Cátodos para producción de cobre - L. Nordlund

8/13/2019 Ctodos para produccin de cobre - L. Nordlund

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TANKHOUSE EQUIPMENT

Torren 2013-05-24


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Outotec Tankhouse Equipment

ANODE PREPARATION MACHINE (APM)

Proven technology

Worldwide benchmark

TANKHOUSE CRANE

Multifunctional Bale (Anode+Cathode)

Fully Automatic

FULL DEPOSIT ROBOT STRIPPING MACHINE (FDRSM)

Reliable solution

Modern technology

ANODE SCRAP WASHING MACHINE (ASWM)

Maximum recovery of slime

Low water consumption

PERMANENT CATHODE

Rigid Design

Best edgestrip


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Robotic Stripping Machines

Outotec is the Worlds leading supplier of robotic supported

Cathode Stripping Machines. The total amount of installed

robots are now 40 pcs. With the main customers being some of

the worlds biggest Cu Refineries.

Site: Country:

No. Of

Robots:

Copper

Production:

1 Caserones, Pan Pacific Chile 1 45.000

2 RCC Novgorod Russia 2 75.000

3 TNMG Tongling China 6 > 400.000

4 Daye NF China 6 > 300.000

5 JNMC Fangchenggang China 6 > 400.000

6 Paranapanema, Caraiba Brasil 3 > 275.0007 Boliden cathodes Sweden 5 > 275.000

8 Norilsk Nickel Russia 6 > 325.000

9 Fuchunjiang smelter* China 3 > 200.000

10China Gold* China 3 > 200.000

Total number of robots: 40


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2. Success Stories

Russia Copper Company wanted to upgrade their old Cathode stripping machine that had low

capacity and was considered non safe to the operators. In tuff competition Outotec came up

with the safest, most flexible and time efficient solution to the customer. By replacing the old

conventional stripping machine Outotec installed two robots and their strip station for

Taco/Kidd Cathodes the performance of the stripping went up by more than 50%.

Implementation time, Maintenance and Safety has been the key drivers and Outotec fulfilled all

of the criteria's set by the client. In 4 weeks the new stripping solution was in place and

production up and runninga minimum of production losses was achieved!
http://localhost/var/www/apps/conversion/Videos/OT%20FDRSM%20MOVIE%202012%20NOVGOROD%20UPGRADE.wmv


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Building Success together with Clients!

Before.. .After!

Low average speed: 140-150 c/h

Unsafefrequent incidentsTime consuming manual interference due to low

strip ability

Damaged cathodes (edgestrip and surface)

Increased sped: 250 c/h

SafeNo human interferenceReduced maintenance

Increased interval between cathode

maintenance

Open solution Easy to keep clean & maintain

Fast implementation
http://c/Users/launor/Documents/--%20CLIENTS%20--/--%20FDrSM%20--/OT%20FDRSM%20MOVIE%202012%20NOVGOROD%20UPGRADE.wmvhttp://c/Users/launor/Documents/--%20CLIENTS%20--/--%20FDrSM%20--/OT%20FDRSM%20MOVIE%202012%20NOVGOROD%20UPGRADE.wmvhttp://c/Users/launor/Documents/--%20CLIENTS%20--/--%20FDrSM%20--/OT%20FDRSM%20MOVIE%202012%20NOVGOROD%20UPGRADE.wmv


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The Tongling Case400.000 tpa

One of Chinas largest producer of

cathode copper selected Outotecsrobotstripping machines for their new 400.000

tpa. tankhouse

By using Only two machines, Outotec

was the only one who could meet their

production demand in a safe and cost

effective way!


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The Daye Case300.000 tpa

Another of the Chinese Copper giants,

Daye Nonferrous, selected Outotec for their

newly build Copper RefineryKey factors in their chooise was Outotecs

local presence, advanced technology,

machine data and the capability of doing a

record fast installation on site to secure the

customers cash flow.


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DAYE Tankhouse
http://localhost/var/www/apps/conversion/Videos/JNMC%20test%20201302.mp4


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FDRSMStack handling


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The Paranapanema Case

An old starting sheet technology based tankhouse

that is converting to a full deposit cathode production

needed the best availabletechnology

Outotec was selected to convert their operation andinstall Cathodes and a Stripping Machine with a

capacity of 700 cathodes/h (630 practical)

A doubble strip station solution was selected to strip

the Taco/Kidd cathodes in the 275.000 tpa tankhouse
http://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avi


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In Feed / Out Feed Robots

24.5.2013 Outotec11

The feeding robot transfers the cathode and

copper deposit from the wash conveyer to

stripping station 1 and stripping station 2 and

afterstripping to the discharge conveyor or the

optional cathode scanners.. The robot gripper

is equipped with a special tool that prevents

the copper deposit from pre-stripping during

movement.


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Stacking robot

24.5.2013 Outotec12

The stacking robot takes the plates from

the cathode conveyer and builds a stackof copper plates onto the stack-lifting

table. The stacking robot can also place

B-grade cathodes in the B-grade storage.

The stacking robot also feed the sampling

unit. The stacks are even and neath and

easy to strapp.


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Stripping Station

24.5.2013 Outotec13

The stripping station pre strip and strips the cathodes.

When the copper comes loose the strip station tilts the

cathode from vertical to horizontal position and releases thecopper onto the cathode conveyor.

In case of a planned maintenance, stripping station 1 or 2

can be shut off and the stripping machine can still run with

just a slightly lower capacity.

The frames are manufactured in carbon steel. The carbon

steel parts are protected against corrosion by acid resistant

epoxy paint.


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Pre-weighing of Cathodes

Performance of each cathode

Automatic selection of A or B

grade cathode

Can be combined with TIMS

Cell performance (summarizing)
http://localhost/var/www/apps/conversion/Videos/Pre-weighing%20Unit.AVI


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CathodeSense overview

Online Physical Quality Inspection Cathode deposit (nodules, thickness)

Edge strips (missing parts, nodules)

Plate straightness

Versatile Classification Criteria size, count, area, location and type of

defects

Integration with FDSM and TIMS

Quality Classification

Automatic reject forMaintenance

Historical analysis

Quality analysis

Troubleshooting


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OutotecCathode

OutotecCathode - More out of Cathodes

Over 350 000 permanent stainless steel cathodes manufactured for more

than 25 different plants.

Part of OutotecTankhouse Solutions

High mechanical strength

Permanent protection against corrosion

Permanent protection against mechanical wear and tear

High current efficiency and consistent electrical properties

New edge strip technology

Individual identification code for tracking

Global presenceworldwide service network


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OutotecCathode

General problems with stainless steel cathodes

Galvanic corrosion of the hangerbar and corrosion of the plate to

bar welding

Uneven electrical conductivity

Bending hangerbar structure and failing plate to bar welding

Edge strip problems

Stripping problems especially in wax less process

These generally known problems with the permanent cathodes inspirited Outotec in the 90s to start

developing its own cathode technology with significant improvements.


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OutotecCathode

SEPARATECATHODESSHEETS(SPLIT)

ENVELOPECATHODESSHEETS(TACO)

Cathodes can be delivered either for separate (SPLIT) or envelope (TACO) cathode sheet technology

In the SPLITcathode process the copper sheets

are separated at the V-groove edge.

Accurately and correctly manufactured cathode

V-groove enables optimum separation of the

copper sheets for separate cathodes when using

split cathode technology.

In the TACOcathode process the copper sheets

are partly grown together at the bottom edgewith patented V-groove technology.

This assures the copper sheets stay together

after stripping in trimmed form. This enables

reliable and trouble free handling of the copper

sheets in future process stages.


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OutotecCathode

All stainless steel structure

with laser welded joints

Only bus bar contact

areas are exposed

Integrated OutotecEdge Strips

Patented hanger bar technology

V-groove


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OutotecCathode

Continuous laser welding

Only stainless steel to stainless steel laser welding

No dissimilar metal welds which eliminates problems with galvanic corrosion

No welding inclusion (Excellent corrosion resistance)


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OutotecCathode - Hangerbar

Hanger bar construction

Stainless steel tube with copper core

Sound metallurgical bond

Permanent protection against corrosion

Excellent long term electrical conductivity

Strong mechanical structure designed for heavy

duty mechanized stripping


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OutotecCathode - Manufacturing

Manufacturing

Outotecs cathodes are manufactured at its own workshop withautomated production lines.

Fully automatic production lines for cathode manufacturing and

quality control.

OutotecCathodedelivery comply with ISO and OHSAS quality

assurance systems for:

Research and Development ISO 9001:2000

Environmental System ISO 14001

Health and Safety OSHA 18001

Project Implementation ISO 9001:2000

Manufacturing ISO 9001:2008


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OutotecCathode - 2nd generation Edge Strips

Edge strip manufacturing

Outotecs edge strips are integrated to the vertical sides ofthe steel platewith patented high pressure molding technology.

Permanently fixed edge strips are designed for high mechanical stresses

and impacts caused by mechanized stripping.

Since 2009 Outotec has been using in-house developed second

generation upgraded manufacturing process.

This high pressure manufacturing process guarantees identical edgestrip quality through production and maintenance.

Outotec has upgraded material from HD-PE (black) to new higher

perfomance special grade of PP (white).


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OutotecCathodeQuality Control

Cathode quality is guaranteed by continuos follow up ofmaterial, manufacturing and operation qualities in our own

research facilities.

Plate straightness and dimension

Laser welding quality

Cathode conductivity check

Random plate surface quality

Edge strip quality

V-groove dimension


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OutotecCathode - References


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OutotecCathode - Service

Cathode service options:

Minimum service

Hand held maintenances tools and racks

On-site cathode service shop

Edge strip detachment machine

Cathode sheet straightening unit

Edge strip replacement machine (ESRM)

Outotec cathode service center

Automated edge strip detachment machine

Cathode sheet straightening unit

Automatic edge strip replacement machine

V-grooving machine
http://c/Users/launor/Documents/--%20TRAINING%20--/Cathode_Maintenance_V4_1280x720.wmv


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Edge Strip Replacement Machine (ESRM)

Dimensions 5000x2200x2500 mm

Weight 8000 kg

Capacity, Single table 6-10 cathodes/h

Double table 10-14 cathodes/hOperators required 1 with lifting equipment

OR

2 without lifting equipment

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http://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmv


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Plant / Operation Equipment YearNovgorod Metallurgy Plant, Russia Semi automatic edge strip replacement machine (ESRM) with cathode

maintenance equipment.

2002

Kyshtym Copper Plant Expansion, Russia Semi automatic edge strip replacement machine,

Hand held edge strip repairing tools

2006

Xiangguang Copper Plant, China Semi automatic edge strip replacement machine withcathode maintenance

equipment,

Hand held edge strip repairing tools

2007

Lane Xang Minerals Sepon Copper, Laos Semi automatic edge strip replacement machine 2008

Montanwerke Brixlegg AG, Austria Hand held edge strip repairing tools 2008

Cobre Las Cruces, Spain Semi automatic edge strip replacement machine with cathode maintenance

equipment

2008

Ta Mara, Peru 2ndGeneration automatic edge strip replacement machine with cathodemaintenance equipment

2010

Assarel Medet JSC, Bulgaria Hand held edge strip repairing tools 2010

CNMC Luanshya Copper Mines PLC, Zambia Hand held edge strip repairing tools 2011

Paranapanema S.A. , Brazil 2ndGeneration automatic edge strip replacement machine with bottom edge

strip tooling for Ti-motherblanks.

2012

Plant / Operation Equipment YearNewBoliden Harjavalta Copper, Finland 2ndGeneration automatic edge strip replacement machine.

Full Service cathode maintenance at Outotec Turula Workshop / Finland

2009present day

Montanwerke Brixlegg AG, Austria 2ndGeneration automatic edge strip replacement machine.

Full Service cathode maitenance at Outotec Turula Workshop / Finland

2010present day

Novgorod Metallurgy Plant, Russia 2ndGeneration automatic edge strip replacement machine.

Upgrade of edge strip quality from original 2002 delivered 1stgeneration

extrusion machine. On-site service visit with mobile ESRM unit.

06/201209/2012

(one time overhaul)

Anglo Rustenburg Mines Limited, South Africa 2ndGeneration automatic edge strip replacement machine.

Upgrade of edge strip quality from original 2007 delivered 1st

generation extrusion machine with bottom edge strips.

On-site service visit with mobile ESRM unit.

04/2013

References List / Maintenance Services

References List / Equipment deliveries

OutotecCathode - Service

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RCC Novgorod Metallurgy plant (Russia)

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Anglo Platinum Rustenburg (RSA)

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Anglo Platinum Rustenburg (RSA)

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Job DoneHappy Customer

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