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Base Metals
Raimo Kuusisto, Pertti Pekkala and George J. Karcas
Raimo Kuusisto
Outokumpu Technology Oy, Metals Processing, Hydrometallurgy
Pertti Pekkala
Outokumpu Technology Oy, Metals Processing, Hydrometallurgy
George J. Karcas
Outokumpu Technology Oy, Metals Processing, Hydrometallurgy
ABSTRACT
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INTRODUCTION
The Outokumpu Technology Solvent Extraction and Electrowinning packages combine
Basic Engineering, Integrated Proprietary Equipment, and Supervision Services with
Process Guarantees, as well as the possibility of Copper Off Take Agreements.
Outokumpus proven track record in SX EW, offering technically advanced equipment,
which renders optimal operation at all stages of the process, gives the operator the ability
to maximize the benefits while minimizing operational costs.
VERTICAL SMOOTH FLOW TECHNOLOGY
The Vertical Smooth Flow (VSF) Solvent Extraction Technology Package is predominant
in North and South America, accounting for over 25% of the worlds Copper SX capacity.
New applications are being commissioned in Laos and Mexico during the 2005 calendar
year.
Solvent Extraction is a frequently used unit process in Outokumpu hydrometallurgical
operations. Twelve out of nineteen SX processes in our reference list (1) are or have been
in use in Finland. A constant pursuit of better SX performance has resulted in an
uninterrupted development work covering all aspects of the SX processes. In the early 90s
the accumulated SX know-how had already passed a level, after which the keystone ideas
of uniform mixing and low shear pumping could be realized. The first SX processes to use
mixer-settlers relying on, what is nowadays known as Spirok mixing and DOP pumping,
were a cobalt/magnesium circuit and a nickel circuit. Since that time, four more VSF SX
plants have been built in Finland including one large plant for cobalt recovery and a very
compact one for copper.
Simultaneously with the SX progress in Finland, the VSF concept was introduced for large
copper SX plants like Zaldvar and Radomiro Tomic in Chile and Morenci in USA. This
development has now resulted in the OutoCompact Copper SX focusing on economical
key items impacting on stable copper cathode production, efficient space utilization and
top-level operational performance. A glimpse of how our cobalt and copper SX
developments interrelate with each other can be obtained from Figure 1 showing a typical
OutoCompact cobalt mixer-settler and its counterpart for copper, shown in Figure 2.
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Separate pumping and mixing, which prevent the formation of extra fine droplets.
Capturing of occasional high Rich Electrolyte O/A entrainments, caused, for
example through operator error, by the Rich Electrolyte After Settler.
Efficient washing of any remaining aqueous entrainment with a combination
washing mixer-settler and a scrubber type LO-tank.
The VSF mixer settlers are also efficient coalescers, actually performing better than
commercial coalescers, hence, eliminating the need for additional coalescers.
Flow
Stabilizer
Turbine
Conical
Overflow
Rim
Suction
Cylinder
Uptake
Channel
Cover
Cylindrical
Mixing
Tank
Spirok
Stirrer
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launders. The aqueous inner circulation is taken from the settler bulk. The settler design is
presented in figures 6, 7, and 8.
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Full Deposit Stripping Machine with wide range of manual or automated options
Stainless Steel Permanent Cathodes
Lead - Anodes
Double Contact Bus Bar System
Crane and Bale with integrated electrode washing system
Polymer concrete electrolytic cells with up to 84 cathodes per cell
Acid Mist Capture System
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Additional benefits of mechanised stripping are that the Outokumpu full deposit stripping
machine can physically sort higher and lower quality deposits into separate stacks without
requiring manual intervention. It can also execute automatic or manual sampling,
corrugating, weighing, marking, labelling, and strapping.
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The Outokumpu permanent cathode comes equipped with a-strong integrated edge strip,
made from HDPE, which is effectively extruded onto the cathode, giving a much longer
life than other technologies.
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This reduces the risk of corrosion, both inside and outside the tankhouse, and the capacity
and the cost of the general ventilation system can be considerably less when compared to
conventional systems. This system eliminates the need for balls or foam on the surface of
the electrolyte, simplifying drastically the everyday plant operation. Sulphuric acid
consumption is minimized as it can be recycled. No gas masks are required in the cell aisle
and health and safety requirements are fulfilled in all countries throughout the world.
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