cátodos para producción de cobre - l. nordlund
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TANKHOUSE EQUIPMENT
Torren 2013-05-24
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Outotec Tankhouse Equipment
ANODE PREPARATION MACHINE (APM)
Proven technology
Worldwide benchmark
TANKHOUSE CRANE
Multifunctional Bale (Anode+Cathode)
Fully Automatic
FULL DEPOSIT ROBOT STRIPPING MACHINE (FDRSM)
Reliable solution
Modern technology
ANODE SCRAP WASHING MACHINE (ASWM)
Maximum recovery of slime
Low water consumption
PERMANENT CATHODE
Rigid Design
Best edgestrip
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Robotic Stripping Machines
Outotec is the Worlds leading supplier of robotic supported
Cathode Stripping Machines. The total amount of installed
robots are now 40 pcs. With the main customers being some of
the worlds biggest Cu Refineries.
Site: Country:
No. Of
Robots:
Copper
Production:
1 Caserones, Pan Pacific Chile 1 45.000
2 RCC Novgorod Russia 2 75.000
3 TNMG Tongling China 6 > 400.000
4 Daye NF China 6 > 300.000
5 JNMC Fangchenggang China 6 > 400.000
6 Paranapanema, Caraiba Brasil 3 > 275.0007 Boliden cathodes Sweden 5 > 275.000
8 Norilsk Nickel Russia 6 > 325.000
9 Fuchunjiang smelter* China 3 > 200.000
10China Gold* China 3 > 200.000
Total number of robots: 40
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2. Success Stories
Russia Copper Company wanted to upgrade their old Cathode stripping machine that had low
capacity and was considered non safe to the operators. In tuff competition Outotec came up
with the safest, most flexible and time efficient solution to the customer. By replacing the old
conventional stripping machine Outotec installed two robots and their strip station for
Taco/Kidd Cathodes the performance of the stripping went up by more than 50%.
Implementation time, Maintenance and Safety has been the key drivers and Outotec fulfilled all
of the criteria's set by the client. In 4 weeks the new stripping solution was in place and
production up and runninga minimum of production losses was achieved!
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Building Success together with Clients!
Before.. .After!
Low average speed: 140-150 c/h
Unsafefrequent incidentsTime consuming manual interference due to low
strip ability
Damaged cathodes (edgestrip and surface)
Increased sped: 250 c/h
SafeNo human interferenceReduced maintenance
Increased interval between cathode
maintenance
Open solution Easy to keep clean & maintain
Fast implementation
http://c/Users/launor/Documents/--%20CLIENTS%20--/--%20FDrSM%20--/OT%20FDRSM%20MOVIE%202012%20NOVGOROD%20UPGRADE.wmvhttp://c/Users/launor/Documents/--%20CLIENTS%20--/--%20FDrSM%20--/OT%20FDRSM%20MOVIE%202012%20NOVGOROD%20UPGRADE.wmvhttp://c/Users/launor/Documents/--%20CLIENTS%20--/--%20FDrSM%20--/OT%20FDRSM%20MOVIE%202012%20NOVGOROD%20UPGRADE.wmv -
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The Tongling Case400.000 tpa
One of Chinas largest producer of
cathode copper selected Outotecsrobotstripping machines for their new 400.000
tpa. tankhouse
By using Only two machines, Outotec
was the only one who could meet their
production demand in a safe and cost
effective way!
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The Daye Case300.000 tpa
Another of the Chinese Copper giants,
Daye Nonferrous, selected Outotec for their
newly build Copper RefineryKey factors in their chooise was Outotecs
local presence, advanced technology,
machine data and the capability of doing a
record fast installation on site to secure the
customers cash flow.
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DAYE Tankhouse
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FDRSMStack handling
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The Paranapanema Case
An old starting sheet technology based tankhouse
that is converting to a full deposit cathode production
needed the best availabletechnology
Outotec was selected to convert their operation andinstall Cathodes and a Stripping Machine with a
capacity of 700 cathodes/h (630 practical)
A doubble strip station solution was selected to strip
the Taco/Kidd cathodes in the 275.000 tpa tankhouse
http://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Paranapanema%20Simulation%20clip.avi -
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In Feed / Out Feed Robots
24.5.2013 Outotec11
The feeding robot transfers the cathode and
copper deposit from the wash conveyer to
stripping station 1 and stripping station 2 and
afterstripping to the discharge conveyor or the
optional cathode scanners.. The robot gripper
is equipped with a special tool that prevents
the copper deposit from pre-stripping during
movement.
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Stacking robot
24.5.2013 Outotec12
The stacking robot takes the plates from
the cathode conveyer and builds a stackof copper plates onto the stack-lifting
table. The stacking robot can also place
B-grade cathodes in the B-grade storage.
The stacking robot also feed the sampling
unit. The stacks are even and neath and
easy to strapp.
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Stripping Station
24.5.2013 Outotec13
The stripping station pre strip and strips the cathodes.
When the copper comes loose the strip station tilts the
cathode from vertical to horizontal position and releases thecopper onto the cathode conveyor.
In case of a planned maintenance, stripping station 1 or 2
can be shut off and the stripping machine can still run with
just a slightly lower capacity.
The frames are manufactured in carbon steel. The carbon
steel parts are protected against corrosion by acid resistant
epoxy paint.
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Pre-weighing of Cathodes
Performance of each cathode
Automatic selection of A or B
grade cathode
Can be combined with TIMS
Cell performance (summarizing)
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CathodeSense overview
Online Physical Quality Inspection Cathode deposit (nodules, thickness)
Edge strips (missing parts, nodules)
Plate straightness
Versatile Classification Criteria size, count, area, location and type of
defects
Integration with FDSM and TIMS
Quality Classification
Automatic reject forMaintenance
Historical analysis
Quality analysis
Troubleshooting
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OutotecCathode
OutotecCathode - More out of Cathodes
Over 350 000 permanent stainless steel cathodes manufactured for more
than 25 different plants.
Part of OutotecTankhouse Solutions
High mechanical strength
Permanent protection against corrosion
Permanent protection against mechanical wear and tear
High current efficiency and consistent electrical properties
New edge strip technology
Individual identification code for tracking
Global presenceworldwide service network
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OutotecCathode
General problems with stainless steel cathodes
Galvanic corrosion of the hangerbar and corrosion of the plate to
bar welding
Uneven electrical conductivity
Bending hangerbar structure and failing plate to bar welding
Edge strip problems
Stripping problems especially in wax less process
These generally known problems with the permanent cathodes inspirited Outotec in the 90s to start
developing its own cathode technology with significant improvements.
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OutotecCathode
SEPARATECATHODESSHEETS(SPLIT)
ENVELOPECATHODESSHEETS(TACO)
Cathodes can be delivered either for separate (SPLIT) or envelope (TACO) cathode sheet technology
In the SPLITcathode process the copper sheets
are separated at the V-groove edge.
Accurately and correctly manufactured cathode
V-groove enables optimum separation of the
copper sheets for separate cathodes when using
split cathode technology.
In the TACOcathode process the copper sheets
are partly grown together at the bottom edgewith patented V-groove technology.
This assures the copper sheets stay together
after stripping in trimmed form. This enables
reliable and trouble free handling of the copper
sheets in future process stages.
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OutotecCathode
All stainless steel structure
with laser welded joints
Only bus bar contact
areas are exposed
Integrated OutotecEdge Strips
Patented hanger bar technology
V-groove
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OutotecCathode
Continuous laser welding
Only stainless steel to stainless steel laser welding
No dissimilar metal welds which eliminates problems with galvanic corrosion
No welding inclusion (Excellent corrosion resistance)
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OutotecCathode - Hangerbar
Hanger bar construction
Stainless steel tube with copper core
Sound metallurgical bond
Permanent protection against corrosion
Excellent long term electrical conductivity
Strong mechanical structure designed for heavy
duty mechanized stripping
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OutotecCathode - Manufacturing
Manufacturing
Outotecs cathodes are manufactured at its own workshop withautomated production lines.
Fully automatic production lines for cathode manufacturing and
quality control.
OutotecCathodedelivery comply with ISO and OHSAS quality
assurance systems for:
Research and Development ISO 9001:2000
Environmental System ISO 14001
Health and Safety OSHA 18001
Project Implementation ISO 9001:2000
Manufacturing ISO 9001:2008
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OutotecCathode - 2nd generation Edge Strips
Edge strip manufacturing
Outotecs edge strips are integrated to the vertical sides ofthe steel platewith patented high pressure molding technology.
Permanently fixed edge strips are designed for high mechanical stresses
and impacts caused by mechanized stripping.
Since 2009 Outotec has been using in-house developed second
generation upgraded manufacturing process.
This high pressure manufacturing process guarantees identical edgestrip quality through production and maintenance.
Outotec has upgraded material from HD-PE (black) to new higher
perfomance special grade of PP (white).
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OutotecCathodeQuality Control
Cathode quality is guaranteed by continuos follow up ofmaterial, manufacturing and operation qualities in our own
research facilities.
Plate straightness and dimension
Laser welding quality
Cathode conductivity check
Random plate surface quality
Edge strip quality
V-groove dimension
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OutotecCathode - References
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OutotecCathode - Service
Cathode service options:
Minimum service
Hand held maintenances tools and racks
On-site cathode service shop
Edge strip detachment machine
Cathode sheet straightening unit
Edge strip replacement machine (ESRM)
Outotec cathode service center
Automated edge strip detachment machine
Cathode sheet straightening unit
Automatic edge strip replacement machine
V-grooving machine
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Edge Strip Replacement Machine (ESRM)
Dimensions 5000x2200x2500 mm
Weight 8000 kg
Capacity, Single table 6-10 cathodes/h
Double table 10-14 cathodes/hOperators required 1 with lifting equipment
OR
2 without lifting equipment
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http://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmvhttp://c/Users/launor/Documents/--%20TRAINING%20--/ESRM_v6_1270x720.wmv -
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Plant / Operation Equipment YearNovgorod Metallurgy Plant, Russia Semi automatic edge strip replacement machine (ESRM) with cathode
maintenance equipment.
2002
Kyshtym Copper Plant Expansion, Russia Semi automatic edge strip replacement machine,
Hand held edge strip repairing tools
2006
Xiangguang Copper Plant, China Semi automatic edge strip replacement machine withcathode maintenance
equipment,
Hand held edge strip repairing tools
2007
Lane Xang Minerals Sepon Copper, Laos Semi automatic edge strip replacement machine 2008
Montanwerke Brixlegg AG, Austria Hand held edge strip repairing tools 2008
Cobre Las Cruces, Spain Semi automatic edge strip replacement machine with cathode maintenance
equipment
2008
Ta Mara, Peru 2ndGeneration automatic edge strip replacement machine with cathodemaintenance equipment
2010
Assarel Medet JSC, Bulgaria Hand held edge strip repairing tools 2010
CNMC Luanshya Copper Mines PLC, Zambia Hand held edge strip repairing tools 2011
Paranapanema S.A. , Brazil 2ndGeneration automatic edge strip replacement machine with bottom edge
strip tooling for Ti-motherblanks.
2012
Plant / Operation Equipment YearNewBoliden Harjavalta Copper, Finland 2ndGeneration automatic edge strip replacement machine.
Full Service cathode maintenance at Outotec Turula Workshop / Finland
2009present day
Montanwerke Brixlegg AG, Austria 2ndGeneration automatic edge strip replacement machine.
Full Service cathode maitenance at Outotec Turula Workshop / Finland
2010present day
Novgorod Metallurgy Plant, Russia 2ndGeneration automatic edge strip replacement machine.
Upgrade of edge strip quality from original 2002 delivered 1stgeneration
extrusion machine. On-site service visit with mobile ESRM unit.
06/201209/2012
(one time overhaul)
Anglo Rustenburg Mines Limited, South Africa 2ndGeneration automatic edge strip replacement machine.
Upgrade of edge strip quality from original 2007 delivered 1st
generation extrusion machine with bottom edge strips.
On-site service visit with mobile ESRM unit.
04/2013
References List / Maintenance Services
References List / Equipment deliveries
OutotecCathode - Service
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RCC Novgorod Metallurgy plant (Russia)
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Anglo Platinum Rustenburg (RSA)
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Anglo Platinum Rustenburg (RSA)
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Job DoneHappy Customer
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