Project Overview
The Modular 2500TPA ×2 Copper Electrowinning Plant is a landmark project delivered by PRS under a turnkey EPC model, representing our capability to design and construct modular, scalable, and high-efficiency copper EW systems.
The project consists of two independent 2500TPA production modules, forming a total capacity of 5000TPA refined copper cathode.
Each line operates autonomously, sharing key infrastructure such as reagent preparation, electrolyte circulation, and acid mist treatment systems - enabling rapid installation, flexible operation, and future expansion.
This modular approach allows the client to start production faster, optimize investment return, and maintain stable output with lower operating costs.
Site & Process Layout on Google Map
This project is located in a copper mining zone with complete upstream and downstream processes.
On the interactive Google Map, each production area is clearly marked:
- Crushing & Ball Milling: Ore preparation and grinding.
- Flotation: Separation of copper minerals from waste rock.
- Agitation Leaching: Dissolution of copper into solution using acid and reagents.
- PLS Pond (Pregnant Leach Solution): Collection of copper-rich leachate.
- Solvent Extraction (SX): Copper is transferred from leachate to organic phase.
- EW Plant (Electrowinning): Copper is deposited onto stainless steel cathodes.
- Raffinate & Tailing Pond: Return of barren solution and safe disposal of residue.
These process sections are connected by a closed-loop system, ensuring efficient resource utilization and environmental compliance.
PRS designed and supplied the complete EW section, including cells, busbars, anodes, cathodes, and stripping machines.
Copper Electrowinning Process
The copper EW process begins when rich electrolyte (Cu²⁺ 45–50g/L) from the SX plant enters the EW cells through a controlled circulation system.
Here's how it works:
- Electrolyte Circulation: The electrolyte flows continuously between the rich tank, circulation tank, and EW cells, keeping copper concentration uniform.
- Electrowinning Reaction: Under DC power from the rectifier, copper ions deposit on stainless steel cathodes while oxygen evolves at lead anodes. After 6–8 days of continuous operation, high-purity copper layers are formed.
- Stripping & Handling: The auto-crane lifts cathodes to the stripping machine, where copper sheets are automatically peeled, stacked, and bundled for sale. The stainless steel cathodes return to the EW cells for the next cycle.
- Electrolyte Return: The poor electrolyte (Cu²⁺ ~40g/L) flows back to the SX system for copper recovery, forming a closed loop with minimal loss.
This system achieves stable current efficiency, uniform copper quality, and optimized energy consumption through automation and precise process control.
On-site Highlights
The project includes the complete supply of PRS's core EW equipment:
- Polymer concrete EW cells with FRP lining
- Lead-calcium anodes and 316L stainless steel cathodes
- Cathode stripping machines (semi-automatic type)
- Busbars, mist hoods, and scrubber systems
- Rectifier and circulation pumps
On-site photos showcase:
- EW tankhouse construction and layout
- Equipment installation and commissioning
- Final high-purity copper cathodes ready for delivery
Every detail demonstrates PRS's ability to integrate engineering design, manufacturing, and field execution into one efficient EPC workflow.
Project Significance
This modular EW plant showcases the advantages of PRS's integrated design philosophy:
- Short project cycle - installation and commissioning within 4 months per module
- Standardized design - easier transportation and assembly
- Optimized energy use - reduced operating cost
- Scalable structure - flexible capacity expansion
Through this project, PRS once again proves its position as a reliable EPC partner in global copper hydrometallurgy.
Quick Facts
|
Item |
Data |
|
Project Type |
Modular Copper EW Plant |
|
Total Capacity |
5000 TPA (2 × 2500TPA Modules) |
|
Scope |
EPC design, equipment manufacturing, installation, commissioning |
|
Core Equipment |
EW Cells, Anodes, Cathodes, Busbars, Stripping Machine |
|
Construction Period |
8 months (both modules) |
|
Output Product |
High-purity Copper Cathode (≥99.99%) |
Conclusion
The Modular 2500TPA ×2 Copper EW Plant stands as a typical case of how PRS transforms complex metallurgical processes into efficient, modular, and sustainable production systems.
From 3D design and process engineering to on-site execution, PRS delivers end-to-end EPC solutions for copper producers worldwide.
