Project Overview
PRS delivered a complete 5,000 TPA copper electrowinning plant, integrating high-efficiency equipment and robust engineering to maximize client return on investment. This turnkey solution features optimized cell design, automated handling, and advanced process control for reliable, high-purity cathode production.
Key Technical Specifications
|
Parameter |
Specification |
|
Production Capacity |
5,000 TPA (with +30% expansion potential) |
|
Current Efficiency |
90% (standard operation) |
|
Time Efficiency |
95% |
|
Current Density |
260–300 A/m² |
Core System Design & Components
1. Cell Configuration & Capacity
|
Capacity |
Work Days |
Capacity |
Deposit Area |
Current Density |
No. of Cathodes |
Current |
C.E. |
T.E. |
Product |
Cells Need |
No. of Cells |
|
TPA |
Days/Year |
TPD |
m² |
A/m² |
Pcs/Cell |
A |
% |
% |
T/Cell/Day |
Pcs |
Pcs |
|
5000 |
300 |
16.67 |
2 |
250 |
45 |
22500 |
90 |
95 |
0.52 |
32.15 |
32 |
In normal operation (without power failure frequently and much problems in the process), CE (current efficiency) can reach to 90%, T.E (Time efficiency or Utilization) can reach to 95%, and the current density can reach to 300A/M2, So, the capacity can be increased by Max. 30%.
2. Rectifier System
- Configuration: 1 × SCR rectifier with integrated transformer
- Output Capacity: DC 80V × 27KA (maximum 71V × 27,000A)
- Design Calculation: 2.0 m²/cathode × 45 cathodes/cell × 300 A/m² = 27,000 A
3. Cathode Plates
- Material: SS316L stainless steel
- Active Deposit Area: 2.0 m² per plate
- Configuration: 45 plates per cell
4. Anode Specification
- Material: Lead alloy (Pb >99%, Sn 0.8%, Ca 0.04–0.08%)
- Corrosion Resistance: Optimized for long service life
5. Polymer Concrete Cells
- Dimensions: 5000(L) × 1200(W) × 1450(H) mm
- Capacity: 45 cathodes + 46 anodes per cell
- Material: Corrosion-resistant polymer construction
6. Circulation System
- Flow Rate: 100 L/min per cell at a maximum current density of 260 A/m²
- Pump Configuration: 1 operational + 1 standby
- Performance: 330 m³/h, with a head of 13 m
- Copper Maintenance: [Cu²⁺] drop <5 g/L across cells
7. Cathode Stripping Machine
- Throughput: 250 plates/hour
- Daily Operation: <2 hours for 5,000 TPA production
- Functions: Washing, stripping, stacking, weighing
- Optional: Bundling and sampling capabilities
8. Crane & Lifting System
- Control: Ground-based remote operation
- Hoist Configuration: Dual-hoist system for stable cathode handling
- Design Update: Updated drawings reflect dual-point lifting for improved stability
9. Reagent System
- Custom Design: Tailored to client's specific process requirements
- Precision Dosing: Automated control for optimal reagent utilization
10. Acid Mist Control
- Technology: Integrated mist hoods on all cells
- Emission Control: Effective suppression of oxygen-induced acid mist
11. Bus Bar System
- Custom Design: Optimized for minimal voltage drop
- Material Selection: High-conductivity copper with proper insulation
12. Walk Platforms
- Material: FRP grating for corrosion resistance
- Safety: Non-slip surfaces with proper guardrails
Operational Highlights
Efficiency Optimization
- Current Density: Operates at 260–300 A/m² for maximum production
- Copper Quality: Consistent LME Grade A cathode production
- System Reliability: 95% time efficiency through robust design
Maintenance & Accessibility
- Easy Access: Strategic platform placement for routine maintenance
- Component Longevity: Corrosion-resistant materials throughout
- Quick Service: Modular design facilitates rapid component replacement
Client Value Delivery
- ROI Focus: Engineering decisions prioritized return on investment
- Operational Economy: Low energy and maintenance costs
- Production Consistency: Stable operation with minimal downtime
- Future Flexibility: 30% capacity expansion capability