Refineries considered and their capacities...

Refinery Name Location Country Process

Capacity,
MTA
Port Kembla Port Kembla Australia ISA 120000
Falcon Bridge Kidd creek Canada Kidd 130000
Boliden Sweeden Sweeden ISA 140000
LG Metals Onsan S.Korea Kidd 160000
STERLITE Silvassa India ISA 165000
Huttenwerke Kayser Lunen Geramny ISA 180000
Birla Copper Dahej India ISA 150000
Cyprus Miami Miami USA ISA 190000
Hibi Kyodo Tamano Japan ISA 191000
PT Smelting Gresik Indonesia ISA 200000
Atlantic copper Huelva Spain ISA 250000
CRL Townsville Australia ISA 270000
Kennecott Utah Magma USA Kidd 281000
Mexicana De Cobra Nacozori Mexico Kidd 300000
Union Miniere Olen Belgium ISA 350000
Norddeutsche Affinerie Hamburg Germany ISA 370000
Jhagadia Copper Jhagadia India ISA 50000
Anode parameters.
Refinery Name
Anode Wt.
Kgs
Cathode
Weight
Anode/
cathode cycle
No. of
crops
Boliden 270 50 14/7 2
Kennecott Utah 330 65 21/10 2
Mexicana De Cobra 342 70 20/10 2
Port Kembla 344 50 21/7 3
Atlantic copper 350 50 18/6 3
PT Smelting 357 50 21/14/7 2
Birla Copper 365 40-50 21/7 3
Cyprus Miami 369 55 21/7 3
CRL 370 50 21/7 3
Hibi Kyodo 371 78.5 19/9 2
LG Metals 380 55 21/7 3
Huttenwerke Kayser 394 57 21/7 3
Union Miniere 400 50-60 21/7 3
Norddeutsche Affinerie 406 40-76 21/7 3
STERLITE 346/365 40-50 19/7 3
JHAGADIA COPPER 320+/-10 40-52 20/7 3
Cells...
Refinery Name
Anode/cathode per
cell
Anode gap,
mm
CRL 45/44 95
Port Kembla 53/52 100
Union Miniere 61/60 98
Falcon Bridge 45/44 84
Huttenwerke Kayser 39/38 98
Norddeutsche Affinerie 57/56 95
PT Smelting 59/58 103.5
Hibi Kyodo 54/53 -
Mexicana De Cobra 58/57 105
LG Metals 98
Atlantic copper 40/39 98
Boliden 44/43 100
Cyprus Miami 61/60 102
Birla Copper 54/53 100
Kennecott Utah 47/46 98
STERLITE 55/54 100
JHAGADIA COPPER 44/43 100
..
Refinery Name
Electrolyte
Copper, gpl
Electrolyte
Acid, gpl
Electrolyte
Temperature,
Deg. C
Electrolyte
flow/cell, L/m
CRL 46 170 63 25
Port Kembla 45 180 62 30
Union Miniere 40 170 63 30
Falcon Bridge 42 180 65 550(JUMBO)
Huttenwerke Kayser 45 165 65 25
Norddeutsche Af f inerie 46 170-200 63 25
PT Smelting 45 180 63 35
Hibi Kyodo 48.9 192 65 30
Mexicana De Cobra 45 180 65 25
LG Metals 42 155 64 30
Atlantic copper 45 180 64 20
Boliden 47 175 65 20
Cyprus Miami 45 175 64 40
Birla Copper 46 172 65 25
Kennecott Utah 45 170 66 20
STERLITE 50 165 65 25
JHAGADIA COPPER 45 160-170 62-64 27-30
ELECTROLYTE
Reagent addition and control....
Refinery Name Glue, Kg/MT
Thiourea,
Kg/MT
Avitone, Kg/MT
Chloride
Level
Autosensing
CRL 41 77 46 45 Reatrol
Port Kembla 50 80 0 42 No
Union Miniere 90 60 0 50 Yes
Falcon Bridge 110 45 0 40 Colamat
Huttenwerke Kayser 80 80 0 60 No
Norddeutsche Affinerie - - - - Colamat
PT Smelting 40-60 60-90 5-10 30-40 No
Hibi Kyodo 116 86 35 No
Mexicana De Cobra 77 65 49 35 No
LG Metals 71 80 0 40 No
Atlantic copper 64 64 0 30 Yes
Boliden 45 90 0 50 No
Cyprus Miami 50 65 7 35 Yes
Birla Copper 83 81 15 45 -
Kennecott Utah 75 65 0 45 No
STERLITE 55 60 0 50 No
JHAGADIA COPPER 85-90 72-80 40-45 No
CELL INSPECTION METHODS
Refinery Name
Cell
inspection/day
Methods
CRL 2
Infrared camera,
Cell voltage monitoring
Port Kembla 1
Infrered camera,
Gaussmeter
Union Miniere 1
Infrared Camera,
Cell voltage monitoring
Falcon Bridge 1
Infrared Camera,
Cell voltage monitoring
Huttenwerke Kayser 3
Infrared Camera,
Cell voltage monitoring
Norddeutsche Affinerie 1.5
Infrared Camera,
Cell voltage monitoring,
Gauss meter
PT Smelting 1 to 2
Cell voltage monitoring,
Gauss meter
Hibi Kyodo 2 or 3
Cell voltage monitoring,
Gauss meter
Mexicana De Cobra 3
Cell voltage monitoring,
Gauss meter
LG Metals 1
Infrared Camera,
Gauss meter
Atlantic copper 2
Infrared Camera,
Cell voltage monitoring,
Gauss meter
Boliden 3
Cell voltage monitoring,
Gauss meter
Cyprus Miami 2
Infrared Camera,
Cell voltage monitoring,
Gauss meter
Birla Copper - -
Kennecott Utah 1
Infrared Camera,
Cell voltage monitoring
STERLITE 3
Cell voltage monitoring,
Gauss meter
Jhagadia Copper 2
Cell voltage monitoring,
Gauss meter
Refinery Name Step-1 Step-2 Step-3
CRL Liberator Arsenic extraction NiSO4 plant
Port Kembla Liberator NiSO4 plant
Union Miniere
Falcon Bridge Liberator Acid purification unit ETP
Huttenwerke Kayser CuSO4 plant Liberator NiSO4 plant
Norddeutsche Affinerie Liberator Ni,Fe,As removal
PT Smelting Liberator NiSO4 plant
Hibi Kyodo Liberator Chelating resin NiSO4 plant,
LG Metals Liberator NiSO4 plant
Atlantic copper Liberator NiSO4 plant
Boliden Liberator NiSO4 plant
Birla Copper
Kennecott Utah Liberator To other plant
STERLITE Liberator Acid purification unit ETP
Jhagadia Copper Liberator ETP
Bleeding to chemical plant
Direct Neutralisation
ELECTROLYTE PURIFICATION METHODS
Current Density
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
330
265
0 50 100 150 200 250 300 350
Port Kembla
Falcon Bridge
Mexicana De Cobra
Kennecott Utah
PT Smelting
LG Metals
CRL
Boliden
Hibi Kyodo
Huttenwerke Kayser
Birla Copper
Cyprus Miami
STERLITE
Union Miniere
Norddeutsche Affinerie
Atlantic copper
Jhagadia Copper
Current Efficiency,%
90
91
92
93
94
95
96
97
98
99
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Refinery Name
Current
Density
Time
Efficiency, %
Equipments
Kennecott Utah 280 92 Automatic crane
Falcon Bridge 280 94 Automatic crane
STERLITE 321 94 Manual crane
Port Kembla 274 95 Automatic crane
Union Miniere 330 95 Automatic crane
LG Metals 290 95 Automatic crane
Cyprus Miami 320 95 Automatic crane
Birla Copper 315 95 Automatic crane
CRL 300 95 Automatic crane
Norddeutsche Affinerie 330 96 Automatic crane
PT Smelting 285 96 Automatic crane
Huttenwerke Kayser 315 97 Automatic crane
Hibi Kyodo 308 97 Automatic crane
Atlantic copper 332 97 Automatic crane
Mexicana De Cobra 280 - -
Boliden 300
Jhagadia Copper 265 95 Automatic crane
Sl. No. Parameter Present Value Target value
1 Operating current density 265 Amps/m2 280 Amps/m
2
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
Bench marking Parameters
Put actual figs for last three months and
what is target for Business Plan
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 <1
4 Tellurium < 1 < 0.5
5 Selenium 0.3-1.0 < 0.5
Cathode 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 <100 PPM
4 Antrimony 450-550 PPM <300 PPM
5 Arsenic 10-11 10
4 Tellurium 5 PPM < 5 PPM
ELECTROLYTE QUALITY
Consumables
Item Birla Sterlite JHAGADIA
Glue
Specific Consumption, Gms/MT 85 55 100
Thiuorea
Specific Consumption, Gms/MT 81 52 80
Wax
Specific Consumption, Gms/MT 97 50 99
CHEMICALS CONSUMPTION
Too much additives ?????
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
M
T
ANODE RECEIPT 238.88 220.07 245.21 322.91 835.55 837.81 1118.8 1212 679.14 1148.1 861.21 690.93 700.88
CATHODE PRODUCTION 176.71 288.53 186.58 282.93 484.94 690.47 1149.4 775.88 774.17 970.89 642.51 577.01 583.34
Apirl'
- 04
May'
-04
June'
-04
July'
-04
Augus
t'
-04
Sep'
-'04
Oct'
-04
Nov'
-04
Dec'
-04
Jan'
-05
Feb'
-05
Mar'
-05
ANODE RECEIPT AND CATHODE PRODUCTION FOR 2004-2005
Talk also about future
99.97
99.26
98.08
99.32
99.34
99.5
99.01
98.94
99.46
98.74
97.8
98.23
96.5
97
97.5
98
98.5
99
99.5
100
Apirl'
- 04
May'
-04
June'
-04
July'
-04
August'
-04
Sep'
-'04
Oct'
-04
Nov'
-04
Dec'
-04
Jan'
-05
Feb'
-05
Mar'
-05
CURRENT EFFICIENCY %
Current Efficiencies for the year 2004-2005
Talk also about future
85.14
90.04
93.68
89.59
94.69
95.59
95.26
94.78
95.85
95.38
95.19
94.27
85
87
89
91
93
95
97
Apirl'
- 04
May'
-04
June'
-04
July'
-04
August'
-04
Sep'
-'04
Oct'
-04
Nov'
-04
Dec'
-04
Jan'
-05
Feb'
-05
Mar'
-05
Time Efficiencies for the 2004-2005
Talk also about future
10
10.5
11
11.5
12
12.5
13
13.5
14
14.5
15
ANODE SCRAP% 14.55 12.06 13.99 13 13.89 11.84 12.07 12.03 14.51 13.08 12.44
Apirl'
- 04
May'
-04
June'
-04
July'
-04
Augus
t'
-04
Sep'
-'04
Nov'
-04
Dec'
-04
Jan'
-05
Feb'
-05
Mar'
-05
Anode scrap ratio for 2004-2005
Talk also about future