Mapua Institute of Technology

School of Earth and Material Science and Engineering

Intramuros, Manila

Report on Mill Practice

In the Outokumpu Research Center,

Outokumpu Oy, Pori, Finland

01 April 2003 to 31 May 2003

In Partial Fulfillment

Of the Requirements for the

Summer Mine and Mill Practice

(MTBL 406)

Michael Francis G. Lagman

Bachelor of Science in

Metallurgical Engineering

June, 2003

2

Abstract

The training at Outokumpu Research started from 01

April 2003 to 31 May 2003. The duties there were a three

weeks of measurement in which the temperature, cell voltage

and flow rate were measured. Two commercial cells were

measured daily, one in the morning and one in the

afternoon. During and after the measurements, a report was

done right after the measurement campaign, in which the

report was regularly checked and being edited by the

assigned tutors. Description of the job and the report was

not mentioned because of the confidentiality paper that was

signed. The electrolytic copper refining process, was known

and that a good experience was obtained. Rather, a brief

discussion was reported about the company. In this report

some background of the Outokumpu Company were discussed and

briefly explained. Pictures of the worldwide presence of

the company were shown and some key figures of their plant

were shown for added information. The company is present

globally and locally, that is making a difference and

bringing another meaning in the world of metals. Adding

value to metals was one of their key objectives.

3

Table of Contents

Chapter 1

1.1 Description of Facility………………………………………………………………………………6

1.1.1 Outokumpu as a Group……………………………………………………………………….6

1.1.2 Outokumpu Research Center…………………………………………………………13

1.1.3 Outokumpu Harjavalta Metals Copper Refinery…………17

1.2 Background………………………………………………………………………………………………………………18

1.3 Location……………………………………………………………………………………………………………………20

1.4 Accessibility………………………………………………………………………………………………………21

1.5 History………………………………………………………………………………………………………………………22

Chapter 2

2.1 Division of Facilities…………………………………………………………………………………25

2.2 Flow Chart/Organizational Chart…………………………………………………………25

2.3 Experimental Research Activities………………………………………………………28

2.4 Competence Areas…………………………………………………………………………………………………29

2.5 Mineral Technology……………………………………………………………………………………………30

2.6 Hydrometallurgy……………………………………………………………………………………………………36

2.7 Pyrometallurgy…………………………………………………………………………………………………….38

Chapter 3

3.1 Environment………………………………………………………………………………………………………………42

3.2 Social Aspects………………………………………………………………………………………………………44

4

Chapter 4

4.1 Activities…………………………………………………………………………………………………………………45

4.2 Description of the Job…………………………………………………………………………………48

Chapter 5

5.1 Conclusion…………………………………………………………………………………………………………………52

5.2 Recommendations……………………………………………………………………………………………………52

6.0 References…………………………………………………………………………………………………………………53

Appendix A Average Statistics of Outokumpu Harjavalta

Metals Copper Refinery……………………………………………………………………………………………54

5

Acknowledgement

The training at Outokumpu Research Center, was made

possible by my father, Manuel M. Lagman and to his superior

the president of Okphil, Inc., Mr. Mario Guillermo, for the

training in Pori, Finland.

A great deal of appreciation is also mentioned to my

tutors in Pori, Finland. Sade Harle, Development Manager

for the Outokumpu Research. Henri Virtanen, Hydrometallurgy

Department manager. Petteri Pesonen, Plant Superintendent

of Outokumpu Harjavalta Metals Copper Refinery for helping

me in taking the measurements in the plant.

Lastly, I would also like to thank my professors,

friends, family and especially God on making this training

possible and the writing of the report easier.

6

Chapter 1

1.1 Description of Facility

1.1.1 Outokumpu as a Group

Outokumpu consist of companies that specialize in

stainless steel, fabricated copper and zinc metal

production and development and sales of related technology.

The group operates worldwide, more than 90 percent of net

sales are generated outside of Finland. It employs

approximately 21,000 people in more than 40 countries. The

company’s vision is “to be the leading metals and

technology Group that creates real value added both to its

customers and shareholders.” Figure 1.1.1e shows the

division of services of the group.

Operational structure of the Outokumpu Group of

companies is shown in figure 1.1.1. Research and

development is given special attention by the company,

which explains its leadership in the world of metal

development and fabrication. Outokumpu is globally present,

assuring the future of metal consumption and metal

technology for the human race. Figure 1.1.1d shows the

pictorial view of the company.

7

Figure 1.1.1. Operational Structure of the Outokumpu Group

5%10%

15%

16%25%

29%Others

Building and Construction

Welded Tubes

Transportation

Catering and Households

Process Industry

Figure 1.1.1a. Pie Chart showing the Stainless Steel

Products at Outokumpu

8

1.1.1a Stainless Steel Production

Durability, resistance to corrosion and easy cleaning

make stainless steel the ideal choice for various demanding

applications including cutlery, facing and razor blades and

oil platforms. Figure 1.1.1a shows the stainless steel

products of AvestaPolarit.

Stainless steel operations are the responsibility of

AvestaPolarit, which is partly own by Outokumpu, is one of

the world’s largest producer of stainless steel. The slab

capacity will increase from 1.75 million tons to 2.75

million tons due to large investments by the end of 2004.

The most important production units are located in Finland,

Sweden, Britain and the US. The Group has a chromium mine

in Kemi and a ferrochrome smelter in Tornio, both in

Finland. Table 1.1.1a shows the key figures for the

stainless steel.

AvestaPolarit’s market share in stainless steel coil

market is 28 % in Europe and 8 % globally.

Table 1.1.1a. Key Figures for the Stainless Steel

Production, 2002

Net Sales (EUR million) 3,002

Personnel 9,147

9

Production (tons)

Steel Slabs 1,594,000

Cold Rolled 807,000

White Hot Strips 385,000

Tubes and Tube Fittings 70,000

Quarto Plate 95,000

Long Products 180,000

Precision Strip 21,000

5%10%

13%

14%

15%

43%Others

Industrial Machinery and Equipment

Electrical

Electronics and Communication

Building and Construction

Heat Transfer

Figure 1.1.1b. Pie Chart showing the Copper Products at

Outokumpu

10

1.1.1b Copper Production

Outokumpu makes use of superior properties of copper:

heat transfer, electrical conductivity and signal

transmission, which are needed increasingly to enhance

communications, heat transfer, energy production and

construction. Figure 1.1.1b shows the copper products of

Outokumpu.

Outokumpu is the second largest producer of fabricated

copper products with a 10 % global market share. Outokumpu

has production in 14 countries. The products include ACR

tubes, radiator strips used in the automotive industry,

copper tubes, strips and connectors used in the electronics

and communication industries, sanitary tubes and roofing

and architectural products used in the building and

construction industries and welding electrodes. Production

has also been shifted to higher value-added products, such

as components for electrical and air-conditioning and heat

exchanger appliance manufactures and superconducting wire.

Table 1.1.1b shows the copper production for the year 2002.

Outokumpu produces copper for copper products’ raw

material at Harjavalta and Pori, both in Finland.

11

Table 1.1.1b. Key Figures for the Copper Production, 2002

Net sales (EUR million) 1,669

Personnel 7,564

Deliveries / Production

(tons)

Fabricated Copper Products 415,000

Blister Copper 161,000

Copper Cathode 115,000

7%

23%

25%

45%Industrial Machinery and Equipment

Computers and Electronics

Transportation

Building and Construction

Figure 1.1.1c. Pie Chart showing the Zinc Products at

Outokumpu

12

1.1.1c Zinc Production

Outokumpu produces high quality zinc at Kokkola,

Finland and Odda, Norway. Main products are two-ton zinc

ingots, which are used mainly for corrosion preventing

coating of carbon steel (galvanization). The most important

use of galvanized steel is in construction and

transportation. Figure 1.1.1c shows the zinc production for

2002.

Outokumpu’s share of zinc production in Europe, the

main market area, is 15 % and globally 5 %.

Table 1.1.1c. Key Figures for the Zinc Production, 2002

Net Sales (EUR million) 418

Personnel 1,117

Production (tons)

Zinc 380,000

Figure 1.1.1d. Pictorial View for the Whole Outokumpu Group

13

Figure 1.1.1e. Part of Outokumpu – a leading metals and

technology group

1.1.2 Outokumpu Research Center

Outokumpu Research Oy is the research and development

center of the Outokumpu Group. For 50 years the research

center has helped develop new and innovative processes,

which have enhanced the cost efficiency of metals

production, and increased the competitiveness of its

clients. As a part of Outokumpu Group, Outokumpu Research

is well aware that its research work must lead to results,

which can be turned, into practical benefits. Comprehensive

problem solving capability requires the ability to fully

prove that the problem has truly been solved, also from a

financial point of view.

14

For the description of the facilities, Outokumpu

Research Center has the widest range of laboratory

equipment and test pilot plants in the world. Laboratory

equipment has range from atomic adsorption spectrometer to

scanning electron microscopes. The Center houses all

laboratory equipments in one building. Outokumpu Research

Center, with its facilities, can analyze specimen from the

ore, with its compounds or elemental components, to

metallographic specimens. Computers run almost all the

facilities and equipment in the Center so data acquisition

is versatile.

Outokumpu Research Center, with its world class

facilities and standards can develop new and improve

technologies when it comes to mining, metallurgy and the

like, making it the backbone of the Outokumpu Company. It

is here where the famous Flash Smelter was developed.

Outokumpu Research Center can carry out research and

analytical services in chemistry, fluid dynamics, materials

selection and modeling, and simulations. The state-of-the-

art laboratories are constantly being improved and

developed to guarantee outstanding research quality and

accuracy. The Center has its own library and a network of

information retrieval in order to have more reference and

material and access to international data banks.

15

Figure 1.1.2. Pie Chart for the Portfolio of the Research

Activities at Outokumpu

1.1.2a Portfolio of Research Activities

Product development examples include: solvent

extraction of copper, nickel, cobalt, zinc, molybdenum and

precious metals, mineral processing and refining of

platinum group metals (PGM) and a new copper metal

production process-HydroCopper which offers copper

producers a way to reduce their investments and operating

costs by using minimum amount of chemicals and equipments.

New innovations are also being carried out for membrane

5% 11%

9%

35%

40% Development of Research Methods

New Innovations (Explorative)

Services

Product Development (Strategic)

Process Research (Incremental)

16

technologies, ion exchange, new depolarizing, anode

materials, and new metal joining techniques, future zinc

process, and PGM refining techniques. Figure 1.1.2 shows

the portfolio of research activities.

1.1.2b Portfolio of Research Center

Outokumpu Research Center employs 197 people of which,

29 are post-graduate, and 56 graduated, 85 technicians and

27 operators. Research facilities include: 8 laboratories

and 2-bench scale pilot plants, which are

hydrometallurgical and pyrometallurgical, pilot plants.

Table 1.1.2 shows the research and development of the

Outokumpu Research Center.

Table 1.1.2. Research and development Activities at

Outokumpu Research Center

Process Research Problem solutions in

production

Process improvements

Expansion investments

Technology sales and services

Product Development Development of existing

technologies

17

Development of new

technologies

Services Standardized research

services as environmental

measurements, chemical

analysis

New Innovations New business products or

essential improvements in the

existing technologies

New initiative ideas not

having any technology

definition, yet

Development of Research

Methods

Development of existing and

new experimental research

methods

New tools to carry out

research work

1.1.3 Outokumpu Harjavalta Metals Copper Refinery

Electrolytic refining of copper in Outokumpu uses the

basic principle of other refineries when it comes to

recovering high purity copper. Copper anodes are being

transported by train from Outokumpu Harjavalta Smelter,

which is about 20 kilometers from the electrolysis plant.

18

The basic principle of electrolytic refining of copper is

by passing a current and then dissolving the copper anodes

into the electrolyte, which is a solution of CuSO4 – H2SO4

– H2O, by way of diffusion and convection. Then the copper

ions and electrons that were dissolved are being

electroplated to the copper cathodes thus giving a high

purity copper. Figure 1.1.3 shows the crane operated

loading of copper cathodes into electrolytic cells.

Figure 1.1.3. Harvesting of Copper Cathodes at Outokumpu

Copper Refinery.

1.2 Background

The versatility of the intellectual and physical

resources available enables Outokumpu Research’s clients to

save on investments in research facilities. It has helped

19

develop new and innovative ideas and processes, which

enhanced the performance and the efficiency of metal

productions, and their uses. Outokumpu Research is aware

that its research work must lead to results that could lead

to practical benefits. The problem solving aspect is

comprehensive and it requires the ability to fully probe

the problem, and must be in a practical or financial point

of view.

Outokumpu Research is well known for its flexibility

are democratic approach to research. Their clients can

somewhat participate in the operations and the conduction

of the research. Most of the needed analysis of Outokumpu

is being made in–house because basically its facilities are

located in just only one roof. The Outokumpu group brings

about cost–efficiency oriented, so that every detail and

every aspect of the research would be of value, to its

client. Services provided by Outokumpu Research Center

cover a wider array of research doings, coming from process

and equipment development to consultative research covering

mineral technology, hydrometallurgy and pyrometallurgy.

Many innovations were also developed in Outokumpu Research

Center, in order to facilitate its growing hunger for

intelligence and high quality of research and development.

The quality of the research and development, and its works

20

are mainly certified by SFS–EN ISO 9001 certificate.

Outokumpu Research laboratory’ s emission measurements are

accredited by FINAS (Finnish Accreditation Service), which

is an accreditation body that checks for the safety of the

wastes emitted by a facility and is controlled by the

government of Finland. Table 1.2 shows the sales of the

Center.

Table 1.2. Outokumpu Research Sales

Sales in 2002 EUR 10.8 million

Sales inside Outokumpu Group

• Stainless Steel

• Copper

• Zinc

• Technology

• Other Operations

• Outokumpu Technology

Management

92 %

1 %

24 %

9 %

35 %

1 %

22 % (Corporate)

Sales outside Outokumpu Group 8 %

1.3 Location

Outokumpu Research Center is situated for about 200

kilometers north of Helsinki. Outokumpu Research Center is

21

just within a compound of other facilities, like the

Outokumpu Pori Copper, that produces copper products. The

refinery for the copper cathodes is also situated inside

the compound, which is practical for the whole company.

Figure 1.3 shows the compound layout of the plant in Pori,

Finland.

Figure 1.3. Compound Layout of Outokumpu in Pori

1.4 Accessibility

Accessibility to the Outokumpu Compound, specifically

the Outokumpu Research Center, is about a four and a half

to five hours bus trip from Helsinki to Pori, and about

twenty minutes drive from Pori to the plant or compound.

22

There are two ways of means of transportation for the

Outokumpu Plant in Pori. Airplane is also an option to

travel there, and takes about 30 minutes to an hour to get

to the airport in Pori. Accessibility of the plant is quite

easy, because as you go along the way there is directions

that are shown on how to get to the plant. Figure 1.4 shows

the location of Outokumpu in Pori, Finland.

Figure 1.4. Location of Outokumpu at Pori, Finland

1.5 History

Basically the word Outokumpu was named after a place,

which has a massive ore deposit discovered in Eastern

Finland in 1910. Outokumpu means “strange hill.” In its

23

nine decades of operation, it has evolved from a completely

Finnish company to a metals and technology group with

global operations. The company started in 1910, thus

expanding it globally and internationally as years pass by,

the company holds a lot of shares and greatly affects the

technology of metals on how we used and produce them today.

The history of the Outokumpu Group brings about many

innovations and discoveries on the value of metals.

1.1.5 Focus of Metallurgical Research of Outokumpu

In 1970’s Flash Smelting of copper concentrates to

blister copper was developed. The Flash Smelting furnace

pilot runs for foreign customers in the production of

copper lead and sulfur. Ferro-alloys and chromium salts was

also developed.

The 1980’s, lead flash smelting was introduced. Flash

converting was also developed for copper production. Cobalt

and Nickel chemicals and powders were studied and started

up in 1984 for the cobalt and nickel production.

Bioleaching was also developed, that use bacteria or

organic materials in order to leached ores for copper

production.

In the 1990’s, PyroZinc and HydroZinc were introduced

for the zinc production, which started in 1998 at Kokkola.

24

Finland. For the production and refining of nickel, the DON

(direct oxidation of nickel) smelting was also introduced

for nickel concentrates, which started up in 1995 in

Harjavalta, Finland. Another innovation was also being

developed during the 1990’s up to present for the treatment

of copper (HydroCopper) which is a new method of copper

production. Figure 1.1.5 shows the operations of the

company.

The focus of metallurgical research of Outokumpu for

the last 30 years developed new and improves innovations

for the metal industry. Flash Smelting Technology is one of

their prides and joys, that for now it is regarded as the

most energy efficient and environmentally friendly smelter

in the whole world.

Figure 1.1.5. Competent operations of Outokumpu

25

Chapter 2

2.1 Division of Facilities

The facilities of Outokumpu Research Center are highly

accessible, because almost all of its laboratories are

situated in one roof. The main laboratories for

hydrometallurgy, pyrometallurgy and mineral technology are

situated in the first floor of the building. The

laboratories for ore analysis are basically in the first

and second floor. Library facilities and other multimedia

equipments are situated at the second floor of the

building. The pilot scale plants are situated in the

compound besides the refinery. A new pilot plant is now

being set-up for the HydroCopper™ project of the company.

2.2 Flow Chart/Organizational Chart

For the flowchart and organizational chart are given,

so that a better understanding of the hierarchy on the

staff is observed, and that some flow sheet and flowchart

of some processes present in the compound are shown and

explained briefly. Figure 2.2 shows the organizational

Chart of Outokumpu Research Center. Mineral technology,

hydrometallurgy and Pyrometallurgy operations and pictures

were also discussed in order to know some of the

operational expertise of the Outokumpu group of Companies.

26

Figure 2.2a. Organizational Chart of the Outokumpu Research

Center

Organizational Chart of the Outokumpu Research Center

brings about many competent personnel that are actively

involved to one another in order analyze and determine the

best possible way to deal with metals. The center with

almost all of its personnel is postgraduate and some have a

doctor’s degree.

27

Figure 2.2b. Typical Flowsheet for a Copper Refinery.

Figure 2.2b shows a typical flowsheet for a copper

refinery. Outokumpu harjavalta Metals Copper Refinery uses

the basic flowsheet above, except for minor details or

specifications of the plant that needs to be set in order

to cope up with the environment in the area. Flowsheet for

the Electrolytic Refining of Copper at Outokumpu is

basically pattern in the above flowsheet. The flowsheet

that was made simple in order to be understood easily for

the reader.

28

2.3 Experimental Research Activities

Figure 2.3. Pictorial View of the Experimental

Research Activities

The Experimental Research Activities for the Outokumpu

Research Center has experimentations for the

hydrometallurgy and pyrometallurgy department. From the

diagram above, the two competent areas are the backbone of

metallurgy. Technical support, method development and

analytical services are offered both in the hydrometallurgy

and pyrometallurgy department. Technical Support assists on

the maintenance and construction of test equipments and

materials management. Method Development brings about

developing of research and analytical methods and then

29

research equipment investments. The Analytical Services

gives support for chemical analysis and material

characterization. Figure 2.3 shows the experimental

activities of the Center.

2.4 Competence Areas

Figure 2.4. Competence Areas of the Group

From the diagram above, figure 2.4, it shows the

special competence areas of the Research Center. Core

competence areas include Mineral Technology, Extractive

Metallurgy having the sub-headings of hydrometallurgy and

pyrometallurgy, ferrotechnology and other special

competence areas. Special competence areas includes

30

mineralogy, solvent extraction, material science,

electrochemistry, reactor technique, fluid dynamics,

structure analysis, analytical chemistry, process

chemistry, process control and thermodynamics. Outokumpu

Research Center has the one of the most sophisticated

techniques in the processing and fabrication of metals. The

center gives the full report for their customers to meet

their growing needs for the metal industry.

2.5 Mineral Technology

Mineral technology for the Outokumpu Group is one

important aspect for the company. Figure 2.5f shows the

involvement of the company in mineral technology. The

Company is involved in the technology and operations of

equipments as well as maintenance for the mineral

processing industry. Figure 2.5a shows some grinding mills.

Figure 2.5a. Outokumpu Grinding Mills for the Mineral

Processing Industry

31

From the figure 2.5a, grinding mills are used in the

mineral processing department in order to have a desirable

size for the ores that were crushed so that the

concentrations of the ores will be easier.

Figure 2.5b. Ceramec® Classifiers and Thickeners,

respectively

Classifiers and thickeners figure 2.5b, are also used

in the mineral processing industry, in the department of

flotation. Chemicals and equipment maintenance is also

offered by the company. The concentration of minerals may

vary for ages, but the principle is always the same. Some

processes were old, but they are being used today.

Outokumpu looks for ways and tries to improve the processes

that were in the past in order to have a better value for

the metals industry of today. The metals industry of today

32

brings about many technologies, but basically meets the

same principle.

Figure 2.5c. Flotation Cell and a computer generated

diagram of the cell

Outokumpu is fusing the high technology of computers

today and the principles of mineral processing. Computer

simulations for the mineral technology (figure 2.5c) The

flow of the different liquids and chemicals are being

monitored for the studies and profitability of operations

of the processes. The laboratories for the mineral

processing technology is aided by computers in order to

observed and define problems of the processes. Computers

are really a great help in the processing and fabrication

33

of metals. Mineral Technology is truly main factor in the

Outokumpu Group. Figure 2.5e shows the mineral technology

of the company.

Figure 2.5d. Separators and Induction Chamber

Research Work at high temperatures with different gas

atmospheres. Figure 2.5d shows a separator and an induction

chamber that can be used to higher temperatures. This

equipment enables the Center to analyze samples to a level,

which some laboratories are unable to perform. Separators,

also product of the company brings the needed equipment and

production in the mineral technology industry. Mineral

technology is one of the main production and specialty of

the Outokumpu Group. Outokumpu brings the needed equipment

34

and techniques that needs to be acquired by the mineral

industry.

Figure 2.5e. Outokumpu Mineral Technology Division

35

Figure 2.5f. Involvement of Outokumpu Research in Mineral

Technology

36

2.6 Hydrometallurgy

Figure 2.6a. Hydrometallurgical Equipments of Outokumpu

Outokumpu has the widest range of equipment for the

hydrometallurgical department. Flotation equipments for the

industry are a rare breed because of their fusion with high

technology computers that makes the needed analysis and

other experimentation easier. Figure 2.6a shows some

hydrometallurgical equipments of the company.

37

Figure 2.6b. Hydrometallurgical Reactions Process

Involvement

Hydrometallurgical reactions process involvement for

the Outokumpu Group are sophisticated and proven. The Group

brings many compilations of equipments and different

strategies for the hydrometallurgy department. Figure 2.6c

shows the involvement of Outokumpu in Hydrometallurgy.

38

Figure 2.6c. Involvement of Outokumpu Research in

Hydrometallurgy

2.7 Pyrometallurgy

Figure 2.7a. Outokumpu Anode Casting Wheel

Anode Casting Wheels of the Outokumpu Company are high

tech and that full automization of the process is used.

39

This makes the job easier. Figure 2.7a shows the Anode

Casting Wheel Of Outokumpu.

Figure 2.7b. Outokumpu Flash Smelting Furnace

40

Figure 2.7c. Shows a worker operating at high temperatures

41

Figure 2.7d. Involvement of Outokumpu Research in

Pyrometallurgy

The pyrometallurgy department of the Outokumpu Group

is leading in the smelter industry. Outokumpu Flash

Smelting was name as one of the best available techniques

in recovering copper, nickel, etc. Figure 2.7b shows the

famous flash smelter of the company. Figure 2.7d shows the

involvement of Outokumpu research in pyrometallurgy.

42

Chapter 3

3.1 Environment

The working environment at the Outokumpu Research

Center was I think a very good one, because almost all of

its employees have access to each other in order to have a

synergy that could make a group cooperation, to make a

productive projects or research that is being done. For the

employees, they all work together and at the same time

correlate what is being done, and what is being asked, in

order to meet a client’s demand or the companies demand.

Career building or enrichment is one of its main

objectives, in order to have an excellent working

environment. As for the physical environment, the

temperature ranges from – 2 to about + 8 degrees Celsius.

The country basically has a winter season, nut for these

months it is common that it is spring. The environment was

cold, and that it is snowing. The end of the month, which

is April, or for the first week of May, the environment

changes and springtime comes; the sprouting of the leaves,

in the trees makes it beautiful. As much as possible the

company strictly implements environmental safety in order

to care for the environment. It is annually reporting the

waste disposal and the analysis of its waste on nearby

43

river systems, and other ecosystems. Environmental hazards

are also published annually in order to inform the

surrounding community, as well as the government that the

wastes are disposed correctly and responsibly. Figure 3.1

shows the involvement of the company in the world of

metals.

Figure 3.1. Life Cycle of Metals; Outokumpu is involved on

the shaded parts.

44

3.2 Social Aspects

The social aspects of the company are quite very good.

The employees are much more willingly to help others, if

you only ask. The people are helpful, and that they offer

their assistance when you are in need and or in somewhat in

trouble. Employees greatly affect the evolution of the

company because it is the working force or the backbone of

every business. The development of the company, I guess

mainly the social aspects greatly brings about the

efficiency of the business, and also the success of it.

45

Chapter 4

4.1 Activities

For the duration of two months, I was assign to

different areas, and facilities. In the first week of

training I was thought to the different working equipments

that are available at the office. Almost all of the

employees have an access to a computer that is

interconnected with a network in order to have group

cooperation for its research or project works. The later

weeks, I was assign to the electrolytic refining of copper

in order to know the principles and actual operation of an

electrolysis plant. Actual data were observed and obtained

so that a true working environment in electrolytic refining

of copper could be experienced. The people there also

thought me on how to take measurements for temperature,

cell voltage, flow rate, amount of shorts and how to

determine a good quality of cathode copper. For the

remaining few weeks, office assignment was given in order

to make the report or research, to evaluate and correlate

the data obtained in the training practice at the

electrolysis plant. Everyday activities are basically,

measurement of data from cell section to cell section, then

interpretation and recording of data to be presented later.

Figure 4.1b and 4.1c shows different test simulations

46

observed in the Center. Figure 4.1a shows a laboratory

size flotation cell that was observed during the training.

Figure 4.1a. Batch Type flotation Cells.

Figure 4.1b. Simulations for Equipment Testing

47

Figure 4.1c. Gas Colored Simulations for Analysis.

Figure 4.1d. Pictures of the plant in Outokumpu Copper

Refinery at Pori, Finland

48

4.2 Description of the Job

For the two months training, I was as assign to the

Outokumpu Pori copper, in which I was to train in the

electrolytic refining of copper. For the duration of or for

about four to five weeks in the electrolysis area, in which

I am suppose to measure the cell voltage, temperature, flow

rate, amount of shorts and the quality of the cathodes of

each cells. The job description as I was train to is the

observation and the measurements of data needed to be

analyzed in order to have a report or somewhat a

correlation to the parameters that I have obtained. A

research or a report was done for the remaining few weeks

of stay in order to present this data to the tutors and

managerial heads of the department. The measurements or the

obtaining of data was not that difficult, but the only

thing that was hard is the environment, in which, the smell

of the sulfuric acid, this is by the way; the electrolyte

used in the refinement of copper foul smells. The

temperature inside the plant is also uncomfortable, because

the electrolyte should have a temperature ranging form 65 –

70 degrees Celsius. Some data that were obtained are a

little bit close to each other, because the Outokumpu Pori

Copper was already using standard data in order to refined

copper. Electrolytic refinement of Copper consists mainly

49

of electrochemically dissolving copper from impure anodes

and selectively plating the dissolved copper in pure form

to the copper cathodes. The anodes contain for about 99 –

99.8 % copper, which is some of the industrial range of

anode composition. The impurities of the anode include from

oxygen to gold. Traces of these elements will be reduced in

order to obtain a high purity copper cathode, which may

result to about 99.999+ % copper. The copper cathode are

further melted or cast to form products such as wires or

tubes and other desired final product in order for them to

use other adaptive purposes. The electro-refined copper may

contain less than twenty parts per million impurities, plus

oxygen, which is controlled at about 0.025 %.

Figure 4.2a. Pyrometallurgical process for copper sulfides

50

Figure 4.2b. Copper Products of Outokumpu in Pori, Finland.

Figure 4.2c. Colled Rolled Copper Products.

51

Figure 4.2d. Cold Rolled Copper Products

Figure 4.2e. Outokumpu Superconductors

52

Chapter 5

5.1 Conclusion

For this report, the summer plant practice at

Outokumpu Research Center is really a very good learning

experience for soon to be graduates of metallurgical

engineering. Sophisticated equipments and high technology

facilities are observed and operated. The facilities at

Outokumpu Research Center are state of the art and also the

pilot plants are excellent in obtaining metallurgical data.

The learning and working environment is highly concussive

because of the applications of the theories and principles

that are learn from school.

5.2 Recommendations

Based from my experience, I highly recommend training

in this facility because the learning and working

experience is out of the ordinary. For the training, makes

up for the opportunities that are waiting for us in our

chosen field in the future. The working experience mainly

boasts of the standards of other companies in the

Philippines. The Outokumpu Research Center has great pride

on its employees that are mainly of higher degree of

education, including doctor’s degree that could mould the

trainee to its highest potential.

53

Reference:

Baltazar, V. and Caissey, J. (1991) Electrorefining of

Copper Anodes with Silver Levels, in copper 91/Cobre 91,

Volume iii, Hydrometallurgy and Electrometallurgy of

Copper, edited by Copper W. C., Kemp, D. J., Lagos, G. E.

and Tan, K. G., Pergamon Press, New York, 329-340.

Biswas, A. K. and Davenport, W. G. (1994) Electrolyte

Properties in Copper Refining, in Extractive Metallurgy of

Copper, Pergamon, Oxford, 324-357.

Outokumpu Company Magazines, PO Box 60, FIN-28101

Pori, Finland.

54

Appendix A. Average Statistics of Outokumpu Harjavalta

Metals Copper Refinery

Type Conventional Anodes, Copper Starting Sheets

Cathode Production Rate, Capacity tons/year

Production for 2001, tons/year Production for 2002, tons/year

125000

115471 114906

Electrolytic Cells Number of Commercial

Number of Stripper Cells Construction Material

Lining Material

Dimensions, L x W x H, (inside)

Anodes, cathodes per cell

692 (PRC)

68 (DC) Pre cast reinforced concrete plane

elements (old) and T-elements (new) PP

3600 x 1100 x 1200 (old) 3580 x 1090 x (1240 – 1390) (new)

30, 31 Anodes

Type % Cu

L x W x T, mm

Weight, kg

Center line spacing, mm Life, days % Scrap

Year: 2001 Year: 2002

Anode slimes, per ton of cathode, kg Year: 2001 Year: 2002

Conventional

99,1 925 x 900 x 45 (commercial)

965 x 945 x 45 (stripper) 310 (commercial)

370 (stripper) 112 16

21,9 23,0

5,9 5,6

Removed after 16 days Cathodes

Type

L x W x T, mm Plating time, days

Weight of cathode, kg (average) Total impurities

Year: 2001 Year: 2002

Copper Starting Sheets, starting sheet

blank is stainless steel 960 x 960 x 0,7

8 120

< 16,7

< 18,07 Electrolyte

55

Cu, g/L Year: 2001 Year: 2002 H2SO4, g/L Year: 2001 Year: 2002

Addition Agents, g/ton of cathode Glue

Year: 2001 Year: 2002 Thiourea

Year: 2001 Year: 2002

Is the electrolyte filtered?

61 58

147 145

126 128

68 67

Electrolyte is not filtered Thiourea is regularly analyzed

(polalography). Power and Energy

Cathode current density, A/m2 Year: 2001 Year: 2002

Cathode Current Efficiency, % (average)

Year: 2001 Year: 2002

Cell Voltage, V Cell Current, kA

Year: 2001 Year: 2002

kWh/ton of cathode, AC Year: 2001 Year: 2002

316-commercial, 230-stripper (effective)

318-commercial, 230-stripper (effective)

92,0 90,6

550 (average)

17,3 17,4

445 (average, PRC + DC) 453 (average, PRC + DC)