Copper

Electrorefinery/Electrowinning
Process Control System
 Automatic control of an electrolytic These decentralized units, such
Automatic copper plant can be subdivided as crane control, rectifier control,
Control into several different areas: stripping machine control, etc.,
are placed locally, i.e. in the
• DC power supply from rectifiers
of an and thyristors
environment of the actual
electrolysis equipment, and linked
• Electrolysis cells
Electrolytic • Electrolyte treatment
to the main computer by means
of a data bus, e.g. a PROFIBUS,
Copper Plant • Crane system
• Machines for anode and
or over a point-to-point link.
cathode preparation. On the up-line side of the actual
electrolytic refining plant is the
The higher-level control tasks and
anode casting plant, which can
planning tasks are performed by
be controlled and supervised by
a computer that is normally
a separate computer. Similarly, a
installed in a control room or the
separate computer can also be
manager’s office, i.e. in a relatively
used for the continuous casting
clean environment.
plant, comprising several casting
The computer is, in fact, a power- machines and furnaces, on the
ful SIMATIC® programmable down-line side of the refining
controller and the plant is operated plant.
from several operator terminals
All three systems can be linked
incorporating colour monitors.
together as an interconnected
The lower control level comprises network:
distributed SIMATIC controllers
• the main computer
assigned to each of the process
• the computer for the anode
machines which they can control
casting plant, and
and supervise individually.
• the computer for the continuous
casting plant.

Shift protocol Alarm protocol

Operator Terminal Operator Terminal
printer printer

Industrial Ethernet
Programmer Central controller

PROFIBUS

Measuring-point Local controller Rectifier systems Preperation Crane system Electrolyte

multiplexer machines circuits

Block diagram
Functions

1.
Main computer

Operation of the baths Voltage monitoring and Electrolyte monitoring Planning

• Keeping a time table for each
bath for anode changing,
cathode changing and
cleaning intervals
• Issuing the command for by-
passing the baths where
electrode changing is being
performed
• Calculating the total
ampere-hours for each bath
• Notifying the crane of the
positions of the relevant
baths, in the form of a daily
schedule, and calculating the
acceleration, travelling and
deceleration needed to reach
those positions
• Starting the stripping and
preparation machines
• Taking into account all
the interlocking conditions
between the machines
and the crane, as well as
the appropriate safety
regulations
• Signalling any faults and,
if necessary, interrupting
the current program
• Printing out a daily log in
which all the work to be
carried out is recorded
• Recording all the weights
involved in the process.
accounting
• Inputting all the bath
voltages and currents at
predetermined intervals
• Checking the values for
plausibility
• Calculating the total kAh
and kWh consumption of
each bath
• Checking all bath voltages
for a lower limit value
(short-circuit) and upper limit
value, with corresponding
printouts and displays
• Calculating the quantity of
copper produced per bath
each time a cathode is
changed, and the kWh
consumption per tonne of
copper, and recording
the values
• Preparing shift, batch and
fault logs
• Recording anode and
electrolyte analysis data
received from the
laboratory.
SECTION VOLT.: 5961 mV
SECTION AVERAGE VOLT.: 372 mV
• Cyclical inputting of
electrolyte temperature
from the electrolyte
circuits
• Controlling the flow of hot
water/steam to the heat
exchanger so that a
predetermined electrolyte
temperature is maintained
• Controlling all motors,
stirrers, pumps and solenoid
valves
• Metering the addition of
sulphuric acid and inhibitors
• Controlling the levels in
vessels and tanks
• Recording electrolyte
analysis data, e.g. at the end
of the shift.
SECTION/GROUP: 10.3
CROP-NO.: 1 CURRENT DENSITY:
• Calculating, from the
production orders, the
quantity of anode plates
needed for a specific period
of time and transferring
the figure to the casting
plant control system
• Calculating, from the
electricity tariffs (day/night)
and the production orders,
the load curve to be
followed
• Issuing appropriate control
commands to the power
rectifiers
• Controlling the data traffic
to the crane, rectifier
system and preparation
machines, also to the
laboratory, the anode
casting plant and the
continuous casting plant
• Operating the colour
monitors and printers.
RECTIFIER CURRENT: 21000 A
250 A/m2
CURRENT CONSUMPTION: 3500 kAh/CROP

mV
Limit 500
Values

400
AH
409 mV
+ 10%
300

AL 200
353 mV
–5%

100

0
CELL-NO.: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CELL-VOLT.: 369 359 376 378 363 355 373 369 390 393 369 354 370 390 378 375

PRINTOUT SELECTION: 10.5 RETURN

Cell Voltages
2. 3. 4.
Crane control Preparation machine control Power rectifier control
• Receiving from the main computer, • Receiving start and stop signals from • Inputting the DC current and voltage
before each travel movement, new the main computer
• Acquiring the meter readings for kAh,
positioning and travelling data both for
• Controlling the logic sequence of the kVh and kWh
the long travel and the crab travel
machining
systems • Changing the current setpoint
• Responding to all the necessary logic
• Controlling the long travel and crab • Executing constant-current control
gating and interlocking conditions
travel appropriately
for the machines • Signalling faults to the main computer.
• Monitoring the distances travelled
• Monitoring the occupancy of the input
• Signalling arrival at the given position and output conveyors
to the main computer, or giving an
• Acquiring all weights involved in the
alarm in the event of a fault
process
• Controlling the hoisting mechanism
• Signalling faults to the main computer.
according to a program algorithm in
order to remove coated cathode plates
from the bath to be serviced, or to
fit new cathode plates, or to change
the anodes
• Monitoring the insulation between
the crane and the beam
• Monitoring all limit switches and
interlocking conditions needed for
satisfactory operation of the
crane
• Receiving manual commands issued
from a manual control panel
and controlling the crane
accordingly
• Recording, with
an input signal, the
counter status of a
manually-driven position
as a new reference.
Description
The main computer searches through
time tables or ampere-hours tables
to find which baths will be the next to
be serviced, i.e. will need anode chang-
ing, cathode changing or cell cleaning,
within a given period of time.
The sequence of servicing is estab-
lished according to a system of opti-
mizing the amount of travel required.
Each movement of the crane is broken
down into an acceleration distance,
a travel distance and a deceleration
distance which are then transferred
to the crane control system as
positioning data.
The crane and crab travel mechanisms
are positioned by means of a digital
position pulse counting system. A pulse
encoder mounted on one of the non-
driven axles supplies pulses as the long
travel or crab travel mechanisms are
operating and they are totalled by a
counter. By comparing the instantaneous
counter states with the given values
it is possible to produce stop and speed-
changing commands for the drive con-
trol system.
Sensors placed at suitable points ensure
proper synchronizing of the position
counters so that a safe approach to
the given position is made. A mechanical
or optical device is provided to ensure
precise positioning of the beam over
the bath.
When the crane is in position above
the selected bath, a checkback signal
is sent to the main computer. Lowering
of the beam with the electrode hook
can now be performed either fully auto-
matically or manually. Manual operation
is from a control panel.
Upon completion of the positioning,
the anode or cathode changing can be
started.
The crane transfers the cathode plates
taken from the bath to the entry area
of the stripping machine, picks up a set
of prepared plates from the exit area
of the machine and brings them back to
the cell.
Anode changing comprises taking a
complete set of anodes from the bath
and transferring them to the entry
area of the anode residual machine. At
the exit area of the anode preparation
machine there are new sets of anodes
for replacing in the cells.
At the main computer it is pos-
sible to select whether the loading
procedures are to be performed entirely
automatically or whether they will be
dependent on acknowledgement signals
from the plant operators at certain points
in the sequence. Individual baths can
be selected and deselected from the
operating keyboard for the servicing
cycle, e.g. for cleaning or maintenance.
The automatic program sequence can
be interrupted by issuing the ”Manual
operation“ command. The crane will
then have to be driven to the appropriate
position manually from the manual
control panel. The automatic mode can
only be re-engaged when the crane
is in certain basic positions which must
be approached under manual control.
Automatic operation can then be con-
tinued from the point at which it was
discontinued.
The operating plan and actual position
of the crane at any instant can be dis-
played on the monitor screen.
Remotely-operated bath short-circuiters
can be operated by the main computer,
either according to the operating plan
for anode/cathode changing, or according
to separate time tables, or in the event
of a fault.
The main computer monitors the indi-
vidual machine control systems and
records any faults that occur in their area.
If any of these faults affects the pro-
duction process, the computer stops
operation of the crane completely or
issues the command for reducing the
DC current and extending the refining
process accordingly.
The baths of the refining plant are
organized into separate groups. In order
to measure the bath voltages, the
voltages of the individual baths that make
up a group are fed to a multiplexer which
transfers each measured value in turn
in a predetermined time cycle to a
DC isolating amplifier whose output is
connected to the analog input of the
main computer.
There are as many multiplexer units,
isolating amplifiers and analog inputs as
there are bath groups. The multiplexer
units operate in parallel, i.e. at a particular
instant the measured values present at,
say, Input 1 of the various multiplexers
are switched through. The total cycle
time, i.e. the time that elapses before
the same bath is selected again, depends
on the number of baths.
The measured values are integrated
over a period of 20 ms and then pro-
cessed to give mean values. A mean
value is calculated every minute
and stored.
All the input values of voltage are
checked for plausibility and adherence
to upper and lower limits.
Each group of baths can be selected
from the keyboard and all the relevant
cell voltages appear on the colour monitor.
Via a counter module, the main
computer acquires the kAh pulses being
output by the DC current measuring
device of the power rectifier system.
While a group of baths is operating,
the totalled metering values are stored
in a memory assigned to a particular
bath. When that bath group is switched
off, the acquisition for the bath is stopp-
ed. This gives a relationship between
kAh consumption and the amount of
metal produced by each bath. The kAh
data is used for calculating bath effi-
ciency.
The temperature of the electrolyte is
measured at various points through-
out the refining process. The main
computer inputs these values cyclically
and sees whether any tendency to
change can be detected. If the tempe-
rature is tending to deviate from a given
setpoint, the main computer regulates
the supply of heat to the heat exchangers
accordingly.
Issued by
Siemens AG
Industrial and Building Systems Group
ANL A98D Electrochemical Industry
P.O. Box 32 40, D-91050 Erlangen
Germany
Tel. ++49-9131-72 67 87
Fax ++49-9131-72 69 70
e-mail: chemical-plants@erlm.siemens.de
Siemens Aktiengesellschaft
The quality of the electrolyte is checked
periodically by taking samples and
performing an analysis. The process can
be carried out by hand; the results are
then entered into the computer from the
keyboard for the purpose of logging.
On the other hand, it is also possible for
the sampling and analysis to be per-
formed automatically. In this case the
results of the analysis are fed to the
computer directly from the analytical
instruments. Depending on the results
of the analysis, the computer then
undertakes appropriate metering of
suitable additives.
The main computer also controls and
monitors all motors, pumps and solenoid
valves.
All operations affecting the production
process, e.g. crane movements, ampere-
hours tables, time tables, analysis results,
production data, etc., can be displayed
on a monitor screen. The individual
displays can be called up by means of
function keys. Setpoints or parameters
can be changed and additional infor-
mation entered from the same keyboard.
Any faults that occur are displayed
on the screen, or on an annunciator
panel, as well as being printed out by
the alarm printer at the same time
together with the date and time. All
production data, current yield, effi-
ciency and bath voltage readings are
contained in an operating log which
is printed out in the form of a shift,
daily or batch log. An optional fea-
ture is the processing of other data
on a PC.
The main computer is actually a power-
ful SIMATIC control system equipped
with the necessary analog and digital
inputs and outputs and the necessary
interfaces for operating the crane control
system, the power rectifier control
system, the monitor screens and the
logging printers.
Subject to change without prior notice
Crane control is executed by a SIMATIC
programmable control system. The
system is mounted in the switchgear
cubicle on the crane, together with
the necessary input/output modules,
and issues all the required commands
to the drive machinery so that the
operating procedures distributed by
the main computer are put into effect.
All the internal interlocking and logic
gating needed for operating the crane
is taken into account.
Data is exchanged between the main
computer and the crane control system
via a 20 mA serial interface. The data
traffic itself can either be carried on a
4-wire trailing cable or by an inductive
system employing a magnetic loop.
Open-loop control, closed-loop con-
trol and monitoring of each power
rectifier assembly are also executed
by a SIMATIC system. The same type
of equipment is used for the control
systems for the cathode stripping
machine and the anode machines.
All the SIMATIC control systems are
linked to the main computer over a
PROFIBUS data bus.
All the controllers are programmed in
the STEP® language; the programming
can use either instruction lists or a
function diagram.
The programs are of modular struc-
ture (data modules, function modules,
organizational modules, etc.) and so
are clear and easy to adapt.
A programming unit is used and
there are also powerful service and
diagnostic devices available.
Summary
Modern Tankhouses are equipped with
full integrated Process control systems,
which allows the monitoring of the cell
voltage, the detection of short circuits,
monitoring and controlling of the com-
plete production process, the full auto-
matic operation of crane and handling
machines as well as extensive protocols
and eventlogs. This guarantees a smooth
plant operation, top quality and reduction
in production costs.
Know-how in
Systems Integration.
Siemens
Order No. E10001-A98-A108-V1-7600
Dispo-No. 21612 SEK 21822
Printed in Germany
11U1233 98E.798209 PA 7972.