Jhagadia benchmarking

Refineries considered and their capacities...

Sheet1

Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping

CRLTownsvilleAustraliaISA27000037021/73162.6106045/449595Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes

Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes

Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes

Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes

Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes

Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring,Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes

PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring,Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes

Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring,Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes

Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring,Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes

LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes

Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring,Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes

BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring,Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes

Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring,Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes

Birla CopperDahejIndiaISA18000036521/7312.668854/53100Direct neutralisation31597392954617265258381

Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes

STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring,Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes

Chart1

274

280

280

280

285

290

300

300

308

315

315

320

321

330

330

332

Current Density

Refinery

Current Density, Amps/m2


Chart2

28593

28094

27495

33095

32095

30096

28096

30096

32196

30896.5

31597

33097

33297

31597

28098

29098

Current Density

Current Efficiency,%

Refinery

CE. %

Current Efficiencies

Chart4

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Scrap Gen., %

REFINERY

Chart5

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12.5

Slime fall, Kg/MT

Slime fall, Kg/MT

Refinery

Chart6

245

280

295

310

320

325

342

350

350

359

362

370

377

392

Power Cons. Units/MT

Chart7

280245

320280

300295

285310

280320

290325

308342

330350

315350

274359

280362

332370

321377

315392

Current Density


Refinery

Power Consumption, Units/MT


Sheet2

Refinery NameLocationCountryProcessCapacity, MTA

Port KemblaPort KemblaAustraliaISA120000

Falcon BridgeKidd creekCanadaKidd130000

BolidenSweedenSweedenISA140000

LG MetalsOnsanS.KoreaKidd160000

STERLITESilvassaIndiaISA165000CRL106045/4495Port Kembla274PT Smelting28593Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245

Huttenwerke KayserLunenGeramnyISA180000Port Kembla48053/52100Falcon Bridge280Kennecott Utah28094Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280

Birla CopperDahejIndiaISA150000Union Miniere91161/6098Mexicana De Cobra280Port Kembla27495Birla Copper12.6CRL2.6CRL300295

Cyprus MiamiMiamiUSAISA190000Falcon Bridge51245/4484Kennecott Utah280Union Miniere33095PT Smelting13.2STERLITE2.7PT Smelting285310

Hibi KyodoTamanoJapanISA191000Huttenwerke Kayser80039/3898PT Smelting285Cyprus Miami32095Union Miniere14Mexicana De Cobra3Kennecott Utah280320

PT SmeltingGresikIndonesiaISA200000Norddeutsche Affinerie108057/5695LG Metals290CRL30096LG Metals14LG Metals3.3LG Metals290325

Atlantic copperHuelvaSpainISA250000PT Smelting65459/58103.5CRL300Falcon Bridge28096Atlantic copper14Hibi Kyodo6Hibi Kyodo308342

CRLTownsvilleAustraliaISA270000Hibi Kyodo63154/53-Boliden300Boliden30096Port Kembla15Port Kembla8Union Miniere330350

Kennecott UtahMagmaUSAKidd281000Mexicana De Cobra111558/57105Hibi Kyodo308STERLITE32196STERLITE15Boliden8Huttenwerke Kayser315350

Mexicana De CobraNacozoriMexicoKidd300000LG Metals512-98Huttenwerke Kayser315Hibi Kyodo30896.5CRL16Kennecott Utah9.7Port Kembla274359

Union MiniereOlenBelgiumISA350000Atlantic copper112040/3998Birla Copper315Huttenwerke Kayser31597Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362

Norddeutsche AffinerieHamburgGermanyISA370000Boliden58844/43100Cyprus Miami320Norddeutsche Affinerie33097Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370

Jhagadia CopperJhagadiaIndiaISA50000

*Under TrailCyprus Miami50461/60102STERLITE321Atlantic copper33297Hibi Kyodo17.5Union Miniere12.5STERLITE321377

Birla Copper68854/53100Union Miniere330Birla Copper31597Boliden20Norddeutsche AffinerieBirla Copper315392

Kennecott Utah140047/4698Norddeutsche Affinerie330Mexicana De Cobra28098Cyprus Miami20Atlantic copperNorddeutsche Affinerie330

STERLITE51855/54*98Atlantic copper332LG Metals29098Falcon Bridge27Birla CopperBoliden300

* 56 anodes per cell is under trail

Sheet3

Anode parameters.

Sheet1


















Chart1

274

280

280

280

285

290

300

300

308

315

315

320

321

330

330

332

Current Density

Refinery



Chart2

28593

28094

27495

33095

32095

30096

28096

30096

32196

30896.5

31597

33097

33297

31597

28098

29098

Current Density


Refinery

CE. %


Chart4

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Scrap Gen., %

REFINERY

Chart5

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12.5

Slime fall, Kg/MT

Slime fall, Kg/MT

Refinery

Chart6

245

280

295

310

320

325

342

350

350

359

362

370

377

392


Chart7

280245

320280

300295

285310

280320

290325

308342

330350

315350

274359

280362

332370

321377

315392

Current Density


Refinery



Sheet2

Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT

Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150274PT Smelting28593Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245

Refinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of crops

Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250280Kennecott Utah28094Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280

BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60280Port Kembla27495Birla Copper12.6CRL2.6CRL300295

LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265280Union Miniere33095PT Smelting13.2STERLITE2.7PT Smelting285310

STERLITESilvassaIndiaISA165000Port Kembla3445021/7357285Cyprus Miami32095Union Miniere14Mexicana De Cobra3Kennecott Utah280320

Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76290CRL30096LG Metals14LG Metals3.3LG Metals290325

Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250300Falcon Bridge28096Atlantic copper14Hibi Kyodo6Hibi Kyodo308342

Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5300Boliden30096Port Kembla15Port Kembla8Union Miniere330350

Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370308STERLITE32196STERLITE15Boliden8Huttenwerke Kayser315350

PT SmeltingGresikIndonesiaISA200000CRL3705021/7355315Hibi Kyodo30896.5CRL16Kennecott Utah9.7Port Kembla274359

Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250315Huttenwerke Kayser31597Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362

CRLTownsvilleAustraliaISA270000LG Metals3805521/7350320Norddeutsche Affinerie33097Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370

Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355321Atlantic copper33297Hibi Kyodo17.5Union Miniere12.5STERLITE321377

Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73330Birla Copper31597Boliden20Norddeutsche AffinerieBirla Copper315392

Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365330Mexicana De Cobra28098Cyprus Miami20Atlantic copperNorddeutsche Affinerie330

Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50332LG Metals29098Falcon Bridge27Birla CopperBoliden300

JHAGADIA COPPER320+/-1040-5220/73

*Under Trail


Sheet3

Cells...

Sheet1

Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, Manhr/MTCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping






Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring, Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes

PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring, Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes

Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring, Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes

Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring, Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes


Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring, Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes

BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring, Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes

Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring, Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes

Birla CopperDahejIndiaISA18000036521/7312.668854/53100--31597392954617265258381


STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring, Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes

Refinery NameAnode/cathode per cellAnode gap, mm

Refinery NameAnode/cathode per cellAnode gap, mm

CRL45/4495

Port Kembla53/52100

Union Miniere61/6098

Falcon Bridge45/4484

Huttenwerke Kayser39/3898

Norddeutsche Affinerie57/5695

PT Smelting59/58103.5

Hibi Kyodo54/53-

Mexicana De Cobra58/57105

LG Metals98

Atlantic copper40/3998

Boliden44/43100

Cyprus Miami61/60102

Birla Copper54/53100

Kennecott Utah47/4698

STERLITE55/54100

JHAGADIA COPPER44/43100

CD

274

280

280

280

285

290

300

300

308

315

315

320

321

330

330

330

STERLITE

BIRLA

Current Density

Refinery



CE

93

94

95

95

95

96

96

96

96

96.5

97

97

97

97

98

98

STERLITE

BIRLA


Refinery

Current efficiency, %

Current Efficiency, %

slime fall

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12

STERLITE

Slime fall, Kg/MT

Refinery

Slime fall, Kg/MT

SCRAP

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Refinery

Scrap Gen., %

Scrap Generation., %

Sheet2

Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightRefinery NameNo. of cellsAnode/cathode per cellAnode gap, mmRefinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT

Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150Port Kembla48053/52100Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245

Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250Cyprus Miami50461/60102Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280

BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60Falcon Bridge51245/4484Birla Copper12.6CRL2.6CRL300295

LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265LG Metals512-98PT Smelting13.2STERLITE2.7PT Smelting285310

STERLITESilvassaIndiaISA165000Port Kembla3445021/7357STERLITE51855/54100Union Miniere14Mexicana De Cobra3Kennecott Utah280320

Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76Boliden58844/43100LG Metals14LG Metals3.3LG Metals290325

Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250Hibi Kyodo63154/53-Atlantic copper14Hibi Kyodo6Hibi Kyodo308342

Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5PT Smelting65459/58103.5Port Kembla15Port Kembla8Union Miniere330350

Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370Birla Copper68854/53100STERLITE15Boliden8Huttenwerke Kayser315350

PT SmeltingGresikIndonesiaISA200000CRL3705021/7355Huttenwerke Kayser80039/3898CRL16Kennecott Utah9.7Port Kembla274359

Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250Union Miniere91161/6098Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362

CRLTownsvilleAustraliaISA270000LG Metals3805521/7350CRL106045/4495Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370

Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355Norddeutsche Affinerie108057/5695Hibi Kyodo17.5Union Miniere12.5STERLITE321377

Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73Mexicana De Cobra111558/57105Boliden20Norddeutsche AffinerieBirla Copper315392

Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365Atlantic copper112040/3998Cyprus Miami20Atlantic copperNorddeutsche Affinerie330

Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50Kennecott Utah140047/4698Falcon Bridge27Birla CopperBoliden300

*Under Trail* 56 anodes per cell is under trail


Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m

CRL461706325

Port Kembla451806230

Union Miniere401706330

Falcon Bridge4218065-

Huttenwerke Kayser451656525

Norddeutsche Affinerie46170-20063-

PT Smelting451806335

Hibi Kyodo48.91926530

Mexicana De Cobra451806525

LG Metals421556430

Atlantic copper451806420

Boliden471756520

Cyprus Miami451756440

Birla Copper461726525

Kennecott Utah451706620

STERLITE501656525

Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing

CRL41774645Reatrol

Port Kembla5080042No

Union Miniere9060050Yes

Falcon Bridge11045040Colamat

Huttenwerke Kayser8080060No

Norddeutsche Affinerie----Colamat

PT Smelting40-6060-905-1030-40No

Hibi Kyodo1168635No

Mexicana De Cobra77654935No

LG Metals7180040No

Atlantic copper6464030Yes

Boliden4590050No

Cyprus Miami5065735-

Birla Copper83811545-

Kennecott Utah7565045No

STERLITE5560050No

Refinery NameCell inspection/dayMethods

CRL2Infrared camera, Cell voltage monitoring

Port Kembla1Infrered camera, Gaussmeter

Union Miniere1Infrared Camera, Cell voltage monitoring

Falcon Bridge1Infrared Camera, Cell voltage monitoring

Huttenwerke Kayser3Infrared Camera, Cell voltage monitoring

Norddeutsche Affinerie1.5Infrared Camera, Cell voltage monitoring, Gauss meter

PT Smelting1 to 2Cell voltage monitoring, Gauss meter

Hibi Kyodo2 or 3Cell voltage monitoring, Gauss meter

Mexicana De Cobra3Cell voltage monitoring, Gauss meter

LG Metals1Infrared Camera, Gauss meter

Atlantic copper2Infrared Camera, Cell voltage monitoring, Gauss meter

Boliden3Cell voltage monitoring, Gauss meter

Cyprus Miami2Infrared Camera, Cell voltage monitoring, Gauss meter

Birla Copper--

Kennecott Utah1Infrared Camera, Cell voltage monitoring

STERLITE3Cell voltage monitoring, Gauss meter

Electrolyte Purification

Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameSlime fall, Kg/MTRefinery NameScrap Gen., %Refinery NameCurrent DensityPower Cons. Units/MTRefinery NameCurrent DensityTime Efficiency, %EquipmentsRefinery NameStep-1Step-2Step-3

Port Kembla274PT Smelting28593Cyprus Miami1.6Norddeutsche Affinerie11Falcon Bridge280245Kennecott Utah28092Automatic craneCRLLiberatorArsenic extractionNiSO4 plant

Falcon Bridge280Kennecott Utah28094PT Smelting2.4Huttenwerke Kayser12Cyprus Miami320360Falcon Bridge28094Automatic cranePort KemblaLiberatorNiSO4 plant

Mexicana De Cobra280Port Kembla27495CRL2.6Birla Copper12.6CRL300345STERLITE32194Manual craneUnion MiniereBleeding to chemical plant

Kennecott Utah280Union Miniere33095STERLITE2.7PT Smelting13.2PT Smelting285310Port Kembla27495Automatic craneFalcon BridgeLiberatorAcid purification unitETP

PT Smelting285Cyprus Miami32095Mexicana De Cobra3Union Miniere14Kennecott Utah280320Union Miniere33095Automatic craneHuttenwerke KayserCuSO4 plantLiberatorNiSO4 plant

LG Metals290CRL30096LG Metals3.3LG Metals14LG Metals290325LG Metals29095Automatic craneNorddeutsche AffinerieLiberatorNi,Fe,As removal

CRL300Falcon Bridge28096Hibi Kyodo6Atlantic copper14Hibi Kyodo308342Cyprus Miami32095Automatic cranePT SmeltingLiberatorNiSO4 plant

Boliden300Boliden30096Boliden8Port Kembla15Huttenwerke Kayser315350Birla Copper31595Automatic craneHibi KyodoLiberatorChelating resinNiSO4 plant,

Hibi Kyodo308STERLITE32196Port Kembla8STERLITE15Union Miniere330355CRL30095Automatic craneLG MetalsLiberatorNiSO4 plant

Huttenwerke Kayser315Hibi Kyodo30896.5Kennecott Utah9.7CRL16Port Kembla274359Norddeutsche Affinerie33096Automatic craneAtlantic copperLiberatorNiSO4 plant

Birla Copper315Huttenwerke Kayser31597Falcon Bridge10Mexicana De Cobra16Mexicana De Cobra280362PT Smelting28596Automatic craneBolidenLiberatorNiSO4 plant

Cyprus Miami320Norddeutsche Affinerie33097Huttenwerke Kayser12Kennecott Utah16Atlantic copper332370Huttenwerke Kayser31597Automatic craneBirla CopperDirect Neutralisation

STERLITE321Atlantic copper33297Union Miniere12Hibi Kyodo17.5STERLITE321377Hibi Kyodo30897Automatic craneKennecott UtahLiberatorTo other plant

Union Miniere330Birla Copper31597Atlantic copperBoliden20Birla Copper315392Atlantic copper33297Automatic craneSTERLITELiberatorAcid purification unitETP

Norddeutsche Affinerie330Mexicana De Cobra28098Birla CopperCyprus Miami20Norddeutsche Affinerie330Mexicana De Cobra280--

Atlantic copper330LG Metals29098Norddeutsche AffinerieFalcon Bridge27Boliden300Boliden300

Sheet3

..ELECTROLYTE

Sheet1


















Chart1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Refinery Name

Refinery



Chart2

28593

28094

27495

33095

32095

30096

28096

30096

32196

30896.5

31597

33097

33297

31597

28098

29098

Current Density


Refinery

CE. %


Chart4

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Scrap Gen., %

REFINERY

Chart5

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12.5

Slime fall, Kg/MT

Slime fall, Kg/MT

Refinery

Chart6

245

280

295

310

320

325

342

350

350

359

362

370

377

392


Chart7

280245

320280

300295

285310

280320

290325

308342

330350

315350

274359

280362

332370

321377

315392

Current Density


Refinery



Sheet2


CRL461706325



Falcon Bridge4218065550(JUMBO)


Norddeutsche Affinerie46170-2006325




LG Metals421556430


Boliden471756520




STERLITE501656525

JHAGADIA COPPER45160-17062-6427-30

Sheet3

Reagent addition and control....

Sheet1


















Chart1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Refinery Name

Refinery



Chart2

28593

28094

27495

33095

32095

30096

28096

30096

32196

30896.5

31597

33097

33297

31597

28098

29098

Current Density


Refinery

CE. %


Chart4

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Scrap Gen., %

REFINERY

Chart5

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12.5

Slime fall, Kg/MT

Slime fall, Kg/MT

Refinery

Chart6

245

280

295

310

320

325

342

350

350

359

362

370

377

392


Chart7

280245

320280

300295

285310

280320

290325

308342

330350

315350

274359

280362

332370

321377

315392

Current Density


Refinery



Sheet2


CRL41774645Reatrol






PT Smelting40-6060-905-1030-40No

Hibi Kyodo1168635No


LG Metals7180040No


Boliden4590050No

Cyprus Miami5065735Yes



STERLITE5560050No

JHAGADIA COPPER85-9072-8040-45No

Sheet3

CELL INSPECTION METHODS

]Sheet1


















]Chart1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Refinery Name

Refinery



]Chart2

28593

28094

27495

33095

32095

30096

28096

30096

32196

30896.5

31597

33097

33297

31597

28098

29098

Current Density


Refinery

CE. %


]Chart4

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Scrap Gen., %

REFINERY

]Chart5

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12.5

Slime fall, Kg/MT

Slime fall, Kg/MT

Refinery

]Chart6

245

280

295

310

320

325

342

350

350

359

362

370

377

392


]Chart7

280245

320280

300295

285310

280320

290325

308342

330350

315350

274359

280362

332370

321377

315392

Current Density


Refinery



]Sheet2





















CRL461706325









LG Metals421556430


Boliden471756520




STERLITE501656525


CRL41774645Reatrol






PT Smelting40-6060-905-1030-40No

Hibi Kyodo1168635No


LG Metals7180040No


Boliden4590050No




STERLITE5560050No















Birla Copper--



Jhagadia Copper2Cell voltage monitoring, Gauss meter

]Sheet3

ELECTROLYTE PURIFICATION METHODS

]Sheet1


















]CD

274

280

280

280

285

290

300

300

308

315

315

320

321

330

330

330

STERLITE

BIRLA

Current Density

Refinery



]CE

93

94

95

95

95

96

96

96

96

96.5

97

97

97

97

98

98

STERLITE

BIRLA


Refinery



]slime fall

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12

STERLITE

Slime fall, Kg/MT

Refinery

Slime fall, Kg/MT

]SCRAP

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Refinery

Scrap Gen., %


]Sheet2





















CRL461706325









LG Metals421556430


Boliden471756520




STERLITE501656525


CRL41774645Reatrol






PT Smelting40-6060-905-1030-40No

Hibi Kyodo1168635No


LG Metals7180040No


Boliden4590050No




STERLITE5560050No















Birla Copper--



Electrolyte Purification

Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameSlime fall, Kg/MTRefinery NameScrap Gen., %Refinery NameCurrent DensityPower Cons. Units/MTRefinery NameCurrent DensityTime Efficiency, %EquipmentsRefinery NameStep-1Step-2Step-3

Port Kembla274PT Smelting28593Cyprus Miami1.6Norddeutsche Affinerie11Falcon Bridge280245Kennecott Utah28092Automatic craneCRLLiberatorArsenic extractionNiSO4 plant

Falcon Bridge280Kennecott Utah28094PT Smelting2.4Huttenwerke Kayser12Cyprus Miami320360Falcon Bridge28094Automatic cranePort KemblaLiberatorNiSO4 plant

Mexicana De Cobra280Port Kembla27495CRL2.6Birla Copper12.6CRL300345STERLITE32194Manual craneUnion MiniereBleeding to chemical plant

Kennecott Utah280Union Miniere33095STERLITE2.7PT Smelting13.2PT Smelting285310Port Kembla27495Automatic craneFalcon BridgeLiberatorAcid purification unitETP

PT Smelting285Cyprus Miami32095Mexicana De Cobra3Union Miniere14Kennecott Utah280320Union Miniere33095Automatic craneHuttenwerke KayserCuSO4 plantLiberatorNiSO4 plant

LG Metals290CRL30096LG Metals3.3LG Metals14LG Metals290325LG Metals29095Automatic craneNorddeutsche AffinerieLiberatorNi,Fe,As removal

CRL300Falcon Bridge28096Hibi Kyodo6Atlantic copper14Hibi Kyodo308342Cyprus Miami32095Automatic cranePT SmeltingLiberatorNiSO4 plant

Boliden300Boliden30096Boliden8Port Kembla15Huttenwerke Kayser315350Birla Copper31595Automatic craneHibi KyodoLiberatorChelating resinNiSO4 plant,

Hibi Kyodo308STERLITE32196Port Kembla8STERLITE15Union Miniere330355CRL30095Automatic craneLG MetalsLiberatorNiSO4 plant

Huttenwerke Kayser315Hibi Kyodo30896.5Kennecott Utah9.7CRL16Port Kembla274359Norddeutsche Affinerie33096Automatic craneAtlantic copperLiberatorNiSO4 plant

Birla Copper315Huttenwerke Kayser31597Falcon Bridge10Mexicana De Cobra16Mexicana De Cobra280362PT Smelting28596Automatic craneBolidenLiberatorNiSO4 plant

Cyprus Miami320Norddeutsche Affinerie33097Huttenwerke Kayser12Kennecott Utah16Atlantic copper332370Huttenwerke Kayser31597Automatic craneBirla CopperDirect Neutralisation

STERLITE321Atlantic copper33297Union Miniere12Hibi Kyodo17.5STERLITE321377Hibi Kyodo30897Automatic craneKennecott UtahLiberatorTo other plant

Union Miniere330Birla Copper31597Atlantic copperBoliden20Birla Copper315392Atlantic copper33297Automatic craneSTERLITELiberatorAcid purification unitETP

Norddeutsche Affinerie330Mexicana De Cobra28098Birla CopperCyprus Miami20Norddeutsche Affinerie330Mexicana De Cobra280--Jhagadia CopperLiberatorETP


]Sheet3

Chart2

274

280

280

280

285

290

300

300

308

315

315

320

321

330

330

330

265

Current Density

sheet1





















CRL461706325









LG Metals421556430


Boliden471756520




STERLITE501656525


CRL41774645Reatrol






PT Smelting40-6060-905-1030-40No

Hibi Kyodo1168635No


LG Metals7180040No


Boliden4590050No




STERLITE5560050No















Birla Copper--



Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%

Port Kembla274PT Smelting28593

Falcon Bridge280Kennecott Utah28094

Mexicana De Cobra280Port Kembla27495

Kennecott Utah280Union Miniere33095

PT Smelting285Cyprus Miami32095

LG Metals290CRL30096

CRL300Falcon Bridge28096

Boliden300Boliden30096

Hibi Kyodo308STERLITE32196

Huttenwerke Kayser315Hibi Kyodo30896.5

Birla Copper315Huttenwerke Kayser31597

Cyprus Miami320Norddeutsche Affinerie33097

STERLITE321Atlantic copper33297

Union Miniere330Birla Copper31597

Norddeutsche Affinerie330Mexicana De Cobra28098

Atlantic copper330LG Metals29098

Jhagadia Copper265

Chart1

93

94

95

95

95

96

96

96

96

96.5

97

97

97

97

98

98

97.5


Chart2

274

280

280

280

285

290

300

300

308

315

315

320

321

330

330

330

265

Current Density

sheet1





















CRL461706325









LG Metals421556430


Boliden471756520




STERLITE501656525


CRL41774645Reatrol






PT Smelting40-6060-905-1030-40No

Hibi Kyodo1168635No


LG Metals7180040No


Boliden4590050No




STERLITE5560050No















Birla Copper--



Refinery NameCurrent DensityRefinery NameCurrent Efficiency,%

Port Kembla274PT Smelting93

Falcon Bridge280Kennecott Utah94

Mexicana De Cobra280Port Kembla95

Kennecott Utah280Union Miniere95

PT Smelting285Cyprus Miami95

LG Metals290CRL96

CRL300Falcon Bridge96

Boliden300Boliden96

Hibi Kyodo308STERLITE96

Huttenwerke Kayser315Hibi Kyodo96.5

Birla Copper315Huttenwerke Kayser97

Cyprus Miami320Norddeutsche Affinerie97

STERLITE321Atlantic copper97

Union Miniere330Birla Copper97

Norddeutsche Affinerie330Mexicana De Cobra98

Atlantic copper330LG Metals98

Jhagadia Copper265Jhagadia Copper97.5

sheet1


]Sheet1


















]CD

274

280

280

280

285

290

300

300

308

315

315

320

321

330

330

330

STERLITE

BIRLA

Current Density

Refinery



]CE

93

94

95

95

95

96

96

96

96

96.5

97

97

97

97

98

98

STERLITE

BIRLA


Refinery



]slime fall

1.6

2.4

2.6

2.7

3

3.3

6

8

8

9.7

10

12

12

STERLITE

Slime fall, Kg/MT

Refinery

Slime fall, Kg/MT

]SCRAP

11

12

12.6

13.2

14

14

14

15

15

16

16

16

17.5

20

20

27

Scrap Gen., %

Refinery

Scrap Gen., %


]Sheet2





















CRL461706325









LG Metals421556430


Boliden471756520




STERLITE501656525


CRL41774645Reatrol






PT Smelting40-6060-905-1030-40No

Hibi Kyodo1168635No


LG Metals7180040No


Boliden4590050No




STERLITE5560050No















Birla Copper--



Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameSlime fall, Kg/MTRefinery NameScrap Gen., %Refinery NameCurrent DensityPower Cons. Units/MTRefinery NameCurrent DensityTime Efficiency, %Equipments

Port Kembla274PT Smelting28593Cyprus Miami1.6Norddeutsche Affinerie11Falcon Bridge280245Kennecott Utah28092Automatic crane

Falcon Bridge280Kennecott Utah28094PT Smelting2.4Huttenwerke Kayser12Cyprus Miami320360Falcon Bridge28094Automatic crane

Mexicana De Cobra280Port Kembla27495CRL2.6Birla Copper12.6CRL300345STERLITE32194Manual crane

Kennecott Utah280Union Miniere33095STERLITE2.7PT Smelting13.2PT Smelting285310Port Kembla27495Automatic crane

PT Smelting285Cyprus Miami32095Mexicana De Cobra3Union Miniere14Kennecott Utah280320Union Miniere33095Automatic crane

LG Metals290CRL30096LG Metals3.3LG Metals14LG Metals290325LG Metals29095Automatic crane

CRL300Falcon Bridge28096Hibi Kyodo6Atlantic copper14Hibi Kyodo308342Cyprus Miami32095Automatic crane

Boliden300Boliden30096Boliden8Port Kembla15Huttenwerke Kayser315350Birla Copper31595Automatic crane

Hibi Kyodo308STERLITE32196Port Kembla8STERLITE15Union Miniere330355CRL30095Automatic crane

Huttenwerke Kayser315Hibi Kyodo30896.5Kennecott Utah9.7CRL16Port Kembla274359Norddeutsche Affinerie33096Automatic crane

Birla Copper315Huttenwerke Kayser31597Falcon Bridge10Mexicana De Cobra16Mexicana De Cobra280362PT Smelting28596Automatic crane

Cyprus Miami320Norddeutsche Affinerie33097Huttenwerke Kayser12Kennecott Utah16Atlantic copper332370Huttenwerke Kayser31597Automatic crane

STERLITE321Atlantic copper33297Union Miniere12Hibi Kyodo17.5STERLITE321377Hibi Kyodo30897Automatic crane

Union Miniere330Birla Copper31597Atlantic copperBoliden20Birla Copper315392Atlantic copper33297Automatic crane

Norddeutsche Affinerie330Mexicana De Cobra28098Birla CopperCyprus Miami20Norddeutsche Affinerie330Mexicana De Cobra280--


Jhagadia Copper26595Automatic crane

]Sheet3

Bench marking Parameters Put actual figs for last three months and what is target for Business Plan

Sl. No.

Parameter

Present Value

Target value

1

Operating current density

265 Amps/m2

280 Amps/m2

2

Current efficiency

97.5 %

98 %

3

Time efficiency

92 %

95 %

4

Scrap generation

12.5 %

12 %

5

Slime fall

4-6 Kg/MT

< 4 Kg/MT

6

DC Power Consumption

400 Units/MT

350 Units/MT

7

Steam Consumption

704 Kg/MT

300 Kg/MT

Cathode Quality

Sl. No.

Parameter

Present Value, ppm

Target value, ppm

1

Silver

8-9

< 6

2

Bismuth

0.6-1.0

0.3

3

Antimony

1-2

ELECTROLYTE QUALITY

Sl. No.

Parameter

Present Value, gpl

Target value, gpl

1

Nickel

8-10

< 15

2

Iron

0.01-0.02

< 1

3

Bismuth

25 PPM

CHEMICALS CONSUMPTIONToo much additives ?????

slime fall

1.6

2.6

2.7

2.7

3

3

3.1

3.3

6

6

6

7

7

7

8

8

8.3

9.7

10

12

12

Sterlite

Slime fall , kg/MT of cathode

scarp %

23

20

20

18

18

18

17.5

17

16

16

16

15

15

15

15

14

14

14

14

12.6

12

11

Sterlite

Birla

Scrap %

TE

91

92

92

94

94

94

94

95

95

95

95

95

95.6

96

96

96.7

97

97

97

97

Sterlite

Birla

Time efficiency, %

CD

231

274

274

280

280

280

280

290

300

300

300

305

308

312.5

315

315

320

325

328

330

330

330

Sterlite

Birla

CURRENT DENSITY, Amps/m2

PLANT CAPACITY

15000

30000

31000

37000

40000

50000

50

Documents

Jhagadia benchmarking