Plant Layout
The total plant area is L 67.5 m × W 36 m, including a storage area for 15 days of cathode copper production.
Compact layout optimizes material flow and operation efficiency.
Project Overview
PRS successfully designed and supplied a 10,000 TPA copper electrowinning (EW) plant, providing a complete set of engineering services - from process design and equipment fabrication to on-site installation and commissioning guidance.
The project integrates optimized cell configuration, stable rectifier output, and efficient acid-mist suppression, achieving high-efficiency operation with excellent current performance. Through close technical cooperation with the client, PRS ensured that the investment payback period remains within one year after stable production.
Basic Parameters
|
No. |
Description |
Unit |
Value |
Remarks |
|
1 |
DC Output Voltage |
V |
120 |
|
|
2 |
DC Output Current |
kA |
35 |
|
|
3 |
Cathode Copper Capacity |
t/a |
10,000 |
|
|
4 |
Current Density |
A/m² |
260 |
Operating @ 250–300 A/m² |
|
5 |
Time Efficiency |
% |
92 |
|
|
6 |
Current Efficiency |
% |
90 |
|
|
7 |
Cell Voltage |
V |
1.9–2.1 |
|
|
8 |
Pitch |
mm |
100 |
|
|
9 |
Cycle Time |
days |
6–8 |
|
|
10 |
Anodes per Cell |
pcs |
55 |
|
|
11 |
Cathodes per Cell |
pcs |
54 |
Deposit Area = 2.04 m² |
|
12 |
Circulation Flow Rate |
L/min·cell |
100 |
Electrolyte flow |
|
13 |
Working Days |
days/year |
330 |
Description
1. Cell Quantity Calculation
For a 10,000 TPA EW plant operating 330 days per year:
• Deposit area per cathode: 2.04 m² × 54 pcs = 110.16 m² per cell
• Current density: 260 A/m²
• Current efficiency: 90 %
• Time efficiency: 92 %
Based on calculations, the plant requires 50 cells to achieve full capacity (≈ 30 tons/day).
2. Rectifier System
• Type: 1 Set SCR Rectifier (integrated with transformer)
• Max. DC Output Current: 2.04 m² × 54 × 300 A/m² = 33,048 A
• Max. DC Output Voltage: 2.2 V × 50 cells = 110 V
• Rated Output: 120 V × 35 kA
3. Cathode Plate
• Material: SS 316 L stainless steel
• Deposit Area: 2.04 m² each side
• Quantity: 54 plates per cell
High-strength, corrosion-resistant plates ensure smooth stripping and long-term stability.
4. Anode Plate
• Material: Lead Alloy (Pb > 99 %, Sn 0.8 %, Ca 0.04 – 0.08 %)
Provides stable electrochemical performance and extended service life.
5. Polymer Concrete Cells
• Size: L 5800 × W 1180 × H 1450 mm
• Capacity: 54 cathodes + 55 anodes per cell
• Features: Excellent chemical resistance and mechanical strength to withstand acidic electrolyte and high current conditions.
6. Circulation Pump System
• Flow Rate: 100 L/min × cell (@ 260 A/m² max)
• Flow rate per set: 330 m³/h Head: 13 m
• Configuration: 1 working + 1 standby
• Ensures [Cu²⁺] drop < 5 g/L to maintain electrolyte balance.
7. Cathode Stripping Machine
One automatic washing and stripping machine is installed.
For 10,000 TPA capacity, the machine operates about 2.5 hours/day at a stripping speed of 250 plates/hour.
Functions include: washing, stripping, stacking, and weighing. Clean blank plates are automatically returned via conveyor (3× pitch = 300 mm).
Optional bundling and sampling modules are available on request.
8. Overhead Crane and Lifting Beam
• Ground remote-controlled cranes
• Each crane equipped with dual hoists for two-point lifting, ensuring smooth and stable cathode handling.
9. Reagent System
Customized design for electrolyte purification and additive control to maintain solution stability and metal purity.
10. Acid Mist Treatment
PP floating balls are used to suppress acid mist generated by oxygen release at the lead anodes, creating a cleaner and safer operating environment.
11. Busbar System
High-conductivity copper busbars are arranged for minimal voltage loss and stable current distribution throughout the EW cells.
12. Walk Platform
Lightweight FRP walk platforms simplify civil construction and reduce costs while ensuring operator safety and maintenance access.
Project Highlights
- Comprehensive EPC design and supply within a tight schedule.
- Efficient power distribution and cell layout ensure stable operation.
- Optimized acid mist control for safe work conditions.
- Automated stripping and lifting equipment reduce labor and improve ROI.
- Short project cycle and fast commissioning lead to payback within 12 months.
