8,000TPA Copper EW Plant

PRS delivered a fully optimized 8,000 TPA copper electrowinning plant, integrating modular design and energy-saving technologies to minimize operating costs and accelerate project commissioning. This turnkey solution features intelligent layout planning, robust equipment selection, and automated operations to ensure rapid production ramp-up and long-term reliability.

• Modular Cell Design: Pre-assembled polymer concrete cells enable parallel installation and phased commissioning, reducing construction time by 30%.
• Smart Power Management: Central SCR rectifier with <3% current ripple and 10% overload capacity ensures stable operation under varying conditions.
• Optimized Hydrodynamics: Multi-point electrolyte distribution maintains Cu²⁺ variation <3 g/L across all cells.
• Integrated Automation: High-speed stripping system (250 plates/hour) with automatic weighing and stacking.
• Energy Conservation: Low-resistance busbars and optimized cell pitch reduce energy consumption by 15% vs. conventional designs.

• Cell System: 42 polymer concrete cells (L×W×H: 5000×1200×1450mm)
• Electrode Package: SS316L cathodes (1.9 m² plating area) + Pb-Sn-Ca anodes
• Power Supply: SCR rectifier 75V/28kA with transformer protection
• Circulation System: 330 m³/h pumps (1 operational + 1 standby)
• Material Handling: Dual-hoist overhead crane + automatic stripping station
• Emission Control: Cell covers + acid mist extraction system

• Phased Approach: Equipment fabrication paralleled with civil works to compress schedule
• Quality Assurance: All major modules underwent factory acceptance testing
• Staged Commissioning: Cell banks energized sequentially to ensure smooth ramp-up
• Knowledge Transfer: Comprehensive operator training and O&M documentation

• Project Timeline: 14 months from design to commissioning
• Energy Efficiency: 2,800 kWh/t copper (DC power consumption)
• Product Quality: Consistent LME Grade A cathode copper
• Operational Uptime: >95% achieved within first 3 months