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Copper ManufacturingProcess
V00664/01 (10.2000) Copyright © Sulzer Pumps Finland Oy 8
Copper anodes
Copper cathodes
Copper
Anode casting
Anode slimetreatment
Preciousmetals
NiSO4
Cu solids
CuSO4
Anode scraps
ElectrolysisElectrolytepurification
Electrolyte
Melting andcasting
Anode shaftfurnace
SO2
Slag
SO2
SlagConverting
Roasting
Smelting
Concentrate
General Flowsheet of Process
Copper Manufacturing Process
V00664/02 (10.2000) Copyright © Sulzer Pumps Finland Oy 9
Pumps in Copper Electrolyse Process
Starting sheets
Electrolyte frompurification
Anode scrapsCopper cathodes tomelting and casting
Electrolyte topurification
Anodes
Cells
Cells
Cells
1.APP/T 2.APP/T
4.WPP/T
Electrorefining
Circulating liquor tank
Filtration
Anode slime to treating
Liquid
+ –
–
–
+
+
3.WSP/T or WKP/T
3 Liquid pH Solids Temp. Density Typical Pump Impeller Seal type Material Dutyo o 3 ( C, F) (kg/m , head type type
3 lb/ft m, ft
Copper Manufacturing Process
V00664/03 (10.2000) Copyright © Sulzer Pumps Finland Oy 10
Pumps in Copper Electrolyse Process
ElectrolyteH SO 140...180 g/l2 4
Anode slimeH SO 140...180 g/l2 4
ElectrolyteH SO 140...180 g/l2 4
Sb, Bi10 mg/l
Cu, Ni,precious metals
Sb, Bi10 mg/l
60/140
60-70/140-158
1230/77
1500/94
1230/77
30/98
35/115
20/66
APP/T
WSP/T/WKP/T
APP/T
Open
1Open
1Open
Singlemechanical
5(ME03)
2Doubl. mech. (MR22) or
Dyn. (DS02)
4654SMO
A890 3A
A890 3A Purification feeder
Anode Slimefrom ElectrolyseCells
Electrolytecirculate
<1
<1
<1
1) Crystallization2) Check always the entraining air through the static seal. The air harms the process3) Material recommendation is only for specified application4) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material5) The shaft seal is not needed with WKP/T6) The floating installation of the pumps in Electrolyse process
1
2
3
2Doubl. mech. (MR22) or
Dyn. (DS02)
4 Anode slimeH SO 140...180 g/l2 4
<1Cu, Ni,
precious metals 60/140
1500/94
35/115
WPP/T Open2Doubl. mech.
(MR22) orDyn. (DS02)
4654SMO Filter feeder toprecious metals
60-70/140-158
Copper Manufacturing Process
V00664/04 (10.2000) Copyright © Sulzer Pumps Finland Oy 11
Electrolyte from electrolysis
CuSO -4
sedimentation
CuSO -crystals4
To Cu removal(electrolysis)
Crystallization
Water
Mother liquor
Mother liquor separation(centrifuge)
Steam
1.APP/T
2.APP/T
3.APP/T
4.APP/T
Pumps in CuSO Crystallization Process4
Copper Manufacturing Process
V00664/05 (10.2000) Copyright © Sulzer Pumps Finland Oy 12
3 Liquid pH Solids Temp. Density Typical Pump Impeller Seal type Material Dutyo o 3 ( C, F) (kg/m , head type type
3 lb/ft ) m, ft
ElectrolyteH SO 140...180 g/l2 4
Sb, Bi10 mg/l
60/140
50/122
50/122
50/122
1230/77
1340/84
1560/97
1340/84
18/59
17/56
20/66
20/66
APP/T 1Open A890 3A
A890 3A
A890 3A
Circulation
Crystallizer discharger
Cu removalfeeder
Crystallizer feeder<1
1) Crystallization2) Check always the entraining air through the static seal. The air harms the process3) Material recommendation is only for specified application
1
Cu-solutionH SO 140...180 g/l2 4
CuSO -solution4
H SO 140...180 g/l2 4
Cu-solutionH SO 250 g/l2 4
Cu, Ni
Cu, Ni
Cu, Ni
APP/T
APP/T
1Open
1Open
Double mech.(MR22)
<1
<1
<1
2
3
4
Pumps in CuSO Crystallization Process4
2Doubl. mech. (MR22) or
Dyn. (DS02)
2Doubl. mech. (MR22) or
Dyn. (DS02)
APP/T 1Open Double mech.
(MR22)A890 3A
Copper Manufacturing Process
V00664/06 (10.2000) Copyright © Sulzer Pumps Finland Oy 13
4.APP/T
Electrolyte fromCuSO -crystallization4
Cu-solids Cu-solids
Storage
Electrolyte toevaporation
Cu-solids
1.APP/T
2.APP/T 3.APP/T
I Cells –+ III Cells –+II Cells –+
Pumps in Cu Removal by Electrolyse Process
Copper Manufacturing Process
V00664/07 (10.2000) Copyright © Sulzer Pumps Finland Oy 14
2 Liquid pH Solids Temp. Density Typical Pump Impeller Seal type Material Dutyo o 3 ( C, F) (kg/m , head type type
3 lb/ft ) m, ft
Cu solutionH SO 250 g/l2 4
Cu, Ni 50-60/122-140
1230-1340/77-84
15/49
15/49
15/49
15/49
APP/T 1Open A890 3A
A890 3A
A890 3A
A890 1B
2nd stage cellspumping tank
3rd stage cellspumping tank
Evaporator feed
1st stage cells pumping tank feeder
<11
Cu-solutionH SO 250 g/l2 4
Cu-solutionH SO 250 g/l2 4
Cu free solutionH SO 250 g/l2 4
Cu, Ni
Ni, Cu
Cu ~ 2 g/l
APP/T
APP/T
APP/T
1Open
1Open
1Open
<1
<1
<1
2
3
4
Pumps in Cu Removal By Electrolyse Process
2Doubl. mech. (MR22) or
Dyn. (DS02)2Doubl. mech.
(MR22) orDyn. (DS02)
2Doubl. mech. (MR22) or
Dyn. (DS02)2Doubl. mech.
(MR22) orDyn. (DS02)
1) Crystallization2) Check always the entraining air through the static seal. The air harms the process3) Material recommendation is only for specified application
50-60/122-140
50-60/122-140
50-60/122-140
1230-1340/77-84
1230-1340/77-84
1230-1340/77-84
Copper Manufacturing Process
V00664/08 (10.2000) Copyright © Sulzer Pumps Finland Oy 15
Electrolyte from Cu removal(electrowinning)
Evaporator
Dropletseparator
Condensate
Condensate
Condensate
Sulphuric acidto process
Filtration NiSO4
Steam
Filtratetank
Heater
1.APP/T
2.APP/T
4.APP/T3.
6.
5.
Pumps in Electrolyte Evaporation Process
Copper Manufacturing Process
V00664/09 (10.2000) Copyright © Sulzer Pumps Finland Oy 16
1 Liquid pH Solids Temp. Density Typical Pump Impeller Seal type Material Dutyo o 3 ( C, F) (kg/m , head type type
3 lb/ft ) m, ft
Cu freeH SO 250 g/l2 4
Ni 1 mg/l
60/140
50/122
120/248
90/194
70/158
60/140
1230/77
1000/62
1500/94
1000/62
1500/94
1600/100
20/66
15/49
3.5/11,5
30/98
20/66
25/82
APP/T Closed 3654SMO
A890 3A
Si-iron
A890 3A
_
_
Condensate
Circulation
Condensate
Filter feeder
NiSO filtrate4
Feeder<11
CondensateH SO 60 g/l2 4
Ni-solutionH SO 300 g/l2 4
H O 2
NiSO4
H SO 300 g/l2 4
H SO 300 g/l2 4
–
Ni5 mg/l
–
Ni5 mg/l
–
APP/T
– – –
APP/T
_
_
Closed
Closed
_
_
Dynamic seal(DS01)
_
_
<1
<1
7
<1
<1
2
3
4
5
6
Pumps in Electrolyte Evaporation Process
Dynamic seal(DS01)
2Doubl. mech. (MR22) or
Dyn. (DS02)
1) Material recommendation is only for specified application2) Check always the entraining air through the static seal. The air harms the process3) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material
Copper Manufacturing Process
V00664/10 (10.2000) Copyright © Sulzer Pumps Finland Oy 17
Anode slime from electrolyse
Autoclave
Filtration
Se solids
Roasting furnace
Convertingand casting
Filtration Filtration
Precipitation
Precipitation
Electrolysis
Leaching Cementation
Ag solids
Te solids
Au solids
Au solids
FiltrationPrecipitation
Solution
Rh solids
Liquid
Pt solids
Waste solution
1.WPP/T
2.WPP/T
6.
4.
5.
7.
3.APP/T
8.
–+
Pumps in Anode Slime Treatment Process
Copper Manufacturing Process
1 Liquid pH Solids Temp. Density Typical Pump Impeller Seal type Material Dutyo o 3 ( C, F) (kg/m , head type type
3 lb/ft ) m, ft
Anode slimeH SO ~200 g/l2 4
80/176
80/176
50/122
80/176
70/158
70/158
60/140
50/122
1500/94
1400/88
1300/81
1400/88
1500/94
1700/106
1700/106
1000/62
20/66
20/66
30/99
30/99
15/49
20/66
20/66
20/66
<11
Te-solutionH SO ~200 g/l2 4
Rh freeH SO ~1300 g/l2 4
Te freeH SO ~200 g/l2 4
Ag freeHCl ~200 g/l
Ag freeH SO ~1300 g/l2 4
Au freeHCl ~200 g/l
Noble metal freeHCl ~200 g/l
Se, Ag, Te
–
–
–
Ag
–
–
<1
<1
<1
<1
<1
<1
<1
2
5
3
6
4
7
8
Pumps in Anode Slime Treatment Process
Se,Te,BaSO , 4
PbSO4
9 1400/87 36/118
WPP/T
WPP/T
APP/T
–
–
–
–
–
Closed
Closed
Closed
–
–
–
–
–
2654SMO
2654SMO
–
–
–
–
–
2654SMODouble mech. (MR22)
Double mech. (MR22)
Dynamic seal (DS01)
Treatment feeder
Te filter
Electrolytepurification
Precipitation
Process circulation
Feed 2nd stageAu separation
Pt filter
Waste solution
–
–
–
–
–
V00664/11 (10.2000) Copyright © Sulzer Pumps Finland Oy
1) Material recommendation is only for specified application2) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material
H2SO4 and Sesolids mixture
<1 1 - 2 % 80/176 APP/T Closed Double mech.
(MR22)Hastelloy E8
Se roasting fuurnaceliquid
ApplicationReport
1(1)
N03845 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Copper cathodes tomelting and casting
Electrolyte topurification
AHLSTAR™ APP for Electrolyte Pumping
+ –
–
–
+
+
Electrolyte frompurification
Starting sheetsAnodes
Anode scrapsCells
Cells
Cells
Anode slime to treatment
Filtration
APP22-80
AHLSTAR™ APP in Copper Electrolysis Process.
Pump......................... APP22-80Impeller..................... Special open impellerType.......................... APP Process pumpMotor.......................... 15 kW (20 hp)Speed....................... 1740 rpmMaterial..................... ASTM890 Grade3ASealing...................... Double mechanical seal
Pump Data
Q............................... 33.3 l/s (528 USGPM)H............................... 15 m (49 ft)Liquid........................ ElectrolytepH............................. 1Temperature.............. 60 oC (140 oF)H
2SO
4 content .......... 13 %
Density...................... 1400 kg/m3 (88 lb/ft3)
Process Data
An APP31-125 pump was installed to pumpelectrolyte from the filtration of anode slime toback to electrorefining. The pump is equippedwith a seal which prevents access of air intothe pumped liquid.
ApplicationReport
1(1)
Copper cathodes tomelting and casting
Electrolyte topurification
AHLSTAR™ APP for Electrolyte Pumping
+ –
–
–
+
+
Electrolyte frompurification
Cells
Cells
Anode scraps
Filtration
Anode slime to treatment
AnodesStarting sheets
APP31-125
AHLSTAR™ APP in Copper Electrolysis Process.
N03846 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Pump......................... APP 31-125Impeller..................... OpenType.......................... APP Process pumpMotor......................... 22 kW (16.4 hp)Speed....................... 1460 rpmMaterial..................... ASTM 743 CF-8MSealing...................... Double mechanical seal
Pump Data
Q................................ 42 l/s (667 USGPM)H................................ 20 m (66 ft)Liquid......................... ElectrolytepH.............................. 1Temperature.............. 70 oC (158 oF)H2SO4 content .......... 14.5 %Density...................... 1230 kg/m3 (77 lb/ft3)
Process Data
An APP31-125 pump was installed to pumpelectrolyte from a circulating liquor tank back toelectrorefining. The pump has been running inthis position for 14 years without bigger prob-lems. The pump is equipped with a seal whichprevents acces of air into the pumped liquid.
ApplicationReport
1(1)
Pump......................... APP11-32Impeller..................... Closed impellerType.......................... APP Process pumpMotor......................... 4 kW (3 hp)Speed....................... 2905 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 1 l/s (16 USGPM)H............................... 30 m (98 ft)Liquid........................ ElectrolytepH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 14.6 %Density...................... 1230 kg/l (77 lb/ft3)
Process Data
N03847 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
AHLSTAR™ APP for Electrolyte Pumping
An APP11-32 pump was installed to pump elec-trolyte from a circulating liquor tank to purifica-tion. The application is quite corrosive and con-tains many kind of impurities. Duplex stainlesssteel was chosen to manage the corrosion.
Electrolyte topurification
+ –
–
–
+
+
Electrolyte frompurification
Cells
Cells
Anode scrapsCopper cathodes tomelting and casting
Filtration
Anode slime to treatment
AnodesStarting sheets
APP11-32
AHLSTAR™ APP in Copper Electrolysis Process.
ApplicationReport
1(1)
N03848 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed......................... 1500 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 2.8 l/s (44 USGPM)H............................... 18 m (59 ft)Liquid........................ ElectrolytepH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 14.6 %Density...................... 1230 kg/m3 (77 lb/ft3)
Process Data
An APP11-32 pump was installed to pump elec-trolyte to crystallization. The application is quitecorrosive and contains many kinds of impuri-ties. Duplex stainless steel was chosen to man-age the corrosion and solids in the pumped liq-uid.
AHLSTAR™ APP for Electrolyte Pumping
To Cu removal(electrolysis)
CrystallizationElectrolyte fromelectrolysis
Steam
CuSO4Sedimentation
Mother liquor separation (centrifuge)Water
Mother liquor
CuSO4 crystalsAHLSTAR™ APP in CuSO
4 Crystallization Process.
APP22-32
ApplicationReport
1(1)
N03849 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Pump......................... APP31-100Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 22 kW (16.4 hp)Speed....................... 1470 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 42 l/s (667 USGPM)H............................... 17 m (56 ft)Liquid........................ Cu solution with solidspH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 14.6 %Density...................... 1340 kg/m3 (84 lb/ft3)
Process Data
CrystallizationElectrolyte fromelectrolysis
Steam
CuSO4Sedimentation
Mother liquor separation (centrifuge)Water
Mother liquor
To Cu removal(electrolysis)
CuSO4 crystals
APP31-100
AHLSTAR™ APP in CuSO4 Crystallization Process.
AHLSTAR™ APP for Cu Solution Pumping
An APP31-100 pump was installed to circulateCu solution in a crystallizer. The pumped liquidcontains crystallizable solids which can crys-tallize inside the pump. This means that the shaftseal should be selected very carefully. Ready-fitted non-flowing double mechanical seal wasselected because of a higher operating temper-ature in the seal faces on the product side.
ApplicationReport
1(1)
N03850 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
To Cu removal(electrolysis)
AHLSTAR™ APP for CuSO4 Solution Pumping
Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kw (2.2 hp)Speed....................... 1430 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 0.5 l/s (8 USGPM)H............................... 20 m (66 ft)Liquid........................ CuSO4 solution with solidspH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 14.4 %Density...................... 1560 kg/m3 (97 lb/ft3)
Process Data
CrystallizationElectrolyte fromelectrolysis
Steam
CuSO4Sedimentation
Mother liquor separation (centrifuge)Water
Mother liquor
CuSO4 crystalsAHLSTAR™ APP in CuSO4 Crystallization Process.
An APP22-32 pump pumps crystallized CuSO4
to sedimentation. The solids content is about16 % and crystallization is still going on insidethe pump. The shaft seal has to be selectedvery carefully. Ready-fitted non-flowing doublemechanical seal was selected because of ahigher operating temperature in the seal faceson the product side.
APP22-32
ApplicationReport
1(1)
N03851 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed....................... 1430 r/minMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Process Data
To Cu removal(electrolysis)
AHLSTAR™ APP for Cu Solution Pumping
Q............................... 1.4 l/s (22 USGPM)H............................... 15 m (49 ft)Liquid........................ Cu solutionpH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 19 %Density...................... 1340 kg/m3 (84 lb/ft3)
An APP22-32 pump pumps Cu solution back to
sedimentation. The sulphuric acid concentrationis quite high in this application, about 19 %. Ifthe temperature rises about 15 to 20 oC, thensuper duplex stainless steel should be select-ed. APP22-32 from normal duplex stainlesssteel has been working for about six years with-out having to replace the volute casing.
CrystallizationElectrolyte fromelectrolysis
Steam
CuSO4Sedimentation
Mother liquor separation (centrifuge)Water
Mother liquor
CuSO4 crystals
APP22-32
AHLSTAR™ APP in CuSO4 Crystallization Process.
ApplicationReport
1(1)
N03852 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Pump......................... APP11-32Impeller..................... Closed impellerType.......................... APP Process pumpMotor........................ 7.5 kW (5.6 hp)Speed....................... 2950 r/minMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 1.4 l/s (22 USGPM)H............................... 50 m (164 ft)Liquid........................ Cu solutionpH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 19 %Density...................... 1340 kg/m3 (84 lb/ft3)
Process Data
AHLSTAR™ APP for Cu Solution Pumping
An APP11-32 pump pumps Cu solution to elec-
trolysis cells to crystallize Cu to solids. Thepump has been running for 12 years now. Thevolute casing of the pump was replaced after 8years of operation. Air is not permitted in theelectrolysis process step. This is why a ready-fitted non-flowing double mechanical seal wasselected.
Electrolyte from CuSO4 crystallization
Cu solids Cu solids Cu solids
I Cells II Cells III Cells
Storage
Electrolyte toevaporation
APP11-32
–+ –+–+
AHLSTAR™ APP in Cu Removal by Electrolysis
ApplicationReport
1(1)
N03853 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Pump......................... APP22-40Impeller..................... Closed impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed....................... 1440 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 6 l/s (95 USGPM)H............................... 15 m (49 ft)Liquid........................ Cu solutionpH............................. 1Temperature.............. 60 oC (140 oF)H
2SO
4 content .......... 19 %
Density...................... 1340 kg/m3 (84 lb/ft3)
Process Data
AHLSTAR™ APP for Cu Solution Pumping
An APP11-32 pump pumps Cu solution to elec-
trolysis cells to crystallize Cu to solids. Air isnot permitted in the electrolysis process step.This is why a ready-fitted non-flowing doublemechanical seal was selected.
Electrolyte from CuSO4 crystallization
Cu solids Cu solids Cu solids
I Cells II Cells III Cells
Storage
Electrolyte toevaporation
APP22-40
AHLSTAR™ APP in Cu Removal by Electrolysis
–+ –+–+
ApplicationReport
1(1)
N15393 / Metal, Copper en (12.2003), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products.Directions for use and safety will be given separately. All information herein is subject to change without notice.
Pump......................... WKP23-50Impeller..................... Open impellerType.......................... WKP Wear resistant
cantilever pumpMotor........................ 11 kW (15 hp)Speed....................... 1450 r/minMaterial..................... ASTM 890 Grade 3A
Pump Data
Q............................... 5.5 l/s (87 USGPM)H............................... 28 m (92 ft)Liquid........................ Floor waterpH............................. 7Temperature.............. 20 oC (68 oF)Solids content .......... 1 - 5 %Density...................... 1050 kg/m3 (66 lb/ft3)
Process Data
AHLSTAR™ WKP Cantilever for Floor Water Pumping
A WKP wear resistant cantilever pump was in-stalled to pump floor water in Cu removal byelectrolysis. The pump has been running for 4years now. The volute casing of the pump is thesame after 4 years’ operation. The pump doesn’tneed shaft seal or support bearings at the bot-tom side.
Electrolyte from CuSO4 crystallization
Cu solids Cu solids Cu solids
I Cells II Cells III Cells
Storage
Electrolyte toevaporation
To watertreatment
–+ –+–+
AHLSTAR™ WKP in Cu Removal by ElectrolysisWKP23-250
ApplicationReport
1(1)
N03854 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
AHLSTAR™ APP for Cu-Free Solution Pumping
Condensate
Condensate
Sulphuric acid to process
NiSO4
Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed....................... 1430 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 1.4 l/s (22 USGPM)H............................... 20 m (66 ft)Liquid........................ Cu-free solutionpH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 19 %Density...................... 1230 kg/m3 (77 lb/ft3)
Process Data
Electrolyte from Cu removal(electrowinning)
Evaporator
Dropletseparator
Steam
Heater
Filtration
Filtrate tank
APP22-32
AHLSTAR™ APP in Electrolyte Evaporation
An APP22-32 pump pumps Cu-free solution toelectrolyte evaporation. The pump has been run-ning for about 6 years without having to changethe volute casing.
ApplicationReport
1(1)
N03855 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
AHLSTAR™ APP for Condensate Pumping
Pump......................... APP11-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 4 kW (3 hp)Speed....................... 2880 rpmMaterial..................... ASTM 890 Grade3ASealing...................... Double mechanical seal
Pump Data
Q............................... 0.8 l/s (13 USGPM)H............................... 30 m (99 ft)Liquid........................ CondensatepH............................. 7Temperature.............. 90 oC (194 oF)Solids content .......... 0 %Density...................... 1000 kg/m3 (62 lb/ft3)
Process Data
Electrolyte from Cu removal(electrowinning)
Evaporator
Dropletseparator
Steam
Heater
Filtration NiSO4
Filtrate tank
APP11-32
AHLSTAR™ APP in Electrolyte Evaporation
Condensate
Condensate
Sulphuric acid to process
An APP11-32 pump pumps condensate fromelectrolyte evaporation step in a Cu manufac-turing process. Duplex stainless steel and dou-ble mechanical seal were selected. The pumphas been running for 6 years without bigger prob-lems.
ApplicationReport
1(1)
N03856 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
AHLSTAR™ APP for Condensate Pumping
Steam
Pump......................... APP11-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 2.20 kW (1.6 hp)Speed....................... 1425 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Single mechanical seal
Pump Data
Process Data
Electrolyte from Cu removal(electrowinning)
Evaporator
Dropletseparator
Heater
Filtration NiSO4
Filtrate tank
APP11-32
AHLSTAR™ APP in Electrolyte Evaporation
Condensate
Condensate
Sulphuric acid to process
Q............................... 0.13 l/s (2 USGPM)H............................... 15 m (49 ft)Liquid........................ CondensatepH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 6 %Density...................... 1100 kg/m3 (68 lb/ft3)
An APP11-32 pump pumps condensate fromelectrolyte evaporation step in a Cu manufac-turing process. The pumped liquid contains 6 %of sulphuric acid. Duplex stainless steel and sin-gle mechanical seal were selected. The pumphas been running for 6 years without bigger prob-lems.
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ApplicationReport
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Pump......................... APP11-40Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 15 kW (11 hp)Speed....................... 2920 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 5.5 l/s (87 USGPM)H............................... 50 m (164 ft)Liquid........................ Te solution with solidspH............................. 1Temperature.............. 90 oC (198 oF)H2SO4 content .......... 14 %Density...................... 1400 kg/m3 (88 lb/ft3)
Process Data
N03857 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Anode slime fromelectrolysis
Autoclave
Filter Precipitation Filter
Se solidsRoastingfurnace
Convertingand casting
Ag solids
Au solids
Rh solids
LiquidAPP11-40
AHLSTAR™ APP for Te Solution Pumping
AHLSTAR™ APP in Anode Slime Treatmement Process
An APP11-40 pump pumps Te solution to Tesolids filtration. The pumped liquid contains 14%of sulphuric acid and Te solids, also Cu and Nisolids. Duplex stainless steel and double me-chanical seal were selected. The pump hasbeen running for 5 years.
ApplicationReport
1(1)
N03858 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
AHLSTAR™ APT for Anode Slime Pumping
Pump......................... APT55-12Impeller..................... Open impellerType.......................... APT Process pumpMotor.......................... 400 hp (298 kW)Speed....................... 1180 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal
Pump Data
Q............................... 7700 USGPM (485 l/s)H............................... 150 ft (46 m)Liquid........................ Anode slimepH............................. 1Temperature.............. 120 oF (49 oC)H2SO4 content .......... 13 %Density...................... 94 lb/ft3 (1500 kg/m3)
Process Data
AHLSTAR™ APT in Anode Slime Treatmement Process
An APT pump pumps anode slime slurry to fil-tration. The pumped liquid contains 14% of sul-phuric acid and different kinds of solids, about30%. Duplex stainless steel and double mechan-ical seal were selected. The pump has been run-ning for 10 years.
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Anode slime fromelectrolysis
Autoclave
Filter Precipitation Filter
Se solidsRoastingfurnace
Convertingand casting
Ag solids
Au solids
Rh solids
Liquid
APT55-12
ApplicationReport
1(1)
N03882 / Metal, Copper en (11.2002), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.
AHLSTAR™ APP for Anode Slime Pumping
Pump......................... APP32-80Impeller..................... Open impellerType.......................... APP Process pumpMotor.......................... 2230 kW (30 hp)Speed....................... 1460 rpmMaterial..................... Hastelloy E8Sealing...................... Double mechanical seal
Pump Data
Q............................... 17 l/s (269 USGPM)H............................... 36 m (118 ft)Liquid........................ Sulphuric acidpH............................. 1Temperature.............. 80 oC ( 176 oF)H2SO4 content .......... 25 - 30 %Density...................... 1400 kg/m3 (87 lb/ft3)
Process Data
AHLSTAR™ APP in Anode Slime Treatment Process
Anode slime from electrolyse
Autoclave
Filtration
Se solidsRoasting
furnace
Convertingand casting
Filtration Filtration
Precipitation
Precipitation
Electrolysis
Leaching Cementation
Ag solids
Te solids
Au solids
Au solids
FiltrationPrecipitation
Solution
Rh solids
Liquid
Pt solidsWaste solution
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Ejector Gas
APP32-80
Se Filter
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Gas from Selenium roasting furnace mixed withsulphuric acid and water was pumped with AHL-STARTM APP process pump. The first materialselection was Hastelloy B type material whichwas lost in couple of months. Hastelloy B mate-rial was tested first because of good experiencein other process equipments. Hastelloy B waschanged to Hastelloy E8 type of material whichis nickel alloyed material also. The pump isequipped with double mechanical seal. APPpump from Hastelloy E8 material has been run-ning three years without problems. The pump isstill running.
copper.xls 03/08/00 13:26
Sulzer Pumps Finland OyPump Lifetime Costs Profile
Industry Copper
Segment 2744
No. of pumps 25 (150) Pump average lifetime (yr) 11,8
Pump types APP, WPP
Volute Casing Impeller Casing Cover Seal Average Liftime Number of pumps Remarks
ELECTROLYSE 9 yr. 5,3 yr. 5,3 yr. 2 yr. 9 yr. 3 Because of low voltage level in electrolyse, avoid
electrical corrosion
Cu REMOVAL by 11,5 yr. 8,8 yr. 8,8 yr. 2 yr. 11,5 yr. 4 Copper sulfate is reason for wearing
ELECTROLYSE
ELECTROLYTE 13,8 yr. 12,4 yr. 12,4 yr. 3,2 yr. 13,8 yr. 6 Some applications are very wearing because of high
EVAPORATION acid and temperature values.
CuSO4 16 yr. 13 yr. 13 yr. 2,3 yr. 16 yr. 4 Crystallized particles makes wearing in some
CRYSTALLIZATION applications
ANODE SLIME 8,7 yr. 5,7 yr. 5,7 yr. 2 yr. 8,7 yr. 8 Low pH, high temperature and solid particles make
TREATMENT some wearing
ADDITIONAL INFO Solid particles (Antimony, Bismuth and Arsenic) are cathered to the inside of pipelines and at least once a year the solid matter has to be removed off by
high pressure washing.
The motor and baseplate have to be protected by cover to avoid external corrosion in case if pumped liquid has got outside.
Recommended