188803663 05 Electrowinning and Electrorefining

Electrowinning and Electrorefining

SYMPOSIUM: 05 ELECTROWINNIG AND ELECTROREFINING

CODE AUTHOR TITLE ABSTRACT

ER01 Shunsuke Kawai CFD SIMULATION OF COPPER ELECTROREFINING PROCESS AND ANALYSIS FOR THE TANKHOUSE OPERATION AT NAOSHIMA SMELTER AND REFINERY

ER02 Luis Navarro CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO REFINERY

ER06 Jari Aromaa CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER ELECTROREFINING

ER07 Michael Moats, Tim Robinson

GLOBAL SURVEY OF COPPER ELECTROREFINING OPERATIONS AND PRACTICES

ER09 Shuklin, M.A. TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMC'S (URALELECTROMED) NEW COPPER ELECTRO REFINERY

ER10 Guillermo Rios RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT PLANT AT ATLANTIC COPPER

ER11 G. Leuprecht - N. Izatt THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE MODERNIZATION PROJECT

ER14 Ari Rantala USE OF REAL-TIME INFORMATION IN TANKHOUSE OPERATIONAL EFFICIENCY IMPROVEMENT AND QUALITY CONTROL

ER16 Jimmy Bidwell TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE PRECIPITATION

ER17 Hidehiro Sekimoto SOLUBILITY PRODUCT OF ANTIMONY ARESENATE AND BISMUTH ARSENATE

ER18 Takahito Kasuno SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT METALS DURING COPPER ELECTROREFINING

ER19 Masaomi Kanazawa RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY

ER20 Yuuki Watanabe QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSHIMA SMELTER & REFINERY

ER21 Masaaki Kato THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND REFINERY

ER23 A.E. Wraith ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE WORLD`S FIRST COMMERCIAL ELECTROREFINERY

ER24 Michael J Nicol IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR CONTACTS?

ER25 Shijie Wang DETERMINATION OF BISMUTH CONTAMINATION IN COPPER

ER28 Nedelcho Dragoev AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE

ER31 Rodrigo Abel STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)


ER33 Stefan Konetschnik COST COMPARISON BETWEEN A CONVENTIONAL ER

TANKHOUSE AND A HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRX-TECHNOLOGY

ER34 Gerardo Cifuentes COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES

ER54 Günter Leuprecht DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS AT AURUBIS, HAMBURG USING EMEW® ELECTROWINNING TECHNOLOGY

ER59 J.P. Ibañez REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS® SYSTEM. LABORATORY INVESTIGATION

ER60 Clyde Wright - Marty Wessman

MOVING COPPER MATERIAL HANDLING FORWARD USING ADVANCED DESIGNS BY BROCHOT COMPANY

ER61 Cristian Cortes E CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC REFINERY OF THE VENTANAS DIVISION

ER62 Michael Stelter PURER CATHODES BY NEW ADDITIVES IN COPPER ELECTROERFINING

ER63 Songlin Zhou COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH CURRENT DENSITY

ER66 Marco Cifuentes A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE EXTRACTION OF ANTIMONY

EW03 Patricio Melani - P.A. Aylwin - N.I. Lagos

SELE MODULAR TECHNOLOGY TO ACHIEVE SUSTAINABLE DEVELOPMENT AND EFFICIENT IN EW PLANTS

EW04 Scott Sandoval OPERATION OF ALTERNATIVE ANODES AT CHINO SXEW

EW05 Tim Johnston HATCH HELM TRACKERTM SYSTEM FOR GUIDING CELL HOUSE PERFORMANCE IMPROVEMENT

EW12 R. Rajasingam ELIMINATION OF ACID MIST IN COPPER ELECTROWINNING

EW15 Luis G. Navarro SMALL COLUMN TESTING OF SUPERLIG® 83 FOR BISMUTH REMOVAL FROM COPPER ELECTRO REFINING ELECTROLYTE

EW22 Robert P. Dufresne CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT SHORT CIRCUITS

EW26 M. Morimitsu A STATE OF THE ART ANODE TECHNOLOGY: SMART ANODE, MSA®, FOR COPPER ELECTROWINNING

EW27 Rob Fraser COMPARISON OF INTERCELL CONTACT BARS FOR ELECTROWINNING PLANTS CONSIDERING THERMAL EFFECTS

EW29 Abbas Mirza OPTIMIZATION OF THE USABLE LIFE OF LEAD ELECTROWINNING ANODES

EW30 Andreas Siegmund ELECTROLYTIC TANKHOUSE ACID MIST CONTROL - MEETING STRINGENT WORKER EXPOSURE LIMITS AND EMISSION TARGETS

EW35 Francisco Sanchez ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL DIVISION


EW36 Michael Moats -Tyler

Helsten AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE ROUGHNESS IN COPPER ELECTROWINNING

EW38 Tomas Vargas THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION AND CATHODE QUALITY

EW53 Ricardo Fuentes EXPERIENCIES ON DESIGN, MANUFACTURING AND OPERATION OF HIGH CONTROLLED TRANSFORMER-RECTIFIERS FOR SX-EW COPPER PLANTS

EW55 A. Fiorucci DE NORA'S SOLUTION - PART I, DSA® ANODES FOR CU ELECTROWINNING

EW56 A. Fiorucci DE NORA'S SOLUTION - PART II, ACID MIST ABATEMENT

EW57 Gabriel Zarate MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS

EW58 Michael J Nicol MASS TRANSPORT TO CATHODES IN THE ELECTROWINNING OF COPPER

EW64 A.Lillo EXMAJET®, POTENTIAL FOR IMPROVED ACID MIST CAPTURE AND CATHODE QUALITY AT HIGH CURRENT DELSITY ELECTROWINNING

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

POTENTIAL-CONTROLLED ELECTROLYSIS AS A NEW METHOD OF COPPER ELECTROREFINING AND ELECTROWINNING - DISCUSSION OF SOME BASIC ASPECTS


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

[email protected]

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 Morris

1, Weldon Read

1, Neil E. Izatt

2, Ronald L. Bruening

2, and

Steven R. Izatt2,

1Asarco

7001 State Highway 136

Amarillo, Texas 79106, U.S.A.

2IBC Advanced Technologies, Inc.

856 E. Utah Valley Drive,

American Fork, Utah 84003, U.S.A.

ABSTRACT

An effective removal system for the separation of dissolved bismuth from copper

electrolyte to reach desired bismuth levels has been developed by IBC Advanced

Technologies, Inc (IBC). This system is being operated at ASARCO in Amarillo, Texas to

produce high purity electrolytic copper. Control of bismuth concentration is necessary

because bismuth levels exceeding 2 ppm in the final copper product result in brittleness

making the product unsuitable for wire production. The bismuth removal system is based

on IBC’s Molecular Recognition Technology (MRT) process.

This process employs proprietary non-ion exchange resin materials, termed

SuperLig®, to effect the separation. Key benefits of the MRT process for bismuth removal

include (1) easy control of the bismuth levels in the tank house electrolyte, (2) avoidance of

brittle copper, and (3) flexibility to handle “dirty” copper concentrates as feedstock. This

paper describes the bismuth MRT plant at the Asarco refinery, the operating process, and

the results. Limitations of alternate technologies for bismuth control are discussed,

particularly with respect to their environmental concerns compared to the MRT

process. Benefits of the MRT system to copper refineries where bismuth problems exist

are presented.


ER06

CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER

ELECTROREFINING

Jari Aromaa, Antti Kekki, Olof Forsén

Aalto University

Department of Materials Science

PO Box 16200

00076 Aalto

Espoo, FINLAND

ABSTRACT

The AISI 316L type stainless steel is considered corrosion resistant in copper

electrorefining electrolyte, both as permanent cathode blank material and in process

equipment and piping. Damaged cathode blanks show increased surface roughness,

corrosion pits and deeper grain boundaries. The test hypothesis was that too high chloride

concentration and temperature can cause localized corrosion.

A synthetic electrolyte with 180 g/l H2SO4, 45 g/l Cu, 15 g/l Ni and 10 g/l As was

used. Test variables were temperature 50-70 oC and chloride concentrations from 40 ppm to

1000 ppm. Test method was cyclic polarization curve based on ASTM standard G61-86.

No pitting or crevice corrosion was seen in the test series but highest chloride

concentration resulted in wider active peak and higher passive current densities. In

transpassive corrosion tests localized corrosion on grain boundaries and detachment of

grains was seen. Two main possibilities for blank corrosion have been identified. High

chloride concentration can cause active dissolution. The concentration of chlorides has to

be at least 10 times higher than the normal chloride level. Polarization to transpassive

potentials causes corrosion on grain boundaries and detachment of grains. The only

possibility for transpassive dissolution is stray currents.


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.

[email protected]

Tim Robinson

Senior Vice President

Republic Alternative Technologies, Inc.

11288 Alameda Dve

Strongsville, OH 44149, U.S.A.

[email protected]

Shijie Wang

Princple Advisor – Process Engineering

Rio Tinto - Kennecott Utah Copper

11500 West 2100 South

Magna, UT 84044, U.S.A.

[email protected]

Andreas Filzwieser

Info

Andreas Siegmund


Gas Cleaning Technologies (GCT) LLC

4953 N. O’Connor Road

Irving, TX 75062 U.S.A

[email protected]

William Davenport

Professor Emeritus


University of Arizona

Tucson, AZ 85721, U.S.A.

[email protected]


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 UMMC’S

(URALELECTROMED) NEW COPPER ELECTRO REFINERY

Shuklin, M.A., Romanov, A.A, Bakhirov, N.Y

JSC Uralelektromed

1 Lenin str., Verkhnyaya Pyshma,

Sverdlovsk region, 624091, Russia

Phone +7 (34368) 4 71 38, 4 61 22

Fax: +7 (34368) 4 60 99, 4 26 26

Larinkari,M., Hukkanen, R.

Outotec (Finland) Oy

Riihitontuntie 7D (P.O Box 84)

02201, Espoo, Finland

Phone +358 20 529 211

Fax: +358 20 529 2200

ABSTRACT

A modern tankhouse relies on high performance material handling, fully automated

process control systems, quality assessment data and consistent operations reporting to

ensure high efficiency of operation and stable quality of final product. In 2012, Outotec’s

and Uralelectromed’s specialists have developed comprehensive tankhouse process

automation solution called Tankhouse Information Management System (TIMS), which has

been implemented at UMMC’s (“Uralelektromed”) new 150 tpa copper electro refinery in

Verkhnyaya Pyshma, Russia.

TIMS collects process data from different systems and material handling equipment

into a central database, providing material tracking and process key performance indicator

calculations. TIMS automates daily production reporting and provides various analytical

views of the process which can be used at higher level in business control systems.

As a result an essential part of the new tankhouse operation information is provided

by TIMS. Systematic and accurate reporting is based on real-time information which

requires minimal manual work by the personnel. Gained benefits are increased visibility


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. Ríos, R. Ramírez, C. Arbizu, I. Ruiz,

Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold)

Av. Francisco Montenegro, s/n

21001 Huelva, Spain

ABSTRACT

Approximately 160 m3/day of electrolyte bleed from the Atlantic Copper Refinery

Tankhouse is sent daily to the Electrolyte Treatment Plant to control the copper content and

impurities (As, Sb and Bi) in the electrolyte. Much of the solution leaving the 3rd stage

liberator circuit is returned to the tankhouse, but a small portion (~28 m3/day) is bled to the

weak acid neutralization plant for minor element control (Fe, Ca). Laboratory and pilot

scale tests have been carried out in order to recover the nickel from this bled solution as

nickel carbonate, using different ion exchange resins technologies. Based on the excellent

results obtained from these tests, Atlantic Copper decided to build a nickel carbonate

production plant, which is expected to be commissioned in February 2013. ECOTEC

Recoflo technology has been chosen for removing the sulphuric acid from the feed

solution.Once the acid is removed, then, through a neutralization process, it is possible first,

to purify the electrolyte and then, to precipitate nickel as nickel carbonate.


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

[email protected]

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


ABSTRACT

Optimizing the operations efficiency and cathode quality of a tankhouse requires not

only the efficient use of energy and labor, but also high availability of machinery and the

ability to rapidly observe and react to disturbances. With the use of proven innovative on-

line monitoring and information management systems now available in the market

parameters such as efficiency, productivity and quality can be assessed in real-time mode.

Some of the systems discussed in the paper include systematic surface quality inspection of

anodes and cathodes and permanent cathode condition.

Another system indicates cell performance on-line, facilitating early reaction to

critical events such as short-circuiting, flow blockages, anode passivation or electrolyte

temperature excursion at the cells. Obviously, it is also highly desirable to integrate such

abovementioned information into one overall management system, along with other

important plant information such as that provided by material handling machinery, process

control systems, on-line analysers and laboratory. Such a management system provides

transparency for operations through real-time production efficiency and quality reporting

and material tracking. Practical benefits of utilizing such systems are described and

illustrated with case examples.


ER16

TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE

PRECIPITATION

Jimmy Bidwell, Luis G. Navarro, Weldon Read, Tracy Morris

ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108

ABSTRACT

The liberator cells department at Amarillo Copper Refinery has the objective of

reducing metal impurities in the copper electrolyte to achieve high quality cathodes via

electrowining. Insoluble lead anodes are used and the copper is depleted from the

electrolyte and then electrodeposited to copper starter sheets.

After the electrowinning process, the decopperized electrolyte solution is sent to the

Acid Purification Unit (APU®), where sulfuric acid and arsenic are absorbed into the resin

and then desorbed using water which is then returned to the tankhouse to be reused as acid

make up and to increase arsenic concentration in the electrolyte. During this process, the

APU generates a byproduct stream that is high in nickel and other valuable metals that can

be further processed and the metals recovered.

This paper discusses how it is possible to precipitate a Nickel Carbonate product

when the de-acidified electrolyte is treated using sodium carbonate. The pH selective, 2-

step process first recovers copper still present in the solution and transforms it into a

product that can be processed and further recovered at the Hayden Smelter in Arizona.


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: [email protected] (Takahito KASLNO)

ABSTRACT

Electrolytic copper contains, on average, 10 ppm silver as impurity, which leads to a

loss of silver as a cash-cow product for copper smelters. Most of silver included in blister

copper anodes passes into anode slime when electrolyzed, keeping the elemental state.

However, once a part of elemental silver oxidatively-dissolves from the anode or from

anode slime for some reason, then silver can co-deposit with electrolytic copper cathode,

since silver is nobler than copper. In the present work, the dissolution behavior of silver

from anode slime was examined using granular silver as a model of the slime.

We have shown that the silver dissolution is caused by dissolved oxygen in the

electrolyte, and that thiourea and/or chloride ions as usual additives play a role to suppress

the silver dissolution approximately to half. Moreover, it was found that the dissolution of

silver was almost perfectly suppressed by galvanic contacting of the granular silver with

less noble metals (Pb or Cu) immersed in the same electrolyte.


ER19

RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY

Masaomi Kanazawa, Akira Ueno, Kimihiro Shimokawa

Saganoseki Smelter & Refinery Pan Pacific Copper Co., Ltd. Japan Tel 81-97-575-3555,

Fax 81-97-575-3513 [email protected] Address, postcode: 879-2201, 3-3382

Saganoseki Oita-shi, Oita, Japan

ABSTRACT

Saganoseki Refinery of Pan Pacific Copper Co., Ltd. integrated three existing

tankhouses into two by introducing the Waxless ISA type permanent cathode process in

2006. To achieve the higher current efficiency and better cathode quality at current density

over 300 A/m2, the electrolyte filtering system was introduced to remove the suspended

solids (S.S) in the electrolyte in 2009.

The additives continuous feeding system, jointly developed with Taman° Refinery

of Hibi Kyodo Smelting Co., Ltd., has been installed in 2011, achiving over 97% current

efficiency at 311A/m2 current density. Several improvements were also executed to ensure

the steady operation and to increase the productivity. Owing to the improvements,

Saganoseki Refinery currently continues the stable and efficient operation with maintaining

the adequate cathode quality. This paper describes the outlines of improvements as well as

the current operational status.


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 [email protected] TEL: +81-246-54-4841 FAX: +81-246-53-3951

Tetsuro Sakai

Managing Director & General Manager Onahama Smelter & Refinery Onahama Smelting

and Refinery Co, Ltd e-mail: tesakaigmmc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-

3951

ABSTRACT

Since 2007, Onahama Smelter and refinery has operated the 0-SR process which

comprises the S-furnace of the Mitsubishi process is followed by two hearths of

reverberatory furnaces in order to increase the capacity of copper concentrates. Such

enhancement at the smelter requested the tank-houses to increase the productivity more

than 25% coping with impurities load of electrolyte. The productivity has been enhanced by

increasing current density which reinforced rectifiers of No.1 and No.2 tank-houses, and

have supplied and increasing the number of daily operation cells by 25%. Impurities in

electrolyte have been managed by resuming the operation of the secondary liberator cells

and controlling impurities load of the electrolyte. Furthermore,


ER23

ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE

WORLD'S FIRST COMMERCIAL ELECTROREFINERY

A.E. Wraith*,

Consultant, Exeter, UK.

P.J. Mackey,

P.J. Mackey Technology Inc., Kirkland QC, Canada.

R. Protheroe Jones,

National Museum of Wales, Swansea, UK.

ABSTRACT

It is well known that the world’s first copper electro-refinery started production in

1869 at Pembrey in South Wales. Built within the Pembrey Copper Smelter which had

commenced operations in 1849, the new refinery was based on principles described in the

British patents issued to J.B. Elkington in 1865 and 1869. Refining principles and practices

pioneered there were key to the foundation of modern electro-refining practice in what is

now a dominant international industry producing 14 Mt of electrical grade copper annually.

This paper explores the background to this pioneering application of the new, early 19th

century, science of “electro-metallurgy” and examines its links to the contemporary

decorative electro-plating industry and to the shortcomings of 19th century fire refining.

The beginnings and early years of the Pembrey electrorefinery are briefly discussed in

relation to the quality, applications and pyrometallurgy of copper at the time. Elkington’s

ideas and the commissioning of the Pembrey refinery can now be recognised as vital

precursors of the modern electrical age.


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


Magna, UT 84044

[email protected]

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.

mailto:[email protected]


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

[email protected]

ABSTRACT

ISA 2000 Refinery was put into operation on July 2008 with design capacity of 180

000 tons copper cathodes per year. Refinery includes two electrolyte circulation systems

and Deep electrolyte decopperization section. Final treatment of the bleed electrolyte is

performed in Waste Water Treatment Plant.

As permanent cathodes are used SS blanks. Between both electrolyte circulation

systems there are situated Anode Preparation machine, Full Deposit Stripping machine and

Anode Scrap Washing machine. Control of each machine is made by its own control panel.

The building of the Refinery is divided into two bays. In each bay one completely

automated overhead crane “Single bale – Single lift system” operates.

During past years Refinery’s capacity was increased up to 231 000 tons of cathodes

per year through adjustment and improvement of technological process and its parameters

as a whole, without any investments.


ER31

STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)

Rodrigo Abel Fuentes*, Isabel Venegas Fuentes**, Cristian Cortés Egaña***, Luis

Felipe Ramirez****

*Senior Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].

**Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].

***Refinery Superintendent, Ventanas Refinery, Codelco

Chile,[email protected].

**** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS),

[email protected]

ABSTRACT

Most SXEW and Refineries currently use permanent stainless steel cathodes.

However, there are refineries and SxEw operations that use starter sheets/traditional

cathodes technology: In Chile, Ventanas and Salvador Refineries; in Peru, Ilo Refinery and

Cerro Verde’s SxEw plant; several in EEUU and Mexico, ASARCO’s Amarillo Refinery

among them. They require copper starter sheets for their final cathode harvesting.

Stripping starter sheets manually is boring, tiring, unsafe and may produce lower

quality sheets which impacts directly in the quality of commercial cathodes and therefore in

operator revenue.

MIRS designed and developed a Starter Sheet Robotic Stripping Machine (SSRSM)

focusing in improving safety and occupational health and reduce hazards in the process.

The patented method and separation device also improves the quality of starter sheets.

In a standard Layout 4 robotic arms interact in the system: the input robot picks

each cathode from a conveyor and places it in the stripping station; 2 stripping robots strip

each sheet and the output robot picks the empty plate from the stripping station and places

it in the output conveyor. This robot also handles rejects and blank reposition.

One MIRS’ SSRSM was commissioned at Ventanas during 2011. An industrial test

was carried out whose objective was to demonstrate functionality to strip in typical

operating conditions. Test results were: capacity 160 plates per hour and stripping

performance higher than 98%.






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-BRX-

TECHNOLOGY

Stefan Konetschnik(1)

, Andreas Filzwieser(1)

, Iris Filzwieser(1)

and Andreas Anzinger(2)

(1) METTOP GmbH

Peter-Tunner-Strasse 4

8700 Leoben

Austria

(2) Montanwerke Brixlegg AG

Werkstrasse 1

6230 Brixlegg

Austria

ABSTRACT

In 2011, the first two electrorefining tankhouses using the METTOP-BRX-

Technology went into operation – one producing cathodes out of ore and one out of

secondary raw material. Both tankhouses show the possibility of achieving Grade A

cathodes at a current density of more than 400 A/m² while maintaining a current efficiency

of 97.0 – 98.5 per cent.

After almost two years of operation it is now possible to directly compare the costs

of the two-part tankhouse of Montanwerke Brixlegg AG. While half of the tankhouse is

operated at standard current density, the other half is equipped with the METTOP-BRX-

Technology.

Basis of the technology is an optimized electrolyte feed system in each electrolytic

cell. Even though the higher current density is directly proportional to the consumption of

electrical energy, the overall operational expenditures keep the same due to the lower costs


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 Ingeniería Ltda., Chile

[email protected]

ABSTRACT

When an electric current flow is present in an electrolysis cell, it follows that the

cell potential, CellE , achieved is equivalent to the voltage difference of the theoretical

thermodynamic equilibrium resulting from the anode and cathode reactions, EqE , plus the

algebraic sum of the terms that reflects the inertia of the reactions involved, normally called

electrode overpotential, ca , plus a resistive term in solution, IRe· , and finally plus the

resistive term due to the external electric circuit, System losses.

Losses in the external electric circuit refer mainly to the Joule effect due to the flow

of current through the conductors. Indeed, intercell bars, also called intercell busbars, work

at an average temperature of 70 to 90 °C, and in short circuit the temperature can go up to

200 °C and higher.

Our CoolBar (WIPO International Patent pending), which has a higher current

conductivity compared to presently used regular intercell bars, will decrease the cell

potential by 2% to 7%, decreasing the specific energy consumption, SEC, by an equivalent

amount. In addition, the Coolbar optimizes the use of thermal energy in the electrolytic

plant by allowing better current flow distribution in the cell, causing a significant drop in

the carbon footprint of the electrolytic process.

Finally, an existing intercell bar can be easily replaced in situ by a Coolbar by just

placing the latter over the cell capping board and making a few small adjustments.



ER54

DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS

AT AURUBIS, HAMBURG USING EMEW® ELECTROWINNING TECHNOLOGY

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

(GCT)

ABSTRACT

A series of on-site trials were conducted at Aurubis AG, Hamburg refinery using EMEW

electrowinning to remove copper from the liberator solution in high quality form with no arsine

emission. The liberator solution at Aurubis Hamburg works is particularly difficult to process as

it contains high acid concentration of 350-400 g/l and other impurities such as chloride (60ppm)

and arsenic 20 g/l. The results of the test program confirm that harvestable copper cathode can

be produced at copper concentrations below 1 g/l with low arsenic content such that arsenic in air

or solid emissions is eliminated.

The data from the series of trials over a range of copper concentrations from 1-8 g/l and

200-450 A/m2 enables an operating curve to produce solid copper product at various copper

concentrations in solution. Operating current efficiency averaged 93% (DC) which confirms

significant power savings in addition to handling and process cost savings.


ER59

REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS®

SYSTEM. LABORATORY INVESTIGATION

J.P. Ibáñez1, S. Cortés

1, P. Suarez

2, A. Labra

2, A. Moyano

3

1 Department of Metallurgical Engineering and Materials -Universidad Técnica Federico

Santa María ([email protected]) 2 Innovaxxion Spa

3 Codelco Chile - División Chuquicamata

ABSTRACT

A new system for reducing the anode scrap in a conventional electro-refining plant

was investigated at laboratory scale. The new system called Earless® is based in the use of

anodes without ears, which are easily mounted in an ad-hoc designed case that provides the

electrical contacts and transportation capability.

Experimental work was carried out to make a critical comparison of the electro-

refining behavior between a typical anode and two types of anodes in the Earless® system.

All the anodes (cathodic copper) and cathodes (stainless steel) were made in a scale of 1:10,

and were processed under the same experimental conditions of current density, anodic

cycle period, electrolyte temperature, electrolyte flow rate and synthetic electrolyte

composition.

The main results indicate that was possible to reach a reduction of the scrap

generation from around 20% (traditional anode) to around 10% (anode in the Earless®

system), all the cathodes obtained having the same quality and furthermore a significant

decrease of the specific energy consumption higher than 20% was observed as well.


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. Cortés, E. Bahamondes and N. Cornejo

Codelco, Ventanas Division

Carretera F-30 E 58270

Ventanas, Puchuncaví

Chile

[email protected]; [email protected]; [email protected]

ABSTRACT

The Electrolytic Refinery of the Ventanas Division in recent years the Refinery has

focused on improving the productivity of its installation through a series of highly creative

initiatives requiring low-cost investments, in order to reinforce the competitiveness of the

Refinery in an increasingly complex business environment. In this context, during the last

four years, projects such as the "Electrode Optimization in Electrolytic Cells" and the

"High Current Density Stripper Circuits Operation" have been carried out.

The project "Electrode Optimization in Electrolytic Cells Phase II" consisted in

reducing the anode spacing to 100 mm, increasing the number of electrodes per cell and

maintaining the current density at 305 A/m2. The project "Stripper circuit operation with

high current density " consisted of reducing the starting sheet production cycle, operating at

a current density of 330 A/m2. Another prominent change of practices implemented in

2009 was the closure of the electrolyte purification plant, owing to the high cost of the

process, which established new trade opportunities by selling the electrolyte to third parties.

This has resulted in a dramatic change in managing impurities’ control, as well as, in new

improvements. The combination of these projects of improving and changing the practices

resulted in the production of 401,500 t of electrolytic copper in the year 2011.



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

[email protected]

ABSTRACT

In copper electrorefining additives are used for a smooth electrodeposition of

copper cathodes. The classical additives glue and thiourea show some disadvantages like

the relatively fast decomposition during electrolysis and the incorporation of sulfur from

thiourea into the cathodes. Only new additive systems avoiding thiourea can help to reduce

the sulfur content in the copper cathodes. Additionally the decomposition of glue and

thiourea forces a continuous dosing of the additives.

Our investigations show that alternative additives can be used in copper

electrorefining indeed. Polyethylene glycols (PEG) act strongly polarizing and can

substitute glue. Current density potential curves show that Bis-(3-sodiumpropyl)disulfide

(SPS), dimethylthiourea, methionin and cystein have a stronger depolarizing effect

compared to thiourea.

Electrolysis experiments with PEG and SPS proceeded without short circuits at a

current density of 500 A/m². However, the cathodes were rough and nodulous. Smoother

cathodes were produced when using glue and thiourea or glue and SPS. In the first case the

sulphur concentration in the cathodes ranged from 4 to 10 µg/g and in the second case only

from 0.3 to 1.5 µg/g. SPS is considerably more stable than thiourea. Thus, there is no need

for continuous addition during electrolysis.



ER63

COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH

CURRENT DENSITY

Songlin Zhou

Xiangguang Copper Co., Ltd

No.1 Xiangguang Road

Shifo Town, Yanggu County, 252327, China

ABSTRACT

This paper introduces the Parallel Flow Device (PFD) technology and production

practices for high current density copper electrolytic refining. The technology has been

successfully implemented for the first time on a large industrial scale, enabling the copper

electrolysis current density to reach 420 A/m², thereby substantially increasing copper

electrolytic productivity. Through this technology, a new level in copper electrolytic

refining has been achieved.


ER66

A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE

EXTRACTION OF ANTIMONY

Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Zúñiga (3)

(1) codelco chile, división chuquicamata, e-mail: [email protected] .

(2) departamento de ingeniería metalúrgica, facultad de ingeniería, universidad de

santiago de chile, santiago, chile.

(3) departamento de ingeniería química, facultad de ingeniería, universidad de santiago de

chile, santiago, chile.

ABSTRACT

An ion exchange pilot plant, located at the University of Santiago of Chile, was

tested for antimony control in the electrolyte of Chuquicamata Refinery. In the pilot plant

were used three different resins: MX-2, UR-3300S and Duolite C-467. The results showed

that the best behavior for antimony extraction follow the sequence UR3300S >Duolite C

467 > MX 2. A model with the experimental results was used as comparative tools to

increase the knowledge of this process.


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

[email protected]

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 Morris

1, Weldon Read

1, Neil E. Izatt


2, and

Steven R. Izatt2,

1Asarco

7001 State Highway 136

Amarillo, Texas 79106, U.S.A.

2IBC Advanced Technologies, Inc.

856 E. Utah Valley Drive,

American Fork, Utah 84003, U.S.A.

ABSTRACT

An effective removal system for the separation of dissolved bismuth from copper

electrolyte to reach desired bismuth levels has been developed by IBC Advanced

Technologies, Inc (IBC). This system is being operated at ASARCO in Amarillo, Texas to

produce high purity electrolytic copper. Control of bismuth concentration is necessary

because bismuth levels exceeding 2 ppm in the final copper product result in brittleness

making the product unsuitable for wire production. The bismuth removal system is based

on IBC’s Molecular Recognition Technology (MRT) process.

This process employs proprietary non-ion exchange resin materials, termed

SuperLig®, to effect the separation. Key benefits of the MRT process for bismuth removal

include (1) easy control of the bismuth levels in the tank house electrolyte, (2) avoidance of

brittle copper, and (3) flexibility to handle “dirty” copper concentrates as feedstock. This

paper describes the bismuth MRT plant at the Asarco refinery, the operating process, and

the results. Limitations of alternate technologies for bismuth control are discussed,

particularly with respect to their environmental concerns compared to the MRT

process. Benefits of the MRT system to copper refineries where bismuth problems exist

are presented.


EW03

SELE® MODULAR TECHNOLOGY FOR SUSTAINABLE DEVELOPMENT AND

EFFICIENT EW PLANT

P.A. Aylwin and N.I. Lagos

New Tech Copper SpA

3397 Exequiel Fernández

Macul, Santiago, Chile

[email protected]

ABSTRACT

Sustainable development is an evolving concept that emerged in the 1980’s in

response to a growing realisation of the need to balance economic and social progress with

concern for the environment and the stewardship of natural resources. The idea has been

defined as using, conserving and enhancing the community’s resources so that ecological

processes on which life depends, are maintained, and the total quality of life, now and in

the future, can be increased. This paper proposes a framework for sustainability indicators

for EW industry in an attempt to further contribute to this on-going work and it compares

qualitatively the SELE Technology against the conventional technology, showing as an

example on the studies that must carry on in accordance to measure the sustainable

development.


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 FCX’s Safford and

Morenci plants with assistance from FMI management and operating personnel. This paper

includes the latest observations and outcomes from these two plants. It also describes the

latest developments for this exciting technology that have been implemented for

electrowinning and electrorefining plant applications.


EW06

CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER

ELECTROREFINING

Jari Aromaa, Antti Kekki, Olof Forsén

Aalto University

Department of Materials Science

PO Box 16200

00076 Aalto

Espoo, FINLAND

ABSTRACT

The AISI 316L type stainless steel is considered corrosion resistant in copper

electrorefining electrolyte, both as permanent cathode blank material and in process

equipment and piping. Damaged cathode blanks show increased surface roughness,

corrosion pits and deeper grain boundaries. The test hypothesis was that too high chloride

concentration and temperature can cause localized corrosion.

A synthetic electrolyte with 180 g/l H2SO4, 45 g/l Cu, 15 g/l Ni and 10 g/l As was

used. Test variables were temperature 50-70 oC and chloride concentrations from 40 ppm to

1000 ppm. Test method was cyclic polarization curve based on ASTM standard G61-86.

No pitting or crevice corrosion was seen in the test series but highest chloride

concentration resulted in wider active peak and higher passive current densities. In

transpassive corrosion tests localized corrosion on grain boundaries and detachment of

grains was seen. Two main possibilities for blank corrosion have been identified. High

chloride concentration can cause active dissolution. The concentration of chlorides has to

be at least 10 times higher than the normal chloride level. Polarization to transpassive

potentials causes corrosion on grain boundaries and detachment of grains. The only

possibility for transpassive dissolution is stray currents.


EW07

GLOBAL SURVEY OF COPPER ELECTROWINNING OPERATIONS AND

PRACTICES

Michael Moats

Associate Professor of Metallurgical Engineering,

Materials Research Center


Missouri University of Science and Technology

Rolla, MO 65409, U.S.A.

[email protected]

Tim Robinson


Republic Alternative Technologies, Inc.

11288 Alameda Dve

Strongsville, OH 44149, U.S.A.

[email protected]

Shijie Wang

Princple Advisor – Process Engineering

Rio Tinto - Kennecott Utah Copper


Magna, UT 84044, U.S.A.

[email protected]

Andreas Filzwieser

Info

Andreas Siegmund


Gas Cleaning Technologies (GCT) LLC

4953 N. O’Connor Road

Irving, TX 75062 U.S.A

[email protected]

William Davenport

Professor Emeritus


University of Arizona

Tucson, AZ 85721, U.S.A.

[email protected]


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 UMMC’S

(URALELECTROMED) NEW COPPER ELECTRO REFINERY

Shuklin, M.A., Romanov, A.A, Bakhirov, N.Y

JSC Uralelektromed

1 Lenin str., Verkhnyaya Pyshma,

Sverdlovsk region, 624091, Russia

Phone +7 (34368) 4 71 38, 4 61 22

Fax: +7 (34368) 4 60 99, 4 26 26

Larinkari,M., Hukkanen, R.


Riihitontuntie 7D (P.O Box 84)

02201, Espoo, Finland

Phone +358 20 529 211

Fax: +358 20 529 2200

ABSTRACT

A modern tankhouse relies on high performance material handling, fully automated

process control systems, quality assessment data and consistent operations reporting to

ensure high efficiency of operation and stable quality of final product. In 2012, Outotec’s

and Uralelectromed’s specialists have developed comprehensive tankhouse process

automation solution called Tankhouse Information Management System (TIMS), which has

been implemented at UMMC’s (“Uralelektromed”) new 150 tpa copper electro refinery in

Verkhnyaya Pyshma, Russia.

TIMS collects process data from different systems and material handling equipment

into a central database, providing material tracking and process key performance indicator

calculations. TIMS automates daily production reporting and provides various analytical

views of the process which can be used at higher level in business control systems.

As a result an essential part of the new tankhouse operation information is provided

by TIMS. Systematic and accurate reporting is based on real-time information which

requires minimal manual work by the personnel. Gained benefits are increased visibility


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. Ríos, R. Ramírez, C. Arbizu, I. Ruiz,

Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold)

Av. Francisco Montenegro, s/n

21001 Huelva, Spain

ABSTRACT

Approximately 160 m3/day of electrolyte bleed from the Atlantic Copper Refinery

Tankhouse is sent daily to the Electrolyte Treatment Plant to control the copper content and

impurities (As, Sb and Bi) in the electrolyte. Much of the solution leaving the 3rd stage

liberator circuit is returned to the tankhouse, but a small portion (~28 m3/day) is bled to the

weak acid neutralization plant for minor element control (Fe, Ca). Laboratory and pilot

scale tests have been carried out in order to recover the nickel from this bled solution as

nickel carbonate, using different ion exchange resins technologies. Based on the excellent

results obtained from these tests, Atlantic Copper decided to build a nickel carbonate

production plant, which is expected to be commissioned in February 2013. ECOTEC

Recoflo technology has been chosen for removing the sulphuric acid from the feed

solution.Once the acid is removed, then, through a neutralization process, it is possible first,

to purify the electrolyte and then, to precipitate nickel as nickel carbonate.


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

[email protected]

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


ABSTRACT

Optimizing the operations efficiency and cathode quality of a tankhouse requires not

only the efficient use of energy and labor, but also high availability of machinery and the

ability to rapidly observe and react to disturbances. With the use of proven innovative on-

line monitoring and information management systems now available in the market

parameters such as efficiency, productivity and quality can be assessed in real-time mode.

Some of the systems discussed in the paper include systematic surface quality inspection of

anodes and cathodes and permanent cathode condition.

Another system indicates cell performance on-line, facilitating early reaction to

critical events such as short-circuiting, flow blockages, anode passivation or electrolyte

temperature excursion at the cells. Obviously, it is also highly desirable to integrate such

abovementioned information into one overall management system, along with other

important plant information such as that provided by material handling machinery, process

control systems, on-line analysers and laboratory. Such a management system provides

transparency for operations through real-time production efficiency and quality reporting

and material tracking. Practical benefits of utilizing such systems are described and

illustrated with case examples.


EW15

SMALL COLUMN TESTING OF SUPERLIG® 83 FOR BISMUTH REMOVAL

FROM COPPER ELECTRO REFINING ELECTROLYTE

Luis G. Navarro

1, Weldon Read

1, Tracy Morris

1, Jimmy Bidwell


2,

Neil E. Izatt2

1ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108

2IBC Advanced Technologies, Inc, 856 E. Utah Valley Drive, American Fork, Utah 84003

ABSTRACT

The removal of Bismuth from Copper electro refining electrolyte using SuperLig ®

83 was studied in a small column with a resin bed volume of 150mL. Several loading and

elution cycles were performed. The research showed that no considerable loading

performance variability was observed between the first loading cycles and a high selectivity

for removing Bismuth was also achieved. The Bismuth elution was sharp and rapid and

accomplished with small bed volumes of 9M Sulfuric Acid.

The Superlig® 83 showed a propensity to amass small amounts of Pb and Sb

making it necessary to perform a 6M HCl wash to elute these elements and regain the initial

capacity of the Superlig® 83 without any considerable detriment.


EW16

TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE

PRECIPITATION

Jimmy Bidwell, Luis G. Navarro, Weldon Read, Tracy Morris

ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108

ABSTRACT

The liberator cells department at Amarillo Copper Refinery has the objective of

reducing metal impurities in the copper electrolyte to achieve high quality cathodes via

electrowining. Insoluble lead anodes are used and the copper is depleted from the

electrolyte and then electrodeposited to copper starter sheets.

After the electrowinning process, the decopperized electrolyte solution is sent to the

Acid Purification Unit (APU®), where sulfuric acid and arsenic are absorbed into the resin

and then desorbed using water which is then returned to the tankhouse to be reused as acid

make up and to increase arsenic concentration in the electrolyte. During this process, the

APU generates a byproduct stream that is high in nickel and other valuable metals that can

be further processed and the metals recovered.

This paper discusses how it is possible to precipitate a Nickel Carbonate product

when the de-acidified electrolyte is treated using sodium carbonate. The pH selective, 2-

step process first recovers copper still present in the solution and transforms it into a

product that can be processed and further recovered at the Hayden Smelter in Arizona.


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: [email protected] (Takahito KASLNO)

ABSTRACT

Electrolytic copper contains, on average, 10 ppm silver as impurity, which leads to a

loss of silver as a cash-cow product for copper smelters. Most of silver included in blister

copper anodes passes into anode slime when electrolyzed, keeping the elemental state.

However, once a part of elemental silver oxidatively-dissolves from the anode or from

anode slime for some reason, then silver can co-deposit with electrolytic copper cathode,

since silver is nobler than copper. In the present work, the dissolution behavior of silver

from anode slime was examined using granular silver as a model of the slime.

We have shown that the silver dissolution is caused by dissolved oxygen in the

electrolyte, and that thiourea and/or chloride ions as usual additives play a role to suppress

the silver dissolution approximately to half. Moreover, it was found that the dissolution of

silver was almost perfectly suppressed by galvanic contacting of the granular silver with

less noble metals (Pb or Cu) immersed in the same electrolyte.


EW19

RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY

Masaomi Kanazawa, Akira Ueno, Kimihiro Shimokawa

Saganoseki Smelter & Refinery Pan Pacific Copper Co., Ltd. Japan Tel 81-97-575-3555,

Fax 81-97-575-3513 [email protected] Address, postcode: 879-2201, 3-3382

Saganoseki Oita-shi, Oita, Japan

ABSTRACT

Saganoseki Refinery of Pan Pacific Copper Co., Ltd. integrated three existing

tankhouses into two by introducing the Waxless ISA type permanent cathode process in

2006. To achieve the higher current efficiency and better cathode quality at current density

over 300 A/m2, the electrolyte filtering system was introduced to remove the suspended

solids (S.S) in the electrolyte in 2009.

The additives continuous feeding system, jointly developed with Taman° Refinery

of Hibi Kyodo Smelting Co., Ltd., has been installed in 2011, achiving over 97% current

efficiency at 311A/m2 current density. Several improvements were also executed to ensure

the steady operation and to increase the productivity. Owing to the improvements,

Saganoseki Refinery currently continues the stable and efficient operation with maintaining

the adequate cathode quality. This paper describes the outlines of improvements as well as

the current operational status.


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 [email protected] TEL: +81-246-54-4841 FAX: +81-246-53-3951

Tetsuro Sakai

Managing Director & General Manager Onahama Smelter & Refinery Onahama Smelting

and Refinery Co, Ltd e-mail: tesakaigmmc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-

3951

ABSTRACT

Since 2007, Onahama Smelter and refinery has operated the 0-SR process which

comprises the S-furnace of the Mitsubishi process is followed by two hearths of

reverberatory furnaces in order to increase the capacity of copper concentrates. Such

enhancement at the smelter requested the tank-houses to increase the productivity more

than 25% coping with impurities load of electrolyte. The productivity has been enhanced by

increasing current density which reinforced rectifiers of No.1 and No.2 tank-houses, and

have supplied and increasing the number of daily operation cells by 25%. Impurities in

electrolyte have been managed by resuming the operation of the secondary liberator cells

and controlling impurities load of the electrolyte. Furthermore,


EW22

CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT SHORT

CIRCUITS

Robert P. Dufresne

ABSTRACT

It’s now possible to operate entire Electrowinning or Electrorefining processing

plants Without Short Circuits. Research in the design of capping boards and contact system

calculations have been integrated and synchronized to create entire sections of refinery’s

that are devoid of even the possibility of short circuits. This design is adaptable to every

type of contact system in the industry, including symmetrical and non-symmetrical

electrodes and single, double, triple or quadruple contact bars on the same insulator. Our

Without Short Circuit systems’ capping board design guarantees your production rates

during the stripping process are fully maintained. Symmetrical electrode capping boards

have been successfully redesigned into a Single bus bar insulator. Mechanical strength

studies and simulations of electrical fluidity have been performed, using CAD 3D

technology, to optimize efficiency of the electric current within the contact system - which

incorporated into the Without Short Circuit design - reduces resistivity compared to

existing contact systems. Research has yielded a chemical formulation that resists sulphuric

acid concentrations above 80%. Our standard bus bar insulators are considered permanent,

with operational lifetimes of up to 20 years or more with no maintenance and without

increasing sulphatation during refining.


EW23

ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE

WORLD'S FIRST COMMERCIAL ELECTROREFINERY

A.E. Wraith*,

Consultant, Exeter, UK.

P.J. Mackey,

P.J. Mackey Technology Inc., Kirkland QC, Canada.

R. Protheroe Jones,

National Museum of Wales, Swansea, UK.

ABSTRACT

It is well known that the world’s first copper electro-refinery started production in

1869 at Pembrey in South Wales. Built within the Pembrey Copper Smelter which had

commenced operations in 1849, the new refinery was based on principles described in the

British patents issued to J.B. Elkington in 1865 and 1869. Refining principles and practices

pioneered there were key to the foundation of modern electro-refining practice in what is

now a dominant international industry producing 14 Mt of electrical grade copper annually.

This paper explores the background to this pioneering application of the new, early 19th

century, science of “electro-metallurgy” and examines its links to the contemporary

decorative electro-plating industry and to the shortcomings of 19th century fire refining.

The beginnings and early years of the Pembrey electrorefinery are briefly discussed in

relation to the quality, applications and pyrometallurgy of copper at the time. Elkington’s

ideas and the commissioning of the Pembrey refinery can now be recognised as vital

precursors of the modern electrical age.


EW24

IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR

CONTACTS?

Michael J Nicol and Justin McGinnity


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


Magna, UT 84044

[email protected]

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 sea-

island hybrid structure.

This novel anode gives some excellent properties for use in copper electrowinning.

Oxygen evolution on the anode occurs at a low overpotential so that the cell voltage of Cu

EW is much reduced by 700 mV compared to lead alloy anodes and is 100 mV lower than

the oxide coated titanium anodes with amorphous IrO2. Some unwanted side reactions such

as depositions of PbO2 or manganese oxide are suppressed on the anode, which usually

occurs on lead alloy anodes. This smart anode is produced by Republic Alternative Tech.

(Ohio, USA) under the patent licensing from Doshisha University (Kyoto, Japan) and is

under commercialization with the registered trademark, MSA®.


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

[email protected]

ABSTRACT

ISA 2000 Refinery was put into operation on July 2008 with design capacity of 180

000 tons copper cathodes per year. Refinery includes two electrolyte circulation systems

and Deep electrolyte decopperization section. Final treatment of the bleed electrolyte is

performed in Waste Water Treatment Plant.

As permanent cathodes are used SS blanks. Between both electrolyte circulation

systems there are situated Anode Preparation machine, Full Deposit Stripping machine and

Anode Scrap Washing machine. Control of each machine is made by its own control panel.

The building of the Refinery is divided into two bays. In each bay one completely

automated overhead crane “Single bale – Single lift system” operates.

During past years Refinery’s capacity was increased up to 231 000 tons of cathodes

per year through adjustment and improvement of technological process and its parameters

as a whole, without any investments.


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. O’Connor Blvd.

Irving, TX 75062

[email protected]

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 Cortés Egaña***, Luis

Felipe Ramirez****

*Senior Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].

**Process Engineer, Ventanas Refinery, Codelco Chile, [email protected].

***Refinery Superintendent, Ventanas Refinery, Codelco

Chile,[email protected].

**** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS),

[email protected]

ABSTRACT

Most SXEW and Refineries currently use permanent stainless steel cathodes.

However, there are refineries and SxEw operations that use starter sheets/traditional

cathodes technology: In Chile, Ventanas and Salvador Refineries; in Peru, Ilo Refinery and

Cerro Verde’s SxEw plant; several in EEUU and Mexico, ASARCO’s Amarillo Refinery

among them. They require copper starter sheets for their final cathode harvesting.

Stripping starter sheets manually is boring, tiring, unsafe and may produce lower

quality sheets which impacts directly in the quality of commercial cathodes and therefore in

operator revenue.

MIRS designed and developed a Starter Sheet Robotic Stripping Machine (SSRSM)

focusing in improving safety and occupational health and reduce hazards in the process.

The patented method and separation device also improves the quality of starter sheets.

In a standard Layout 4 robotic arms interact in the system: the input robot picks

each cathode from a conveyor and places it in the stripping station; 2 stripping robots strip

each sheet and the output robot picks the empty plate from the stripping station and places

it in the output conveyor. This robot also handles rejects and blank reposition.

One MIRS’ SSRSM was commissioned at Ventanas during 2011. An industrial test

was carried out whose objective was to demonstrate functionality to strip in typical

operating conditions. Test results were: capacity 160 plates per hour and stripping

performance higher than 98%.






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-BRX-

TECHNOLOGY

Stefan Konetschnik(1)

, Andreas Filzwieser(1)

, Iris Filzwieser(1)

and Andreas Anzinger(2)

(1) METTOP GmbH

Peter-Tunner-Strasse 4

8700 Leoben

Austria

(2) Montanwerke Brixlegg AG

Werkstrasse 1

6230 Brixlegg

Austria

ABSTRACT

In 2011, the first two electrorefining tankhouses using the METTOP-BRX-

Technology went into operation – one producing cathodes out of ore and one out of

secondary raw material. Both tankhouses show the possibility of achieving Grade A

cathodes at a current density of more than 400 A/m² while maintaining a current efficiency

of 97.0 – 98.5 per cent.

After almost two years of operation it is now possible to directly compare the costs

of the two-part tankhouse of Montanwerke Brixlegg AG. While half of the tankhouse is

operated at standard current density, the other half is equipped with the METTOP-BRX-

Technology.

Basis of the technology is an optimized electrolyte feed system in each electrolytic

cell. Even though the higher current density is directly proportional to the consumption of

electrical energy, the overall operational expenditures keep the same due to the lower costs


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 Ingeniería Ltda., Chile

[email protected]

ABSTRACT

When an electric current flow is present in an electrolysis cell, it follows that the

cell potential, CellE , achieved is equivalent to the voltage difference of the theoretical

thermodynamic equilibrium resulting from the anode and cathode reactions, EqE , plus the

algebraic sum of the terms that reflects the inertia of the reactions involved, normally called

electrode overpotential, ca , plus a resistive term in solution, IRe· , and finally plus the

resistive term due to the external electric circuit, System losses.

Losses in the external electric circuit refer mainly to the Joule effect due to the flow

of current through the conductors. Indeed, intercell bars, also called intercell busbars, work

at an average temperature of 70 to 90 °C, and in short circuit the temperature can go up to

200 °C and higher.

Our CoolBar (WIPO International Patent pending), which has a higher current

conductivity compared to presently used regular intercell bars, will decrease the cell

potential by 2% to 7%, decreasing the specific energy consumption, SEC, by an equivalent

amount. In addition, the Coolbar optimizes the use of thermal energy in the electrolytic

plant by allowing better current flow distribution in the cell, causing a significant drop in

the carbon footprint of the electrolytic process.

Finally, an existing intercell bar can be easily replaced in situ by a Coolbar by just

placing the latter over the cell capping board and making a few small adjustments.



EW35

ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS

ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL DIVISION

Francisco Sánchez Pino

Codelco Chile, Gabriela Mistral Division, Calama, Chile, Innovation and Technology

Superintendent, 56-55-328576, [email protected].

ASBTRACT

For our objective of promoting continuous improvement of processes, the

application of electrolyte soft aeration technology has been evaluated since 2009, focused

on quality improvement of cathode production; a pilot testing program culminated, after 3

month, with excellent metallurgical results and data that justified the investment to equip

the 504 Electrowining cells in the Tankhouse.

Soft aeration of the electrolyte inside Electrowining cells contributes to uniform

mass transfer, cinematic viscosity and flow velocity across the entire surfaces of the

cathodes, generating homogenous deposits, without preferential growths, and therefore,

virtually exempt of nodules and short circuits, with enhanced physical and chemical quality

of production, and furthermore, optimizing the efficient use of energy by sustaining in time

electric current efficiencies of 94%, specific consumption of 1.750 kWh/TM of fine copper,

with AR elongation test over 40%, and overall grade A quality copper cathodes above 80%.

The technology implemented homogenizes copper concentration in the "permanent

cathode plate-electrolyte" interphase and uniform migration of copper ions throughout the

deposit surfaces, thus diminishing limit layer thickness.

Electrowining process management is enhanced by allowing cell operation at

current densities above 300 A/m2, enabling 100 kg cathodes to be harvested in less than 6

day cycles.



EW36

AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND

POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE

ROUGHNESS IN COPPER ELECTROWINNING

Tyler Helsten1 and Michael S. Moats

2

1 – University of Utah

2 - Missouri University of Science and Technology

ABSTRACT

Recently, the use of modified polysaccharides and polyacrylamides has been

reported as smoothing agents in commercial copper electrowinning operations. Very little

published data exist on the fundamental behavior of these compounds in copper

electrodeposition. In this study, the polarization behavior and surface roughness of short

term deposits grown in the presence of a modified polysaccharide, a polyacrylamide or a

50/50 mixture of guar and modified polysaccharide in synthetic copper electrowinning

electrolytes are reported. The polyacrylamide demonstrates classical behavior in that

polarization increases with increasing concentration which correlates to a smoother deposit.

The modified polysaccharide and combination of guar and modified polysaccharide did not

exhibit classical behavior in that increasing concentration did not affect polarization but

result in smoother deposits.


EW38

THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING

ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION AND

CATHODE QUALITY.

Tomás Vargas1 and Paz Parra

Department of Chemical Engineering and Biotechnology

Advanced Mining Technology Center (AMTC)

University of Chile, Santiago Chile

ABSTRACT

Dissolved iron present either as ferrous or ferric ions is ubiquitous in electrowining

operations. Its presence arises from undesired incorporation through solvent extraction or

by addition as ferrous ion for reducing purposes. The presence of iron in the electrolyte is

mainly associated to its deleterious effect on current efficiency, which is enhanced if the

electrolyte is somehow stirred. However, the presence of iron in the electrolyte has other

effects which have been somehow overlooked and are not well studied, which could have

some positive influence on the process. The presence of iron as ferric ion helps to

depolarize the cathodic reaction, which can contribute to reduce the voltage drop and

energy consumption in the cell. Also, the presence of dissolved iron interferes with copper

electrocrystallization contributing to reduce the crystal size. The present work analizes

these aspects in detail based on electrochemical studies of the electrokinetics of

ferrous/ferric processes and the electrocrystallization of copper in electrolytes containing

ferrous/ferric ions.


EW53

EXPERIENCIES ON DESIGN, MANUFACTURING AND OPERATION OF HIGH

CONTROLLED TRANSFORMER-RECTIFIERS FOR SX-EW COPPER PLANTS

R Fuentes P Lagos J Estrada R Dunner L Neira

[email protected] [email protected] [email protected] [email protected] [email protected]

IDT SA Avda. Las Parcelas 5490, Estación Central,

Santiago, Chile

ABSTRACT

This paper is focused to Chilean experiences on design, manufacturing,

maintenance and operation of high current controlled rectifiers for copper SX-EW and

refinery plant. It concern with new copper or “greenfield” projects and with the

reengineering of existing transformer-rectifiers or “brownfield” projects.

The extended paper deals with parameters for the design, boundary conditions,

current control, protection criteria, harmonics mitigation, maintenance and spare

components, focusing to the most important requirements of this type of equipment:

reliability and high efficiency. Finally, from the authors experience, this paper recommends

technical specification aspects for the future projects.


EW54

DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS

AT AURUBIS, HAMBURG USING EMEW® ELECTROWINNING TECHNOLOGY

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

(GCT)

ABSTRACT

A series of on-site trials were conducted at Aurubis AG, Hamburg refinery using EMEW

electrowinning to remove copper from the liberator solution in high quality form with no arsine

emission. The liberator solution at Aurubis Hamburg works is particularly difficult to process as

it contains high acid concentration of 350-400 g/l and other impurities such as chloride (60ppm)

and arsenic 20 g/l. The results of the test program confirm that harvestable copper cathode can

be produced at copper concentrations below 1 g/l with low arsenic content such that arsenic in air

or solid emissions is eliminated.

The data from the series of trials over a range of copper concentrations from 1-8 g/l and

200-450 A/m2 enables an operating curve to produce solid copper product at various copper

concentrations in solution. Operating current efficiency averaged 93% (DC) which confirms

significant power savings in addition to handling and process cost savings.


EW55

DE NORA’S SOLUTION – PART I, DSA® ANODES FOR CU

ELECTROWINNING

A. Fiorucci, A. Calderara, L. Iacopetti, F. Timpano, G. Faita, C.W. Brown, Jr., M.H.

Barker and F. Prado (Infotrol).

De Nora - Via Bistolfi, 35 Milan, Italy

Infotrol - C. Ramon y Cajal, 7 MONZON, (Huesca) SPAIN

ABSTRACT

The main stay of industrial electrowinning practice today is based on lead alloy

anodes. De Nora’s advanced R&D combined with over 40 years of expertise & experience

in DSA® anodes for chloride based electrowinning has led to the development of “De

Nora’s Solution” for sulfate based Copper Electrowinning (Cu EW).

In addition to the energy saving, elimination of cobalt from the process, improved

tankhouse operation, De Nora’s Solution will bring extra value to the Cu EW tankhouse - a

custom engineered titanium structure with the latest generation catalytic coating,

breakthrough dendrite mitigation system, simultaneous current & voltage monitoring and

an innovative acid mist abatement system.

This paper will describe De Nora’s rigorous process of testing and validation from

laboratory through to Industrial scale; simulating actual and extreme conditions for stable

operation, performance and longevity before introduction into the tankhouse. Results in

terms of dendrite mitigation, energy saving and cathode quality will be discussed. Acid

mist abatement results will be presented in part II.


EW56

DE NORA’S SOLUTION – PART II, ACID MIST ABATEMENT

A. Fiorucci, A. Calderara, F. Timpano, G. Faita, C.W. Brown, Jr. and M.H. Barker.

De Nora

Via Bistolfi, 35 Milan, Italy

ABSTRACT

Acid mist is an undesirable and costly by-product of copper electrowinning (Cu

EW), damaging to the health of people working in the tankhouse as well as corrosive and

dangerous for all the metal parts in the plant.

De Nora’s mission is to provide safe and environmentally friendly electrochemical

technology. De Nora’s Solution is built around DSA® anodes, with an integrated anode-

frame structure and a permeable separator envelope which captures the acid mist at the

source. De Nora’s Solution thus allows the plant to operate with an unprecedented low

level of atmospheric acid mist, providing extra added value in safer Cu EW tankhouse

operations.

This paper describes the innovative acid mist containment system - an integral part

of De Nora’s Solution - and the related benefits obtained by confining the oxygen micro-

bubbles in an enclosed space. Significant improvement in operating practice, unexplored

areas for costs savings and environmental benefits generated by De Nora’s Solution will

also be presented.


EW57

MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS

Gabriel Zarate,

Anglo American Chile, Santiago, Chile

[email protected]

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)


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. Ibáñez1, S. Cortés

1, P. Suarez

2, A. Labra

2, A. Moyano

3

1 Department of Metallurgical Engineering and Materials -Universidad Técnica Federico

Santa María ([email protected]) 2 Innovaxxion Spa

3 Codelco Chile - División Chuquicamata

ABSTRACT

A new system for reducing the anode scrap in a conventional electro-refining plant

was investigated at laboratory scale. The new system called Earless® is based in the use of

anodes without ears, which are easily mounted in an ad-hoc designed case that provides the

electrical contacts and transportation capability.

Experimental work was carried out to make a critical comparison of the electro-

refining behavior between a typical anode and two types of anodes in the Earless® system.

All the anodes (cathodic copper) and cathodes (stainless steel) were made in a scale of 1:10,

and were processed under the same experimental conditions of current density, anodic

cycle period, electrolyte temperature, electrolyte flow rate and synthetic electrolyte

composition.

The main results indicate that was possible to reach a reduction of the scrap

generation from around 20% (traditional anode) to around 10% (anode in the Earless®

system), all the cathodes obtained having the same quality and furthermore a significant

decrease of the specific energy consumption higher than 20% was observed as well.


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. Cortés, E. Bahamondes and N. Cornejo

Codelco, Ventanas Division

Carretera F-30 E 58270

Ventanas, Puchuncaví

Chile

[email protected]; [email protected]; [email protected]

ABSTRACT

The Electrolytic Refinery of the Ventanas Division in recent years the Refinery has

focused on improving the productivity of its installation through a series of highly creative

initiatives requiring low-cost investments, in order to reinforce the competitiveness of the

Refinery in an increasingly complex business environment. In this context, during the last

four years, projects such as the "Electrode Optimization in Electrolytic Cells" and the

"High Current Density Stripper Circuits Operation" have been carried out.

The project "Electrode Optimization in Electrolytic Cells Phase II" consisted in

reducing the anode spacing to 100 mm, increasing the number of electrodes per cell and

maintaining the current density at 305 A/m2. The project "Stripper circuit operation with

high current density " consisted of reducing the starting sheet production cycle, operating at

a current density of 330 A/m2. Another prominent change of practices implemented in

2009 was the closure of the electrolyte purification plant, owing to the high cost of the

process, which established new trade opportunities by selling the electrolyte to third parties.

This has resulted in a dramatic change in managing impurities’ control, as well as, in new

improvements. The combination of these projects of improving and changing the practices

resulted in the production of 401,500 t of electrolytic copper in the year 2011.



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

[email protected]

ABSTRACT

In copper electrorefining additives are used for a smooth electrodeposition of

copper cathodes. The classical additives glue and thiourea show some disadvantages like

the relatively fast decomposition during electrolysis and the incorporation of sulfur from

thiourea into the cathodes. Only new additive systems avoiding thiourea can help to reduce

the sulfur content in the copper cathodes. Additionally the decomposition of glue and

thiourea forces a continuous dosing of the additives.

Our investigations show that alternative additives can be used in copper

electrorefining indeed. Polyethylene glycols (PEG) act strongly polarizing and can

substitute glue. Current density potential curves show that Bis-(3-sodiumpropyl)disulfide

(SPS), dimethylthiourea, methionin and cystein have a stronger depolarizing effect

compared to thiourea.

Electrolysis experiments with PEG and SPS proceeded without short circuits at a

current density of 500 A/m². However, the cathodes were rough and nodulous. Smoother

cathodes were produced when using glue and thiourea or glue and SPS. In the first case the

sulphur concentration in the cathodes ranged from 4 to 10 µg/g and in the second case only

from 0.3 to 1.5 µg/g. SPS is considerably more stable than thiourea. Thus, there is no need

for continuous addition during electrolysis.



EW63

COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH

CURRENT DENSITY

Songlin Zhou

Xiangguang Copper Co., Ltd

No.1 Xiangguang Road

Shifo Town, Yanggu County, 252327, China

ABSTRACT

This paper introduces the Parallel Flow Device (PFD) technology and production

practices for high current density copper electrolytic refining. The technology has been

successfully implemented for the first time on a large industrial scale, enabling the copper

electrolysis current density to reach 420 A/m², thereby substantially increasing copper

electrolytic productivity. Through this technology, a new level in copper electrolytic

refining has been achieved.


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

[email protected]

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

[email protected]

M. Masalski

Institute of Biomedical Engineering and Instrumentation,

Wroclaw University of Technology, Wybrzeże Wyspiańskiego27, 50-370 Wroclaw, Poland

Department and Clinic of Otolaryngology Head and Neck Surgery,

Wroclaw Medical University, ul.Borowska 213, 50-556 Wroclaw, Poland

M. Kwartnik.

NANOMETALLURY SA,

Cieszkowskiego 20, 51-604 Wroclaw, Poland

ABSTRACT

Copper electrowinning and electrorefining are very effective methods of industrial

electrochemistry. These processes have been carried out without substantial fundamental

modifications for a pretty long time. For instance industrial copper electrowinning and

electrorefining processes are carried out on industrial scale as current-controlled processes.

Review of literature data shows that the fundamental understanding of copper

electrodeposition processes from industrial electrolytes is not sufficient. Although, the

industrial copper electrodeposition is a very complex multi-ion process realized in

concentrated electrolytes with migration, convection and diffusion as mass transfer modes,

most of the published theoretical and experimental copper electroreduction studies are

carried out in diluted electrolytes of relatively simple compositions and the theoretical

approach of diluted electrolytes is used to analyze the results. Consequently, many

conclusions concerning industrial copper electrorefining and electrowinning processes

which are considered as general are valid only in the case of current-control electrolysis

and/or for diluted electrolytes. Potential is the primary parameter of electrolysis to

determine the electrochemical reactions which might undergo at the electrode. In the

present paper some basic (theoretical and experimental) aspects of patented potential-

controlled electrolysis in copper industrial electrolytes as a new method of copper

electrorefining and electrowinning are presented and discussed.


EW66

A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE

EXTRACTION OF ANTIMONY

Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Zúñiga (3)

(1) codelco chile, división chuquicamata, e-mail: [email protected] .

(2) departamento de ingeniería metalúrgica, facultad de ingeniería, universidad de

santiago de chile, santiago, chile.

(3) departamento de ingeniería química, facultad de ingeniería, universidad de santiago de

chile, santiago, chile.

ABSTRACT

An ion exchange pilot plant, located at the University of Santiago of Chile, was

tested for antimony control in the electrolyte of Chuquicamata Refinery. In the pilot plant

were used three different resins: MX-2, UR-3300S and Duolite C-467. The results showed

that the best behavior for antimony extraction follow the sequence UR3300S >Duolite C

467 > MX 2. A model with the experimental results was used as comparative tools to

increase the knowledge of this process.

Documents

188803663 05 Electrowinning and Electrorefining