Projects > 20,000TPA Copper EW Plant

This large-scale electrowinning installation was delivered as a fully integrated EPC project, focusing on high throughput, operational resilience, and long-term cost efficiency. PRS led the process design, multi-vendor coordination, and phased commissioning to ensure robust nameplate performance and streamlined maintenance access for maximum operational availability.

• Scalable Bank Architecture: The plant is arranged in modular cell banks, enabling phased commissioning and early production while subsequent modules are completed.
• Resilient Electrical System: Multiple rectifier strings with redundant busbar routing and segregated power distribution minimize downtime from local faults.
• Maintenance-Optimized Layout: Wide aisles, modular handling systems, and strategic spare parts storage reduce downtime for routine servicing.

• High-Capacity Power Supply: SCR rectifier banks (e.g., 2 × 40,000 A units) with advanced power control and low ripple.
• Polymer Concrete Cells: 80+ large-format cells configured for high throughput and easy maintenance access.
• Automated Cathode Handling: Integrated washing, stripping, and bundling lines with optional inline sampling.
• Electrolyte Circulation: High-flow pumping systems (e.g., 600 m³/h) with full redundancy (1 operating + 1 standby per loop).
• Acid Mist Control: Comprehensive hooding and multi-stage scrubbing systems for full environmental compliance.
• Material Handling: Heavy-duty overhead cranes with dual-hoist lifter beams for safe cathode transport.

Basis for 20,000 TPA Design:

• Cathodes per cell: 50
• Cathode plating area: 1.9 m²
• Current density: 270 A/m²
• Current efficiency: 90%
• Operating days: 330 days/year

• Phased Commissioning: Plant divided into commissioning blocks to enable early production and revenue generation.
• Integrated Quality Assurance: Centralized QA program with coordinated factory acceptance tests for long-lead equipment.
• Optimized Logistics: Carefully scheduled shipments and on-site pre-assembly to streamline erection workflows.
• Performance Validation: Staged performance testing ensures each block meets quality and throughput targets before full operation.
• Lifecycle Planning: Energy recovery options and maintenance planning to minimize lifetime operating costs.

• Comprehensive Emission Control: High-capacity acid mist management using hoods, extraction, and multi-stage scrubbing.
• System Redundancy: Critical systems (pumps, rectifiers) configured with hot-swap capability for uninterrupted operation.
• Advanced HSE Protocols: Comprehensive safety procedures, permit-to-work systems, and operator competency programs.

• Capital Efficiency: Phased delivery reduces initial investment pressure and accelerates revenue generation.
• Operational Reliability: System redundancy and automated handling ensure >94% operational availability.
• Cost Performance: Optimized energy recovery and maintenance planning deliver industry-leading operating costs.
• Operational Simplicity: Centralized controls and remote diagnostics reduce troubleshooting time and improve mean time between failures.

This 20,000 TPA facility demonstrates PRS's capability to deliver large-scale copper electrowinning plants with technically sound designs, verified production capacity, and operational reliability. The project showcases our commitment to delivering plants that not only meet but exceed performance expectations while maintaining lowest lifetime operating costs.