100TPM Copper SX-EW Plant

The 100TPM Copper SX-EW Plant is a compact yet efficient hydrometallurgical system designed and supplied by PRS under an EPC framework.
The project aims to produce 100 tons of refined copper cathode per month with a total recovery rate above 90% across extraction and electrowinning stages.
 

According to the client's ore data, raw materials originate from over 150 different mining sites with varying copper grades and leaching characteristics.

PRS adopted a conservative yet stable design, ensuring consistent output even with fluctuating feed conditions.

1.  Process Design

Based on the leach solution (PLS) with low and variable copper concentration, PRS adopted a two-stage extraction + one-stage stripping + one-stage washing configuration.
This setup minimizes copper loss in raffinate and achieves optimal metal transfer efficiency.

The extraction process operates as follows:

• Feed Flow Rate: 50 m³/h PLS, containing ~3 g/L Cu.
• Mixing & Extraction: PLS is pumped into the extraction mixer, where it fully contacts the organic phase under variable-speed agitation.
• Phase Separation: After two-stage countercurrent extraction, the raffinate is clarified and returned to the raffinate pond.
• Organic Flow Path: Circulation tank → Back Extraction → Extraction I → Extraction II → Washing → Circulation tank.
• Stripping: Loaded organic phase is stripped by lean electrolyte (Cu ≈ 35 g/L, H₂SO₄ ≈ 180 g/L) to produce rich electrolyte (Cu ≈ 45 g/L), which then flows to the EW plant.

After clarification and oil removal, the rich electrolyte (14.5 m³/h) enters the EW circulation system.

2. Third-Phase Control & Maintenance

To ensure stable operation, third-phase residues generated during extraction are periodically removed using portable suction pumps and treated as follows:

• Mix with activated clay in the three-phase tank.
• Filter through plate-and-frame press.
• Recycle the clarified organic phase for reuse; dispose of the residue safely in leach residue storage.

For easier transport and modular assembly, the extraction system is housed in containerized units, with integrated solution tanks and clarifiers at the base.

1.  Process Description

The rich electrolyte flows by gravity to the EW circulation tank and is pumped into the electrowinning cells, where copper is deposited on stainless steel cathodes under DC current.
The process operates in a closed loop with the SX system to minimize losses and ensure clean, continuous production.

During electrolysis:

• Anodes: Lead-calcium alloy plates
• Cathodes: 316L stainless steel plates
• Cycle: 6 days per batch
• Output: ≥ 99.99% copper cathode

After stripping, cathodes are washed, stacked, and packaged for delivery.

2. Basic Parameters

Key Features & Advantages

• High Recovery: Overall extraction + EW recovery rate ≥90%.
• Compact Design: Modular SX system housed in containers, easy for transport and installation.
• Stable Operation: Adaptive to variable ore grade and leaching efficiency.
• Low Maintenance: Simplified flow path and automatic phase separation.
• Reliable Output: High-purity copper cathodes (≥99.99%) with consistent quality.

Project Significance

This 100TPM SX-EW project showcases PRS's ability to design and deliver medium-scale modular copper production lines, combining engineering precision, field practicality, and environmental responsibility.
It serves as a reliable reference for clients seeking cost-efficient and flexible copper recovery solutions.

Conclusion

The 100TPM SX-EW Plant demonstrates how PRS integrates solvent extraction and electrowinning technologies into one efficient production chain - ensuring high metal recovery, short construction time, and low operational cost.
From process design to on-site commissioning, PRS provides complete EPC service for sustainable copper production