Morenci western copper concentrate mineralogy ymixed chalcopyrite, covellite, chalcocite, pyrite medium temperature and direct electrowinning mtdew process selected ybest fit with morenci concentrate production and acid balance yutilize existing ew and sx capacity at morenci copper production capacity 75,000 tons per year. Our qualified and professional staff of technicians monitor and control all the phases of the productive cycle, from design to production, test runs and aftersales assistance. Design of copper electrowinning circuit using conventional. Copper is widely used to make electrical wiring and in other applications that utilize its high electrical conductivity. It is also the oldest metal known to man and was first discovered and used about 10,000 years ago. Aspects of the development of a new copper electrowinning. Modelling the electrolyte flow in a fullscale copper. Electrowinning refers to the process of using electrolysis to extract a metallic element from the compounds in its ore. The electrowinning of copper from a cupric chloride solution.
The electrowinning of copper ions derived from leaching, or solvent extraction, is a significant contributor to the global copper commodity supply. Rsr technologies has developed a new anode for copper electrowinning. They usually consist of up to 60 cathodes and 61 anodes. The chemistry of copper electrolysis handson activity objectives. Lead anode technology has evolved over the years, migrating from pure lead and leadantimonial alloys to the presentday leadcalciumtin alloys for copper electrowinning and leadsilver alloys for zinc electrowinning prengaman, ellis, and mirza, 2010. Wo2006021031a1 process for copper electrowinning and. Electrowinning and refining the electrowinning of metals, or the production of metals from their ores once put in solution or liquefied, is the oldest industrial electrolytic process. The procedure of copper electrowinning circuit simulation concerns two cases. In electro winning of copper lead is used as anode and copper is used as cathode. A wide variety of copper electrowinning options are available to you, there are 424 suppliers who sells copper electrowinning on, mainly located in asia. Electrowinning theory gold is recovered from pregnant gold bearing solution by the process of electrowinning.
Electrowinning of copper from sulfate electrolyte in presence of sulfurous acid article pdf available in hydrometallurgy 591. If it is weak enough, then electrowinning may work, however, i would not expect to get a dense, good quality plate. Electrowinning of copper from sulfate electrolyte in presence. The copper electrowinning cellhouse using the conventional cells has many cells. Copper processing is a complicated process that begins with mining of the ore less than 1% copper and ends with sheets of 99. Electrorefining of copper was first demonstrated experimentally by maximilian, duke of leuchtenberg in 1847.
Pdf electrowinning of copper from sulfate electrolyte in. Copper is a major metal and an essential element used by man. Electrowinning copper at high current densities springerlink. The copper sulphate in the solution of sulphuric acid was recovered by electro winning process. Electrowinning is a fine way to remove copper from phosphoric acid, however, the mixture with nitric acid may make this impractical.
New lead anode for copper electrowinning rsr anodes. Electrowinning of copper using rotating cylinder electrode. Hydrometallurgical recovery of copper from chalcopyrite ore using chloride media has several advantages over sulfate based processes. Aspects of the development of a new copper electrowinning cell based on reactive electrodialysis l. To a better understanding of the electrowinning concepts explained avobe an example of ew calculations is proposed. The second case is the simulation of an old copper electrowinning plant. In the electrowinning stage of the process the copper is reduced electrochemically from copper sulfate in solution to a metallic copper cathode. Theoretical and practical design article in journal south african institute of mining and metallurgy 1096. The anode produces a lower oxygen overvoltage compared to the same rolled lead calcium tin alloy anodes which do not contain cobalt. The new anode contains cobalt as an alloying element in the rolled leadcalcium tin alloy anode. The first case is the simulation of a new copper electrowinning plant consisting to find number and size of equipment and flowrate of electrolytes for a known copper production rate. Pdf laboratory testing using an industrial electrowinning solution was performed to determine the best cell efficiency.
For direct or post solvent extraction copper electrowinning design, key theoretical considerations include current. Electrowinning of copper in two and threecompartment. Electrowinning is the oldest industrial electrolytic process. In the present work, electrowinning is to be considered since it is applied to the primary metallurgy of copper, which is the target metal for recovery from pcbs waste. The results show that waste water can be utilized to create novel composite structures energy efficiently. The catholyte was cupric sulphate and the anolyte was ferrous sulphate, both dissolved in sulphuric acid. The copper sulfate solution the pregnant leach solution is then stripped of copper via a solvent extraction and electrowinning plant, with the barred denuded sulfuric acid recycled back on to the heaps. This paper highlights the successful implementation of combined leachion exchangesolvent extractionelectrowinning process at the bucim copper project, while providing the original operations description as well as the changes and additions within the plant, which will lead to improved overall performance. The longer the experiment is run, the more copper plating will appear on the dime. Italimpianti orafi has been designing and manufacturing machines for the precious metals industry for over 45 years. Extraction mixer with flotation column, filter press, 4 electrowi.
Markets served for electrowinning and metal re ning dc power supply. The top countries of suppliers are china, india, from which the percentage of copper electrowinning supply is 97%, 1% respectively. Organic levels of less than 100 ppm in the copper lectrolyte produced good sheet deposit. The electrowinning tankhouse was designed to produce 33,000 metric tonnes per year mtpy of copper cathode operating with current density of 184 amps per square meter am 2 and 88 percent % electrical current efficiency. The limitations of conventional copper electrowinning ew cells and ways to overcome them have been discussed by cifuentes et al. Electrowinning is one of the oldest electrolytic processes known and.
Copper, nickel, zinc, cobalt and other nonferrous metals that use electrolytic processes. The electrolyte may be the leach solution or the purified solution from solvent extraction. Copper is the predominant metal to be electrorefined, as this is the. And as alloyed in bronze coppertin alloy about 3000 bc, was the first engineering material known to man. An electric current is passed through the solution causing solid gold to plate out on steel wool cathodes. High power rectifiers for the electrowinning industry the. In addition, the values for reagent addition only reflect the best efficiency and should not be assumed to be the best reagent concentration for copper purity. Copper electrowinning expansion samuel engineering epcm. Electrowinning plant maximizing copper output press. Smooth, good quality cathodes were produced in a prototype cell at current densities up to 30 adm2 270 asf. The amount of foaming agent that showed the best efficiency was the using 37.
The effects of operating variables including sulfur dioxide concentration, copper concentration, sulfuric acid concentration, current density and temperature on the cell voltage, anode potential, power consumption, current efficiency, deposit quality, surface. A process and apparatus for electrowinning a high purity copper from an aqueous pregnant liquor acid electrolyte at high efficiency, and high current density in the presence of impurities. Sodium metal was first prepared in 1807 by the english chemist humphrey davy, who obtained it using electrolysis of molten sodium hydroxide. Copper electrowinning is the recovery of copper metal onto the cathode from electrolyte. Solvent extraction and electrowinning sxew is a twostage hydrometallurgical process that first extracts and upgrades copper ions from lowgrade leach solutions into a solvent containing a chemical that selectively reacts with and binds the copper in the solvent. Plant, sxew, copper pilot, 140 kgdayplant, sxew, copper pilot, 140 kgday.
Copper electrodeposition runs were carried out in order to establish the effect of temperature 30, 50 and 60 c and applied cell current 0. The copper bearing aqueous phase is advanced to the electrowinning ew stage of the process while the barren organic phase is returned to the extraction stage of the process. Theoretical and practical design 2 introduction the electrowinning of copper ions derived from leaching, or solvent extraction is a significant contributor to the global copper commodity supply. The oxygen, which is generated in the electrowinning reaction, has several possible consequences. Copper hanger bar rsrs copper hanger bar is another unique feature that makes our anodes. Electrowinning of copper and similar metals youtube. Introduction copper electrowinning is the recovery of copper metal onto the cathode from electrolyte. Specifically, a combination of copper leaching and electrodeposition was applied in order to produce copper powder, appropriate for powder metallurgical applications. Copper electrorefining mainly produce lme cucath1 copper cathode and byproduct anode slime from copper anode. The minimum value of copper concentration in spent electrolyte must be 30 gl to have a compact copper deposit at design current density general rule in copper electrowinning for obtaining a. It is critical to collect and monitor the right data, turn it into information, and automatically disseminate this information to the right people at the right time for them. A method of electrowinning or electrorefining copper from a copper electrolyte solution which contains chloride ions, the method comprising the steps of.
May 24, 2016 electrowinning is a widely used technology in modern metal recovery, mining, refining and waste water treatment applications. Copper wire is used because copper is known for its properties as an excellent electrical conductor it likely does not contribute significantly to the plating of copper on the dime. With the exception of leachingsolvent extractionelectrowinning, the basic methods. Electrorefining general introduction in an electrorefining process, the anode is the impure metal and the impurities must be lost during the passage of the metal from the anode to the cathode during electrolysis, i.
Electrowinning is defined as the cathodic deposition of metal, in this example copper, from a copper bearing solution by the passage of an electric current current using an insoluble anode for copper the electrowinning reaction reaction is. Pilot plant, copper solvent extraction electrowinning. The electrowinning of copper ions derived from leaching, or solvent extraction is a significant contributor to the global copper commodity supply. Recovery of gold, silver, palladium, and copper from waste. Electrowinning produces pure metallic copper from leachsx electrolytes. If the nitric acid is strong enough, it will redissolve the copper as fast as you are plating it out. A bright future for copper electrowinning request pdf. The introduction of emews vortex electrowinning technology has further pushed the boundaries and applications of copper electrowinning. Agitation of the electrolyte by gas sparging was studied as a means of intensifying the electrowinning of copper. Electrolyte is circulated through an external loop system and upwardly between the anodes and cathodes. The recovery of copper from solutions by electrowinning on glassy carbon and carbon nanotube film was studied.
The electrowinning of copper from acidic sulfate solution in the presence of sulfurous acid using a graphite anode was investigated. Estimates of electricity requirements for the recovery of mineral. Unlike zinc and nickel, copper recovery via electrolysis, either refining or. In this work, the eh pcl diagram of the cuclh2o system was established, and the kinetics of copper dissolution in cupric chloride solution were studied with an emphasis on possible difficulties that may occur during copper electrowinning. The results were used to guide an investigation of copper electrowinning from cupric chloride solution. The process of electrolysis for copper was first developed in the late 19th century and despite numerous advancements in technology the principles and basic equipment remain the same. Industrial tankhouse cells can reach an overall length of several meters. The electrowinning tankhouse was designed to produce 33,000 metric tonnes per year mtpy of copper cathode operating with current density of 184 amps per square meter am2 and 88 percent % electrical current efficiency. The solid charge to the inco flash furnace consists mainly of dried feed blend from the fluid bed dryer. Electrowinning was carried out in a two electrode electrochemical cell with graphite electrode 2. One experiment of nickel electrowinning has been performed in a laboratory cell using the following conditions.
Corby anderson adv chem ng 2160 a n c ed c h m ournal of. Copper occurs on earth both as native copper the uncombined element, cu, and in ores copper compounds, or mixtures of compounds, from which copper metal can be extracted profitably. Design of copper electrowinning circuit by kafumbila. Copper is turning black during electrowinning december 14, 2014. Diffusion, migration and bulk species transport combine to describe. Aug 07, 2016 electrowinning, also called electroextraction, is the electrodeposition of metals from their ores that have been put in solution via a process commonly referred to as leaching. Various cell designs including the spouted bed cell and the squirrelcage cell have been tested and shown to produce reductions in energy requirements compared with conventional designs. Recovery of copper from low concentration waste waters by.
Pdf optimization of industrial copper electrowinning solutions. Copper mesh cathodes and graphite bar anodes have been used. An electric current is applied across the anode and cathode which causes the copper to dissolve from the anode to be then plated onto the cathode as pure. Electrowinning entails applying an electrical potential between inert pballoy anodes and stainless steel occasionally copper cathodes in cuso 4 h 2 so 4 electrolyte. Electrowinning, also called electroextraction, is the electrodeposition of metals from their ores that have been put in solution via a process commonly referred to as leaching. Fire refining and electrorefining of blister copper. Typical electrolyte conditions for copper electrorefining figure 6. Steps to improve copper cathode quality are also described.
How hydrometallurgy and the sxew process made copper the. Each cell is rectangular box having 1 m wide, from 1. Copper production technology the last boomin technological innovation for the copper industry occurred in the first two decades of this century, whenopen pit mining, flo tation concentration,and the reverberatory smelter were adapted to porphyry copper ores. This report discusses electrorefining copper research conducted to increase the rate, deposit purity, and overall efficiency in industrial processes used to electrodeposit and purify metals by increasing substantially the operating current density range and optimizing the deposition process. Study of integrated leaching and electrowinning of copper. Alternatively, the copper can be precipitated out of the pregnant solution by contacting it with scrap iron.
The process of electrolysis for copper was first developed in the late 19th century and despite numerous advancements in technology, the principles and basic equipment remain the same. Rsr anodes are engineered for optimal performance and are less prone to these problems. The top countries of suppliers are china, india, from which the percentage of electrowinning for copper supply is 97%, 1% respectively. A wide variety of electrowinning for copper options are available to you, there are 433 suppliers who sells electrowinning for copper on, mainly located in asia. I am working on a project for extracting copper from powderform raw material which is a waste from brass industries, containing 715% copper, 20% zinc and around 10% iron. Metalcess develops mini scale copper er from 1td copper electrorefining system with modular designeasy installation and saving installation instruction cost. Copper recovery using leachsolvent extractionelectrowinning.
Bath solutions for copper and cadmium were prepared in acidic medium. Comparative study of electrowinning of copper and cadmium in. Cerro verde began operations in april 1977, originally formed and operated by minero peru, as a staterun mining company. Two and threecompartment copper electrowinning ew cells based on reactive electrodialysis red have been studied. Copper bing a more noble metal than nickel, can usually tolerate higher level of impurities. The most common types of ore, copper oxide and copper sulfide, undergo two different processes, hydrometallurgy and pyrometallurgy, respectively, due to the different. An engineering houses perspective of required inputs in designing a copper electrowinning tank house and ancillary equipment calls for both understanding of the key fundamental controlling mechanisms and the practical requirements to optimize cost, schedule and product quality. Copper anode arrives at a refinery for electrorefining. Crude copper, which is usually obtained by pyrometallurgical methods, is not suitable to serve in electrical applications because impurities greatly reduce the metals conductivity. Electrowinning is performed in cells, constructed of nonconducting plastic material. The process of electrorefining copper involves an impure copper anode and an inert cathode. In copper electrowinning, copper is usually electrodeposited on 316l stainless steel cathodes for six to seven days. In this plant, an electric current is used to remove the copper from solution into flat sheets of metal.
The process of electrolysis for copper was first developed in the late 19th century and despite numerous advancements in. Request pdf a bright future for copper electrowinning over the past 40 years, the copper mining industry has undergone a dramatic shift toward. New 2014, includes 7 skids of equipment, poly leach and mix tanks. Effect and interactions of commercial additives and chloride. Recovering copper cathode from acidic sulphate solutions using electrowinning is a wellknown and fairly straightforward process that has been in commercial use since the late 19th century. The english chemist humphry davy obtained sodium metal in elemental form for the first time in 1807 by the electrolysis of molten sodium hydroxide. The results showed the possibilit of producing electrolytic grade copper and nickel metals of 99.
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