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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

Copper Manufacturing Process


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

V00664/02 (10.2000) Copyright Sulzer Pumps Finland Oy 9

Copper Manufacturing Process


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

V00664/03 (10.2000) Copyright Sulzer Pumps Finland Oy 10

Copper Manufacturing 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
V00664/04 (10.2000) Copyright Sulzer Pumps Finland Oy 11

Copper Manufacturing Process


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)


Doubl. mech.2 (MR22) or Dyn. (DS02)

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

V00664/05 (10.2000) Copyright Sulzer Pumps Finland Oy 12

Copper Manufacturing Process


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


V00664/06 (10.2000) Copyright Sulzer Pumps Finland Oy 13

Copper Manufacturing Process


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

V00664/07 (10.2000) Copyright Sulzer Pumps Finland Oy 14

Copper Manufacturing Process


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


V00664/08 (10.2000) Copyright Sulzer Pumps Finland Oy 15

Copper Manufacturing 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

Doubl. mech.2 (MR22) or Dyn. (DS02)

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

V00664/09 (10.2000) Copyright Sulzer Pumps Finland Oy 16

Copper Manufacturing Process


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

V00664/10 (10.2000) Copyright Sulzer Pumps Finland Oy 17

Copper Manufacturing Process


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)

AHLSTAR APP for Electrolyte Pumping


Electrolyte from purification Anodes Starting sheets

Cells Cells

Copper cathodes to Anode scraps melting and casting

Electrolyte to purification
APP31-125

Filtration

AHLSTAR APP in Copper Electrolysis Process.

Anode slime to treatment

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)

N03846 / 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)

AHLSTAR APP for Electrolyte Pumping


Electrolyte from purification Anodes Starting sheets

Cells Cells

Anode scraps Copper cathodes to melting and casting

APP11-32

Electrolyte to purification

Filtration

AHLSTAR APP in Copper Electrolysis Process.

Anode slime to treatment


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)

N03847 / 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)

AHLSTAR APP for Electrolyte Pumping


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)

N03848 / 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)

AHLSTAR APP for Cu Solution Pumping


Electrolyte from electrolysis Crystallization

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.

AHLSTAR APP in CuSO4 Crystallization Process.

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)

N03849 / 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)

AHLSTAR APP for CuSO4 Solution Pumping


Electrolyte from electrolysis Crystallization

Steam
APP22-32

Mother liquor

CuSO4 Sedimentation Mother liquor separation (centrifuge)

Water

To Cu removal (electrolysis)

AHLSTAR APP in CuSO4 Crystallization Process.

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)

N03850 / 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)

AHLSTAR APP for Cu Solution Pumping


Electrolyte from electrolysis Crystallization

Steam CuSO4 Sedimentation Mother liquor separation (centrifuge)

Mother liquor

Water

APP22-32

To Cu removal (electrolysis)

AHLSTAR APP in CuSO4 Crystallization Process.

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)

N03851 / 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)

AHLSTAR APP for Cu Solution Pumping


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)

N03852 / 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)

AHLSTAR APP for Cu Solution Pumping


Electrolyte from CuSO4 crystallization

I Cells
+

II Cells
+

III Cells
+

Cu solids

Cu solids Storage

Cu solids

APP22-40

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. 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)

N03853 / 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)

AHLSTAR WKP Cantilever for Floor Water Pumping


Electrolyte from CuSO4 crystallization

I Cells
+

II Cells
+

III Cells
+

Cu solids

Cu solids Storage

Cu solids

To water treatment WKP23-250

Electrolyte to evaporation

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)

N15393 / Metal, Copper en (12.2003), 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)

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)

N03854 / 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)

AHLSTAR APP for Condensate Pumping


Electrolyte from Cu removal (electrowinning) Droplet separator Condensate Steam Heater Evaporator Condensate APP11-32 Filtration Filtrate tank
AHLSTAR APP in Electrolyte Evaporation

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)

N03855 / 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)

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

AHLSTAR APP in Electrolyte Evaporation

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)

N03856 / 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)

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)

N03857 / 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)

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)

N03858 / 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)

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.

N03882 / Metal, Copper en (11.2002), 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.

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