Copper Manufacturing Process: General Flowsheet of Process

Copper Manufacturing Process
General Flowsheet of Process

Concentrate Roasting Smelting Converting Anode shaft furnace Anode casting Copper anodes Electrolyte Electrolysis Copper cathodes Anode slime treatment Melting and casting Copper
V00664/01 (10.2000) Copyright Sulzer Pumps Finland Oy 8
SO2 Slag SO2 Slag
NiSO4 Electrolyte purification Cu solids CuSO4 Precious metals
Anode scraps

Pumps in Copper Electrolyse Process
Starting sheets Electrolyte from purification
Anodes
+ Cells
Anode scraps Copper cathodes to melting and casting 3.WSP/T or WKP/T
+ Cells
+ Cells
Electrorefining Electrolyte to purification 1.APP/T Circulating liquor tank Liquid Filtration 4.WPP/T Anode slime to treating 2.APP/T

Pumps in Copper Electrolyse Process
Liquid pH Solids Temp. Density Typical Pump Impeller (oC, oF) (kg/m3, head type type 3 lb/ft m, ft
60-70/ 140-158 60-70/ 140-158 60/ 140 60/ 140 1230/ 77 1230/ 77 1500/ 94 1500/ 94 20/ 66 30/ 98 35/ 115 35/ 115 APP/T Open1
Seal type
Material3
Duty
1 Electrolyte
H2SO4 140...180 g/l
<1
Sb, Bi 10 mg/l Sb, Bi 10 mg/l Cu, Ni, precious metals Cu, Ni, precious metals
Doubl. mech.2 A890 3A (MR22) or Dyn. (DS02) Doubl. mech.2 A890 3A (MR22) or Dyn. (DS02) Single mechanical (ME03)5 654SMO4
Electrolyte circulate Purification feeder Anode Slime from Electrolyse Cells
2 Electrolyte
H2SO4 140...180 g/l
<1
APP/T
Open1
3 Anode slime
H2SO4 140...180 g/l
<1
WSP/T Open /WKP/ T WPP/T Open
4 Anode slime
H2SO4 140...180 g/l
<1
Doubl. mech.2 4 Filter feeder to (MR22) or 654SMO precious metals Dyn. (DS02)
1) Crystallization 2) Check always the entraining air through the static seal. The air harms the process 3) Material recommendation is only for specified application 4) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material 5) The shaft seal is not needed with WKP/T 6) The floating installation of the pumps in Electrolyse process

Pumps in CuSO4 Crystallization Process
Electrolyte from electrolysis 1.APP/T Crystallization
Steam
2.APP/T
Mother liquor
3.APP/T
Mother liquor separation (centrifuge) Water CuSO4 sedimentation
To Cu removal (electrolysis) 4.APP/T
CuSO4 -crystals

Pumps in CuSO4 Crystallization Process
Liquid pH Solids Temp. Density Typical o o 3 ( C, F) (kg/m , head 3 lb/ft ) m, ft
60/ 140 50/ 122 50/ 122 50/ 122 1230/ 77 1340/ 84 1560/ 97 1340/ 84 18/59
Pump type
APP/T
Impeller type
Open1
Seal type
Material
Duty
1 Electrolyte H2SO4 140...180 g/l 2 Cu-solution H2SO4 140...180 g/l 3 CuSO4-solution H2SO4 140...180 g/l 4 Cu-solution H2SO4 250 g/l
<1
Sb, Bi 10 mg/l Cu, Ni
Doubl. mech.2 (MR22) or Dyn. (DS02)
A890 3A
Crystallizer feeder
<1
17/56
APP/T
Open
Double mech. (MR22) Double mech. (MR22)

A890 3A
Circulation
<1
Cu, Ni
20/66
APP/T
Open
A890 3A
Crystallizer discharger Cu removal feeder
<1
Cu, Ni
20/66
APP/T
Open
A890 3A
1) Crystallization 2) Check always the entraining air through the static seal. The air harms the process 3) Material recommendation is only for specified application

Pumps in Cu Removal by Electrolyse Process
Electrolyte from CuSO4-crystallization
1.APP/T
+ I Cells
+ II Cells
+ III Cells
Cu-solids
Cu-solids
Cu-solids
Storage 2.APP/T 3.APP/T Electrolyte to evaporation 4.APP/T


Pumps in Cu Removal By Electrolyse Process
Liquid pH Solids Temp. Density o o 3 ( C, F) (kg/m , 3 lb/ft ) 50-60/ 1230-1340/ 122-140 77-84 50-60/ 1230-1340/ 122-140 77-84 50-60/ 1230-1340/ 122-140 77-84 50-60/ 1230-1340/ 122-140 77-84 Typical Pump Impeller head type type m, ft 15/ 49 15/ 49 15/ 49 15/ 49 APP/T Open
1
Seal type
Material
Duty
1 Cu solution H2SO4 250 g/l 2 Cu-solution H2SO4 250 g/l 3 Cu-solution H2SO4 250 g/l 4 Cu free solution H2SO4 250 g/l
<1
Cu, Ni
Doubl. mech.2 (MR22) or Dyn. (DS02) Doubl. mech.2 (MR22) or Dyn. (DS02) Doubl. mech.2 (MR22) or Dyn. (DS02) Doubl. mech.2 (MR22) or Dyn. (DS02)
A890 3A
1st stage cells pumping tank feeder 2nd stage cells pumping tank 3rd stage cells pumping tank Evaporator feed
<1
Cu, Ni
APP/T
Open1
A890 3A
<1
Ni, Cu
APP/T
Open
A890 3A
<1
Cu ~ 2 g/l
APP/T
Open1
A890 1B
1) Crystallization 2) Check always the entraining air through the static seal. The air harms the process 3) Material recommendation is only for specified application

Pumps in Electrolyte Evaporation Process
2.APP/T Electrolyte from Cu removal (electrowinning) Evaporator Steam 1.APP/T Heater Condensate Condensate Droplet separator
3.
4.APP/T Condensate 5.
Filtration
NiSO4
Filtrate tank 6. Sulphuric acid to process


Pumps in Electrolyte Evaporation Process
Liquid pH Solids Temp. (oC, oF) Density (kg/m3, 3 lb/ft ) Typical head m, ft Pump type Impeller type Seal type Material 1 Duty
1 Cu free H2SO4 250 g/l 2 Condensate H2SO4 60 g/l 3 Ni-solution H2SO4 300 g/l 4 H2O 5 NiSO4 H2SO4 300 g/l 6 H2SO4 300 g/l
<1
Ni 1 mg/l
60/ 140 50/ 122 120/ 248 90/ 194 70/ 158 60/ 140
1230/ 77 1000/ 62 1500/ 94 1000/ 62 1500/ 94 1600/ 100
20/ 66 15/ 49 3.5/ 11,5 30/98 20/ 66 25/82
APP/T
Closed
654SMO Feeder
<1
APP/T
Closed
Dynamic seal A890 3A (DS01) Dynamic seal (DS01) _ Si-iron
Condensate
<1
Ni 5 mg/l Ni 5 mg/l
Circulation
7 <1
APP/T _
Closed _
A890 3A _
Condensate Filter feeder
<1
NiSO4 filtrate
1) Material recommendation is only for specified application 2) Check always the entraining air through the static seal. The air harms the process 3) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material

Pumps in Anode Slime Treatment Process
Anode slime from electrolyse Autoclave Filtration 1.WPP/T Se solids Roasting furnace 2.WPP/T Te solids 3.APP/T Liquid Electrolysis
+
Precipitation
Filtration
Leaching
Cementation
Precipitation
Converting and casting
Ag solids 4. Au solids 6. Precipitation Rh solids 5. Solution
7. Au solids Filtration Filtration 8. Pt solids Waste solution

Pumps in Anode Slime Treatment Process
Liquid pH Solids Temp. Density (oC, oF) (kg/m3, lb/ft3) 1500/ 94 1400/ 88 1400/ 88 1700/ 106 1300/ 81 1500/ 94 1700/ 106 1000/ 62 1400/ 87 Typical Pump head type m, ft 20/66 WPP/T Impeller type Closed Seal type Material
1
Duty
1 Anode slime H2SO4 ~200 g/l 2 Te-solution H2SO4 ~200 g/l 3 Te free H2SO4 ~200 g/l 4 Ag free H2SO4 ~1300 g/l 5 Rh free H2SO4 ~1300 g/l 6 Ag free HCl ~200 g/l 7 Au free HCl ~200 g/l 8 Noble metal free HCl ~200 g/l 9 H2SO4 and Se solids mixture
<1 Se,Te,BaSO4, 80/ 176 PbSO4 <1 Se, Ag, Te 80/ 176 80/ 176 70/ 158 50/ 122 70/ 158 60/ 140 50/ 122 80/ 176
Double mech. 654SMO2 (MR22) Double mech. 654SMO2 (MR22)

2 Dynamic seal 654SMO (DS01)
Treatment feeder
20/66
WPP/T
Closed
Te filter
<1
30/99
APP/T
Closed
Electrolyte purification Precipitation
<1
Ag
20/66
<1
30/99
Process circulation
<1
15/49
Feed 2nd stage Au separation Pt filter
<1
20/66
<1
20/66
Waste solution Se roasting fuurnace liquid
<1
1-2 %
36/118 APP/T
Closed
Double mech. Hastelloy E8 (MR22)
1) Material recommendation is only for specified application 2) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material V00664/11 (10.2000) Copyright Sulzer Pumps Finland Oy
Application Report
1(1)
AHLSTAR APP for Electrolyte Pumping

Anodes Electrolyte from purification
+ Cells
Starting sheets
Anode scraps Copper cathodes to melting and casting
+ Cells + Cells
Filtration
APP22-80
Electrolyte to purification
AHLSTAR APP in Copper Electrolysis Process.
Anode slime to treatment

An APP31-125 pump was installed to pump electrolyte from the filtration of anode slime to back to electrorefining. The pump is equipped with a seal which prevents access of air into the pumped liquid.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor.......................... Speed....................... Material..................... Sealing...................... APP22-80 Special open impeller APP Process pump 15 kW (20 hp) 1740 rpm ASTM890 Grade3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 33.3 l/s (528 USGPM) 15 m (49 ft) Electrolyte 1 60 oC (140 oF) 13 % 1400 kg/m3 (88 lb/ft3)
N03845 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Application Report
1(1)

Electrolyte from purification Anodes Starting sheets
Cells Cells
Copper cathodes to Anode scraps melting and casting
APP31-125
Filtration
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP 31-125 Open APP Process pump 22 kW (16.4 hp) 1460 rpm ASTM 743 CF-8M Double mechanical seal
An APP31-125 pump was installed to pump electrolyte from a circulating liquor tank back to electrorefining. The pump has been running in this position for 14 years without bigger problems. The pump is equipped with a seal which prevents acces of air into the pumped liquid.
Process Data
Q................................ H................................ Liquid......................... pH.............................. Temperature.............. H2SO4 content .......... Density...................... 42 l/s (667 USGPM) 20 m (66 ft) Electrolyte 1 70 oC (158 oF) 14.5 % 1230 kg/m3 (77 lb/ft3)
Application Report
1(1)

Electrolyte from purification Anodes Starting sheets
Cells Cells
Anode scraps Copper cathodes to melting and casting
APP11-32
Filtration

An APP11-32 pump was installed to pump electrolyte from a circulating liquor tank to purification. The application is quite corrosive and contains many kind of impurities. Duplex stainless steel was chosen to manage the corrosion.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP11-32 Closed impeller APP Process pump 4 kW (3 hp) 2905 rpm ASTM 890 Grade 3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 1 l/s (16 USGPM) 30 m (98 ft) Electrolyte 1 60 oC (140 oF) 14.6 % 1230 kg/l (77 lb/ft3)
Application Report
1(1)

Electrolyte from electrolysis Crystallization
APP22-32
Steam CuSO4 Sedimentation Mother liquor separation (centrifuge)
Mother liquor
Water
To Cu removal (electrolysis) CuSO4 crystals

An APP11-32 pump was installed to pump electrolyte to crystallization. The application is quite corrosive and contains many kinds of impurities. Duplex stainless steel was chosen to manage the corrosion and solids in the pumped liquid.
AHLSTAR APP in CuSO4 Crystallization Process.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed......................... Material..................... Sealing...................... APP22-32 Open impeller APP Process pump 3 kW (2.2 hp) 1500 rpm ASTM 890 Grade 3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 2.8 l/s (44 USGPM) 18 m (59 ft) Electrolyte 1 60 oC (140 oF) 14.6 % 1230 kg/m3 (77 lb/ft3)
Application Report
1(1)
AHLSTAR APP for Cu Solution Pumping

Steam
APP31-100
Mother liquor
CuSO4 Sedimentation Mother liquor separation (centrifuge)
Water
To Cu removal (electrolysis) CuSO4 crystals

An APP31-100 pump was installed to circulate Cu solution in a crystallizer. The pumped liquid contains crystallizable solids which can crystallize inside the pump. This means that the shaft seal should be selected very carefully. Readyfitted non-flowing double mechanical seal was selected because of a higher operating temperature in the seal faces on the product side.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP31-100 Open impeller APP Process pump 22 kW (16.4 hp) 1470 rpm ASTM 890 Grade 3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 42 l/s (667 USGPM) 17 m (56 ft) Cu solution with solids 1 50 oC (122 oF) 14.6 % 1340 kg/m3 (84 lb/ft3)
Application Report
1(1)
AHLSTAR APP for CuSO4 Solution Pumping

Steam
APP22-32
Mother liquor
CuSO4 Sedimentation Mother liquor separation (centrifuge)
Water
To Cu removal (electrolysis)
CuSO4 crystals
An APP22-32 pump pumps crystallized CuSO4 to sedimentation. The solids content is about 16 % and crystallization is still going on inside the pump. The shaft seal has to be selected very carefully. Ready-fitted non-flowing double mechanical seal was selected because of a higher operating temperature in the seal faces on the product side.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP22-32 Open impeller APP Process pump 3 kw (2.2 hp) 1430 rpm ASTM 890 Grade 3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 0.5 l/s (8 USGPM) 20 m (66 ft) CuSO4 solution with solids 1 50 oC (122 oF) 14.4 % 1560 kg/m3 (97 lb/ft3)
Application Report
1(1)

Steam CuSO4 Sedimentation Mother liquor separation (centrifuge)
Mother liquor
Water
APP22-32
To Cu removal (electrolysis)
CuSO4 crystals
An APP22-32 pump pumps Cu solution back to sedimentation. The sulphuric acid concentration is quite high in this application, about 19 %. If the temperature rises about 15 to 20 oC, then super duplex stainless steel should be selected. APP22-32 from normal duplex stainless steel has been working for about six years without having to replace the volute casing.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP22-32 Open impeller APP Process pump 3 kW (2.2 hp) 1430 r/min ASTM 890 Grade 3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 1.4 l/s (22 USGPM) 15 m (49 ft) Cu solution 1 50 oC (122 oF) 19 % 1340 kg/m3 (84 lb/ft3)
Application Report
1(1)

Electrolyte from CuSO4 crystallization
I Cells
+
II Cells
+
III Cells
+
Cu solids
Cu solids Storage
APP11-32
Cu solids
Electrolyte to evaporation
AHLSTAR APP in Cu Removal by Electrolysis An APP11-32 pump pumps Cu solution to electrolysis cells to crystallize Cu to solids. The pump has been running for 12 years now. The volute casing of the pump was replaced after 8 years of operation. Air is not permitted in the electrolysis process step. This is why a readyfitted non-flowing double mechanical seal was selected.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor........................ Speed....................... Material..................... Sealing...................... APP11-32 Closed impeller APP Process pump 7.5 kW (5.6 hp) 2950 r/min ASTM 890 Grade 3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 1.4 l/s (22 USGPM) 50 m (164 ft) Cu solution 1 60 oC (140 oF) 19 % 1340 kg/m3 (84 lb/ft3)
Application Report
1(1)

I Cells
+
II Cells
+
III Cells
+
Cu solids
Cu solids Storage
Cu solids
APP22-40
AHLSTAR APP in Cu Removal by Electrolysis An APP11-32 pump pumps Cu solution to electrolysis cells to crystallize Cu to solids. Air is not permitted in the electrolysis process step. This is why a ready-fitted non-flowing double mechanical seal was selected.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP22-40 Closed impeller APP Process pump 3 kW (2.2 hp) 1440 rpm ASTM 890 Grade 3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 6 l/s (95 USGPM) 15 m (49 ft) Cu solution 1 60 oC (140 oF) 19 % 1340 kg/m3 (84 lb/ft3)
Application Report
1(1)
AHLSTAR WKP Cantilever for Floor Water Pumping

I Cells
+
II Cells
+
III Cells
+
Cu solids
Cu solids Storage
Cu solids
To water treatment WKP23-250
AHLSTAR WKP in Cu Removal by Electrolysis A WKP wear resistant cantilever pump was installed to pump floor water in Cu removal by electrolysis. The pump has been running for 4 years now. The volute casing of the pump is the same after 4 years operation. The pump doesnt need shaft seal or support bearings at the bottom side.
Pump Data
Pump......................... WKP23-50 Impeller..................... Open impeller Type.......................... WKP Wear resistant cantilever pump Motor........................ 11 kW (15 hp) Speed....................... 1450 r/min Material..................... ASTM 890 Grade 3A
Process Data
Q............................... 5.5 l/s (87 USGPM) H............................... 28 m (92 ft) Liquid........................ Floor water pH............................. 7 Temperature.............. 20 oC (68 oF) Solids content .......... 1 - 5 % Density...................... 1050 kg/m3 (66 lb/ft3)
Application Report
1(1)
AHLSTAR APP for Cu-Free Solution Pumping

Electrolyte from Cu removal (electrowinning) Droplet separator Condensate Steam
APP22-32
Heater Evaporator Condensate NiSO4
Filtration Filtrate tank
Sulphuric acid to process

AHLSTAR APP in Electrolyte Evaporation
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP22-32 Open impeller APP Process pump 3 kW (2.2 hp) 1430 rpm ASTM 890 Grade 3A Double mechanical seal
An APP22-32 pump pumps Cu-free solution to electrolyte evaporation. The pump has been running for about 6 years without having to change the volute casing.
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 1.4 l/s (22 USGPM) 20 m (66 ft) Cu-free solution 1 60 oC (140 oF) 19 % 1230 kg/m3 (77 lb/ft3)
Application Report
1(1)
AHLSTAR APP for Condensate Pumping

Electrolyte from Cu removal (electrowinning) Droplet separator Condensate Steam Heater Evaporator Condensate APP11-32 Filtration Filtrate tank
NiSO4
Sulphuric acid to process

An APP11-32 pump pumps condensate from electrolyte evaporation step in a Cu manufacturing process. Duplex stainless steel and double mechanical seal were selected. The pump has been running for 6 years without bigger problems.
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP11-32 Open impeller APP Process pump 4 kW (3 hp) 2880 rpm ASTM 890 Grade3A Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. Solids content .......... Density...................... 0.8 l/s (13 USGPM) 30 m (99 ft) Condensate 7 90 oC (194 oF) 0% 1000 kg/m3 (62 lb/ft3)
Application Report
1(1)
AHLSTAR APP for Condensate Pumping

Electrolyte from Cu removal (electrowinning) Droplet separator
APP11-32
Condensate Steam
Evaporator
Heater Condensate Filtration Filtrate tank Sulphuric acid to process NiSO4
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP11-32 Open impeller APP Process pump 2.20 kW (1.6 hp) 1425 rpm ASTM 890 Grade 3A Single mechanical seal
An APP11-32 pump pumps condensate from electrolyte evaporation step in a Cu manufacturing process. The pumped liquid contains 6 % of sulphuric acid. Duplex stainless steel and single mechanical seal were selected. The pump has been running for 6 years without bigger problems.
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 0.13 l/s (2 USGPM) 15 m (49 ft) Condensate 1 50 oC (122 oF) 6% 1100 kg/m3 (68 lb/ft3)
Application Report
1(1)
AHLSTAR APP for Te Solution Pumping

Autoclave Anode slime from electrolysis Filter Precipitation Filter
Se solids Roasting furnace Converting and casting
Liquid
APP11-40
+
Rh solids Ag solids Au solids
AHLSTAR APP in Anode Slime Treatmement Process
Pump Data
Pump......................... Impeller..................... Type.......................... Motor......................... Speed....................... Material..................... Sealing...................... APP11-40 Open impeller APP Process pump 15 kW (11 hp) 2920 rpm ASTM 890 Grade 3A Double mechanical seal
An APP11-40 pump pumps Te solution to Te solids filtration. The pumped liquid contains 14% of sulphuric acid and Te solids, also Cu and Ni solids. Duplex stainless steel and double mechanical seal were selected. The pump has been running for 5 years.
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 5.5 l/s (87 USGPM) 50 m (164 ft) Te solution with solids 1 90 oC (198 oF) 14 % 1400 kg/m3 (88 lb/ft3)
Application Report
1(1)
AHLSTAR APT for Anode Slime Pumping

Anode slime from electrolysis Autoclave Filter Precipitation
APT55-12
Filter
Se solids Roasting furnace

+
Liquid
Converting and casting Ag solids Au solids

AHLSTAR APT in Anode Slime Treatmement Process
Rh solids
Pump Data
Pump......................... Impeller..................... Type.......................... Motor.......................... Speed....................... Material..................... Sealing...................... APT55-12 Open impeller APT Process pump 400 hp (298 kW) 1180 rpm ASTM 890 Grade 3A Double mechanical seal
An APT pump pumps anode slime slurry to filtration. The pumped liquid contains 14% of sulphuric acid and different kinds of solids, about 30%. Duplex stainless steel and double mechanical seal were selected. The pump has been running for 10 years.
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 7700 USGPM (485 l/s) 150 ft (46 m) Anode slime 1 120 oF (49 oC) 13 % 94 lb/ft3 (1500 kg/m3)
Application Report
1(1)
AHLSTAR APP for Anode Slime Pumping

Anode slime from electrolyse Autoclave Filtration Gas Te solids Se solids Roasting furnace APP32-80 Converting and casting Se Filter Au solids Rh solids Solution Precipitation Liquid Electrolysis
+ +
Precipitation
Filtration
Ejector
Leaching
Cementation
Precipitation
Ag solids
Au solids Filtration Filtration
Pt solids Waste solution
AHLSTAR APP in Anode Slime Treatment Process
Pump Data
Pump......................... Impeller..................... Type.......................... Motor.......................... Speed....................... Material..................... Sealing...................... APP32-80 Open impeller APP Process pump 2230 kW (30 hp) 1460 rpm Hastelloy E8 Double mechanical seal
Process Data
Q............................... H............................... Liquid........................ pH............................. Temperature.............. H2SO4 content .......... Density...................... 17 l/s (269 USGPM) 36 m (118 ft) Sulphuric acid 1 80 oC ( 176 oF) 25 - 30 % 1400 kg/m3 (87 lb/ft3)
Gas from Selenium roasting furnace mixed with sulphuric acid and water was pumped with AHLSTARTM APP process pump. The first material selection was Hastelloy B type material which was lost in couple of months. Hastelloy B material was tested first because of good experience in other process equipments. Hastelloy B was changed to Hastelloy E8 type of material which is nickel alloyed material also. The pump is equipped with double mechanical seal. APP pump from Hastelloy E8 material has been running three years without problems. The pump is still running.
copper.xls
03/08/00 13:26
Sulzer Pumps Finland Oy

Pump Lifetime Costs Profile
Industry Segment No. of pumps Pump types Copper 2744 25 (150) APP, WPP
Volute Casing ELECTROLYSE Cu REMOVAL by ELECTROLYSE ELECTROLYTE EVAPORATION CuSO4 CRYSTALLIZATION ANODE SLIME TREATMENT ADDITIONAL INFO 8,7 yr. 5,7 yr. 5,7 yr. 2 yr. 8,7 yr. 8 16 yr. 13 yr. 13 yr. 2,3 yr. 16 yr. 4 13,8 yr. 12,4 yr. 12,4 yr. 3,2 yr. 13,8 yr. 6 Some applications are very wearing because of high acid and temperature values. Crystallized particles makes wearing in some applications Low pH, high temperature and solid particles make some wearing Solid particles (Antimony, Bismuth and Arsenic) are cathered to the inside of pipelines and at least once a year the solid matter has to be removed off by high pressure washing. The motor and baseplate have to be protected by cover to avoid external corrosion in case if pumped liquid has got outside. 9 yr. 11,5 yr. Impeller 5,3 yr. 8,8 yr. Casing Cover 5,3 yr. 8,8 yr. Seal 2 yr. 2 yr. Average Liftime Number of pumps 9 yr. 11,5 yr. 3 4 Remarks Because of low voltage level in electrolyse, avoid electrical corrosion Copper sulfate is reason for wearing
Pump average lifetime (yr)
11,8

Copper Manufacturing Process: General Flowsheet of Process

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Copper Manufacturing Process: General Flowsheet of Process

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Copper Manufacturing Process

General Flowsheet of Process

SO2 Slag SO2 Slag

NiSO4 Electrolyte purification Cu solids CuSO4 Precious metals