW06
CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER ELECTROREFINING
Jari Aromaa, Antti Kekki, Olof Forsn 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.
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. moatsm@mst.edu Tim Robinson Senior Vice President Republic Alternative Technologies, Inc. 11288 Alameda Dve Strongsville, OH 44149, U.S.A. trobinson@republicgreentech.com Shijie Wang Princple Advisor Process Engineering Rio Tinto - Kennecott Utah Copper 11500 West 2100 South Magna, UT 84044, U.S.A. shijie.wang@riotinto.com Andreas Filzwieser Info Andreas Siegmund Senior Vice President Gas Cleaning Technologies (GCT) LLC 4953 N. OConnor Road Irving, TX 75062 U.S.A siegmund@gcteng.com William Davenport Professor Emeritus Department of Materials Science and Engineering University of Arizona Tucson, AZ 85721, U.S.A. billdavenport@live.com
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.
EW09
TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMCS (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, Outotecs and Uralelectromeds specialists have developed comprehensive tankhouse process automation solution called Tankhouse Information Management System (TIMS), which has been implemented at UMMCs (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
and awareness of the process, which has already supported both active supervision and continuous improvement of tankhouse operations.
EW10
RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT PLANT AT ATLANTIC COPPER
G. Ros, R. Ramrez, 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.
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 g.leuprecht@aurubis.com
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.
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.
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 online 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.
EW15
SMALL COLUMN TESTING OF SUPERLIG 83 FOR BISMUTH REMOVAL FROM COPPER ELECTRO REFINING ELECTROLYTE
Luis G. Navarro1, Weldon Read1, Tracy Morris1, Jimmy Bidwell1, Ronald L. Bruening2, Neil E. Izatt2 1 ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108 2 IBC 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.
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, 2step 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.
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.
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: kasuno.takahito.53w@st.kyoto-u.ac.jp (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.
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 kanazawa@ppcu.co.jp 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.
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
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 rnyoshida@nunc.co.jp 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: +81-246-533951
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,
EW22
CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT SHORT CIRCUITS
Robert P. Dufresne
ABSTRACT Its 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 refinerys 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.
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 worlds 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. Elkingtons ideas and the commissioning of the Pembrey refinery can now be recognised as vital precursors of the modern electrical age.
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.
EW25
DETERMINATION OF BISMUTH CONTAMINATION IN COPPER
Daniel Kim, Shijie Wang Rio Tinto Kennecott Utah Copper 11500 West 2100 South Magna, UT 84044 wangs@kennecott.com
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.
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 seaisland 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.
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.
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 i.djurov@aurubis.com
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 Refinerys 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.
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.
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. OConnor Blvd. Irving, TX 75062 siegmund@gcteng.com
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.
EW31
STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)
Rodrigo Abel Fuentes*, Isabel Venegas Fuentes**, Cristian Corts Egaa***, Luis Felipe Ramirez**** *Senior Process Engineer, Ventanas Refinery, Codelco Chile, rabel@codelco.cl. **Process Engineer, Ventanas Refinery, Codelco Chile, ivene001@codelco.cl. ***Refinery Superintendent, Ventanas Refinery, Codelco Chile,ccort002@codelco.cl. **** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS), framirez@mirs.cl
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 Verdes SxEw plant; several in EEUU and Mexico, ASARCOs 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%.
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.
EW33
COST COMPARISON BETWEEN A CONVENTIONAL ER TANKHOUSE AND A HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRXTECHNOLOGY
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-BRXTechnology 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/m 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-BRXTechnology. 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
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.
EW34
COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES
Gerardo Cifuentes and Rodolfo Mannheim G2M Ingeniera Ltda., Chile gerardocifuentes@yahoo.es
ABSTRACT When an electric current flow is present in an electrolysis cell, it follows that the cell potential, ECell , achieved is equivalent to the voltage difference of the theoretical thermodynamic equilibrium resulting from the anode and cathode reactions, EEq , plus the algebraic sum of the terms that reflects the inertia of the reactions involved, normally called electrode overpotential, a c , plus a resistive term in solution, ReI , 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.
EW35
ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL DIVISION
Francisco Snchez Pino Codelco Chile, Gabriela Mistral Division, Calama, Chile, Innovation and Technology Superintendent, 56-55-328576, fsanchez@codelco.cl.
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.
EW36
AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE ROUGHNESS IN COPPER ELECTROWINNING
Tyler Helsten1 and Michael S. Moats2 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.
EW38
THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION AND CATHODE QUALITY.
Toms 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.
EW53
EXPERIENCIES ON DESIGN, MANUFACTURING AND OPERATION OF HIGH CONTROLLED TRANSFORMER-RECTIFIERS FOR SX-EW COPPER PLANTS
R Fuentes rfuentes@idt.cl
P Lagos plagos@idt.cl
J Estrada jestrada@idt.cl
R Dunner rdunner@idt.cl
L Neira lneira@idt.cl
IDT SA Avda. Las Parcelas 5490, Estacin 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.
EW54
DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS AT AURUBIS, HAMBURG USING EMEW ELECTROWINNING TECHNOLOGY
Gnter 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.
EW55
DE NORAS 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 Noras 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 Noras Solution for sulfate based Copper Electrowinning (Cu EW). In addition to the energy saving, elimination of cobalt from the process, improved tankhouse operation, De Noras 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 Noras 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.
EW56
DE NORAS 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 Noras mission is to provide safe and environmentally friendly electrochemical technology. De Noras Solution is built around DSA anodes, with an integrated anodeframe structure and a permeable separator envelope which captures the acid mist at the source. De Noras 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 Noras Solution - and the related benefits obtained by confining the oxygen microbubbles in an enclosed space. Significant improvement in operating practice, unexplored areas for costs savings and environmental benefits generated by De Noras Solution will also be presented.
EW57
MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS
Gabriel Zarate, Anglo American Chile, Santiago, Chile gabriel.zarate@angloamerican.com
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.
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.
EW59
REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS SYSTEM. LABORATORY INVESTIGATION
J.P. Ibez1, S. Corts1, P. Suarez2, A. Labra2, A. Moyano3 Department of Metallurgical Engineering and Materials -Universidad Tcnica Federico Santa Mara (juan.ibanez@usm.cl) 2 Innovaxxion Spa 3 Codelco Chile - Divisin 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 electrorefining 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.
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
EW61
CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC REFINERY OF THE VENTANAS DIVISION
C. Corts, E. Bahamondes and N. Cornejo Codelco, Ventanas Division Carretera F-30 E 58270 Ventanas, Puchuncav Chile ccort002@codelco.cl; ebaha005@codelco.cl; ncornejo@codelco.cl
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.
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 stelter@inemet.tu-freiberg.de
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/m. 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 g/g and in the second case only from 0.3 to 1.5 g/g. SPS is considerably more stable than thiourea. Thus, there is no need for continuous addition during electrolysis.
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/m, thereby substantially increasing copper electrolytic productivity. Through this technology, a new level in copper electrolytic refining has been achieved.
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 alillo@metalex.cl
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.
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 przemyslaw.los@ichp.pl M. Masalski Institute of Biomedical Engineering and Instrumentation, Wroclaw University of Technology, Wybrzee Wyspiaskiego27, 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 potentialcontrolled electrolysis in copper industrial electrolytes as a new method of copper electrorefining and electrowinning are presented and discussed.
EW66
A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE EXTRACTION OF ANTIMONY
Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Ziga (3) (1) codelco chile, divisin chuquicamata, e-mail: mcifuent@codelco.cl . (2) departamento de ingeniera metalrgica, facultad de ingeniera, universidad de santiago de chile, santiago, chile. (3) departamento de ingeniera qumica, facultad de ingeniera, 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.

05 Electrowinning and Electrorefining

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Electrowinning and Electrorefining

SYMPOSIUM: 05 ELECTROWINNIG AND ELECTROREFINING

Electrowinning and Electrorefining

ER33 Stefan Konetschnik

ER34 Gerardo Cifuentes ER54 Gnter Leuprecht

EW35 Francisco Sanchez

Electrowinning and Electrorefining

EW36 Michael Moats -Tyler Helsten EW38 Tomas Vargas

EW53 Ricardo Fuentes

EW65 P. Los - A. Lukomska - S. Kowalska - M. Masalski M. Kwartnik

Electrowinning and Electrorefining

Electrowinning and Electrorefining

CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO REFINERY

Electrowinning and Electrorefining

CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER ELECTROREFINING

Electrowinning and Electrorefining

GLOBAL SURVEY OF COPPER ELECTROWINNING OPERATIONS AND PRACTICES

Electrowinning and Electrorefining

Electrowinning and Electrorefining

TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMCS (URALELECTROMED) NEW COPPER ELECTRO REFINERY

Electrowinning and Electrorefining

Electrowinning and Electrorefining

RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT PLANT AT ATLANTIC COPPER

Electrowinning and Electrorefining

THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE MODERNIZATION PROJECT

G. Leuprecht and R. Behlmer Aurubis AG Hovestrasse 50 D-20539 Hamburg, Germany g.leuprecht@aurubis.com

Electrowinning and Electrorefining

Ari Rantala Manager, Advanced Process Control Outotec (Finland) Oy

Electrowinning and Electrorefining

TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE PRECIPITATION

Electrowinning and Electrorefining

SOLUBILITY PRODUCT OF ANTIMONY ARSENATE AND BISMUTH ARSENATE HIDEBIRO SEKIMOTO

Fuyuhiko Miyanaga and Katsunori Yamaguchi

Electrowinning and Electrorefining

SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT METALS DURING COPPER ELECTROREFINING

Electrowinning and Electrorefining

RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY

Electrowinning and Electrorefining

QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSLAMA SMELTER & REFINERY

Electrowinning and Electrorefining

Electrowinning and Electrorefining

Electrowinning and Electrorefining

IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR CONTACTS?

Michael J Nicol and Justin McGinnity Murdoch University, Perth, W. Australia

Electrowinning and Electrorefining

DETERMINATION OF BISMUTH CONTAMINATION IN COPPER

Electrowinning and Electrorefining

AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE

Electrowinning and Electrorefining

STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)

Electrowinning and Electrorefining

Electrowinning and Electrorefining

Montanwerke Brixlegg AG Werkstrasse 1 6230 Brixlegg Austria

Electrowinning and Electrorefining

Electrowinning and Electrorefining

COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES

Electrowinning and Electrorefining

Gnter Leuprecht, Peter Stantke (Aurubis);SiddarthGadia (Electrometals);Andreas Siegmund (GCT)

Electrowinning and Electrorefining

REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS SYSTEM. LABORATORY INVESTIGATION

Electrowinning and Electrorefining

Clyde Wright Marty Wessman

Electrowinning and Electrorefining