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Benchmarking of JCL copper refinery
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Refineries considered and their capacities...
Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/449595Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring,Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring,Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring,Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring,Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring,Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring,Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring,Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100Direct neutralisation31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring,Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
Chart1
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
332
Current Density
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
Chart2
28593
28094
27495
33095
32095
30096
28096
30096
32196
30896.5
31597
33097
33297
31597
28098
29098
Current Density
Current Efficiency,%
Refinery
CE. %
Current Efficiencies
Chart4
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Scrap Gen., %
REFINERY
Chart5
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12.5
Slime fall, Kg/MT
Slime fall, Kg/MT
Refinery
Chart6
245
280
295
310
320
325
342
350
350
359
362
370
377
392
Power Cons. Units/MT
Chart7
280245
320280
300295
285310
280320
290325
308342
330350
315350
274359
280362
332370
321377
315392
Current Density
Power Cons. Units/MT
Refinery
Power Consumption, Units/MT
Power Consumption, Units/MT
Sheet2
Refinery NameLocationCountryProcessCapacity, MTA
Port KemblaPort KemblaAustraliaISA120000
Falcon BridgeKidd creekCanadaKidd130000
BolidenSweedenSweedenISA140000
LG MetalsOnsanS.KoreaKidd160000
STERLITESilvassaIndiaISA165000CRL106045/4495Port Kembla274PT Smelting28593Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Huttenwerke KayserLunenGeramnyISA180000Port Kembla48053/52100Falcon Bridge280Kennecott Utah28094Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
Birla CopperDahejIndiaISA150000Union Miniere91161/6098Mexicana De Cobra280Port Kembla27495Birla Copper12.6CRL2.6CRL300295
Cyprus MiamiMiamiUSAISA190000Falcon Bridge51245/4484Kennecott Utah280Union Miniere33095PT Smelting13.2STERLITE2.7PT Smelting285310
Hibi KyodoTamanoJapanISA191000Huttenwerke Kayser80039/3898PT Smelting285Cyprus Miami32095Union Miniere14Mexicana De Cobra3Kennecott Utah280320
PT SmeltingGresikIndonesiaISA200000Norddeutsche Affinerie108057/5695LG Metals290CRL30096LG Metals14LG Metals3.3LG Metals290325
Atlantic copperHuelvaSpainISA250000PT Smelting65459/58103.5CRL300Falcon Bridge28096Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
CRLTownsvilleAustraliaISA270000Hibi Kyodo63154/53-Boliden300Boliden30096Port Kembla15Port Kembla8Union Miniere330350
Kennecott UtahMagmaUSAKidd281000Mexicana De Cobra111558/57105Hibi Kyodo308STERLITE32196STERLITE15Boliden8Huttenwerke Kayser315350
Mexicana De CobraNacozoriMexicoKidd300000LG Metals512-98Huttenwerke Kayser315Hibi Kyodo30896.5CRL16Kennecott Utah9.7Port Kembla274359
Union MiniereOlenBelgiumISA350000Atlantic copper112040/3998Birla Copper315Huttenwerke Kayser31597Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
Norddeutsche AffinerieHamburgGermanyISA370000Boliden58844/43100Cyprus Miami320Norddeutsche Affinerie33097Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Jhagadia CopperJhagadiaIndiaISA50000
*Under TrailCyprus Miami50461/60102STERLITE321Atlantic copper33297Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Birla Copper68854/53100Union Miniere330Birla Copper31597Boliden20Norddeutsche AffinerieBirla Copper315392
Kennecott Utah140047/4698Norddeutsche Affinerie330Mexicana De Cobra28098Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
STERLITE51855/54*98Atlantic copper332LG Metals29098Falcon Bridge27Birla CopperBoliden300
* 56 anodes per cell is under trail
Sheet3
Anode parameters.
Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/449595Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring,Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring,Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring,Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring,Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring,Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring,Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring,Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100Direct neutralisation31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring,Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
Chart1
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
332
Current Density
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
Chart2
28593
28094
27495
33095
32095
30096
28096
30096
32196
30896.5
31597
33097
33297
31597
28098
29098
Current Density
Current Efficiency,%
Refinery
CE. %
Current Efficiencies
Chart4
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Scrap Gen., %
REFINERY
Chart5
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12.5
Slime fall, Kg/MT
Slime fall, Kg/MT
Refinery
Chart6
245
280
295
310
320
325
342
350
350
359
362
370
377
392
Power Cons. Units/MT
Chart7
280245
320280
300295
285310
280320
290325
308342
330350
315350
274359
280362
332370
321377
315392
Current Density
Power Cons. Units/MT
Refinery
Power Consumption, Units/MT
Power Consumption, Units/MT
Sheet2
Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT
Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150274PT Smelting28593Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Refinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of crops
Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250280Kennecott Utah28094Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60280Port Kembla27495Birla Copper12.6CRL2.6CRL300295
LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265280Union Miniere33095PT Smelting13.2STERLITE2.7PT Smelting285310
STERLITESilvassaIndiaISA165000Port Kembla3445021/7357285Cyprus Miami32095Union Miniere14Mexicana De Cobra3Kennecott Utah280320
Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76290CRL30096LG Metals14LG Metals3.3LG Metals290325
Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250300Falcon Bridge28096Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5300Boliden30096Port Kembla15Port Kembla8Union Miniere330350
Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370308STERLITE32196STERLITE15Boliden8Huttenwerke Kayser315350
PT SmeltingGresikIndonesiaISA200000CRL3705021/7355315Hibi Kyodo30896.5CRL16Kennecott Utah9.7Port Kembla274359
Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250315Huttenwerke Kayser31597Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
CRLTownsvilleAustraliaISA270000LG Metals3805521/7350320Norddeutsche Affinerie33097Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355321Atlantic copper33297Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73330Birla Copper31597Boliden20Norddeutsche AffinerieBirla Copper315392
Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365330Mexicana De Cobra28098Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50332LG Metals29098Falcon Bridge27Birla CopperBoliden300
JHAGADIA COPPER320+/-1040-5220/73
*Under Trail
* 56 anodes per cell is under trail
Sheet3
Cells...
Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, Manhr/MTCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/4495952Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring, Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring, Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring, Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring, Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring, Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring, Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring, Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100--31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring, Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
Refinery NameAnode/cathode per cellAnode gap, mm
Refinery NameAnode/cathode per cellAnode gap, mm
CRL45/4495
Port Kembla53/52100
Union Miniere61/6098
Falcon Bridge45/4484
Huttenwerke Kayser39/3898
Norddeutsche Affinerie57/5695
PT Smelting59/58103.5
Hibi Kyodo54/53-
Mexicana De Cobra58/57105
LG Metals98
Atlantic copper40/3998
Boliden44/43100
Cyprus Miami61/60102
Birla Copper54/53100
Kennecott Utah47/4698
STERLITE55/54100
JHAGADIA COPPER44/43100
CD
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
330
STERLITE
BIRLA
Current Density
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
CE
93
94
95
95
95
96
96
96
96
96.5
97
97
97
97
98
98
STERLITE
BIRLA
Current Efficiency,%
Refinery
Current efficiency, %
Current Efficiency, %
slime fall
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12
STERLITE
Slime fall, Kg/MT
Refinery
Slime fall, Kg/MT
SCRAP
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Refinery
Scrap Gen., %
Scrap Generation., %
Sheet2
Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightRefinery NameNo. of cellsAnode/cathode per cellAnode gap, mmRefinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT
Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150Port Kembla48053/52100Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250Cyprus Miami50461/60102Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60Falcon Bridge51245/4484Birla Copper12.6CRL2.6CRL300295
LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265LG Metals512-98PT Smelting13.2STERLITE2.7PT Smelting285310
STERLITESilvassaIndiaISA165000Port Kembla3445021/7357STERLITE51855/54100Union Miniere14Mexicana De Cobra3Kennecott Utah280320
Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76Boliden58844/43100LG Metals14LG Metals3.3LG Metals290325
Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250Hibi Kyodo63154/53-Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5PT Smelting65459/58103.5Port Kembla15Port Kembla8Union Miniere330350
Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370Birla Copper68854/53100STERLITE15Boliden8Huttenwerke Kayser315350
PT SmeltingGresikIndonesiaISA200000CRL3705021/7355Huttenwerke Kayser80039/3898CRL16Kennecott Utah9.7Port Kembla274359
Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250Union Miniere91161/6098Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
CRLTownsvilleAustraliaISA270000LG Metals3805521/7350CRL106045/4495Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355Norddeutsche Affinerie108057/5695Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73Mexicana De Cobra111558/57105Boliden20Norddeutsche AffinerieBirla Copper315392
Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365Atlantic copper112040/3998Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50Kennecott Utah140047/4698Falcon Bridge27Birla CopperBoliden300
*Under Trail* 56 anodes per cell is under trail
* 56 anodes per cell is under trail
Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m
CRL461706325
Port Kembla451806230
Union Miniere401706330
Falcon Bridge4218065-
Huttenwerke Kayser451656525
Norddeutsche Affinerie46170-20063-
PT Smelting451806335
Hibi Kyodo48.91926530
Mexicana De Cobra451806525
LG Metals421556430
Atlantic copper451806420
Boliden471756520
Cyprus Miami451756440
Birla Copper461726525
Kennecott Utah451706620
STERLITE501656525
Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing
CRL41774645Reatrol
Port Kembla5080042No
Union Miniere9060050Yes
Falcon Bridge11045040Colamat
Huttenwerke Kayser8080060No
Norddeutsche Affinerie----Colamat
PT Smelting40-6060-905-1030-40No
Hibi Kyodo1168635No
Mexicana De Cobra77654935No
LG Metals7180040No
Atlantic copper6464030Yes
Boliden4590050No
Cyprus Miami5065735-
Birla Copper83811545-
Kennecott Utah7565045No
STERLITE5560050No
Refinery NameCell inspection/dayMethods
CRL2Infrared camera, Cell voltage monitoring
Port Kembla1Infrered camera, Gaussmeter
Union Miniere1Infrared Camera, Cell voltage monitoring
Falcon Bridge1Infrared Camera, Cell voltage monitoring
Huttenwerke Kayser3Infrared Camera, Cell voltage monitoring
Norddeutsche Affinerie1.5Infrared Camera, Cell voltage monitoring, Gauss meter
PT Smelting1 to 2Cell voltage monitoring, Gauss meter
Hibi Kyodo2 or 3Cell voltage monitoring, Gauss meter
Mexicana De Cobra3Cell voltage monitoring, Gauss meter
LG Metals1Infrared Camera, Gauss meter
Atlantic copper2Infrared Camera, Cell voltage monitoring, Gauss meter
Boliden3Cell voltage monitoring, Gauss meter
Cyprus Miami2Infrared Camera, Cell voltage monitoring, Gauss meter
Birla Copper--
Kennecott Utah1Infrared Camera, Cell voltage monitoring
STERLITE3Cell voltage monitoring, Gauss meter
Electrolyte Purification
Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameSlime fall, Kg/MTRefinery NameScrap Gen., %Refinery NameCurrent DensityPower Cons. Units/MTRefinery NameCurrent DensityTime Efficiency, %EquipmentsRefinery NameStep-1Step-2Step-3
Port Kembla274PT Smelting28593Cyprus Miami1.6Norddeutsche Affinerie11Falcon Bridge280245Kennecott Utah28092Automatic craneCRLLiberatorArsenic extractionNiSO4 plant
Falcon Bridge280Kennecott Utah28094PT Smelting2.4Huttenwerke Kayser12Cyprus Miami320360Falcon Bridge28094Automatic cranePort KemblaLiberatorNiSO4 plant
Mexicana De Cobra280Port Kembla27495CRL2.6Birla Copper12.6CRL300345STERLITE32194Manual craneUnion MiniereBleeding to chemical plant
Kennecott Utah280Union Miniere33095STERLITE2.7PT Smelting13.2PT Smelting285310Port Kembla27495Automatic craneFalcon BridgeLiberatorAcid purification unitETP
PT Smelting285Cyprus Miami32095Mexicana De Cobra3Union Miniere14Kennecott Utah280320Union Miniere33095Automatic craneHuttenwerke KayserCuSO4 plantLiberatorNiSO4 plant
LG Metals290CRL30096LG Metals3.3LG Metals14LG Metals290325LG Metals29095Automatic craneNorddeutsche AffinerieLiberatorNi,Fe,As removal
CRL300Falcon Bridge28096Hibi Kyodo6Atlantic copper14Hibi Kyodo308342Cyprus Miami32095Automatic cranePT SmeltingLiberatorNiSO4 plant
Boliden300Boliden30096Boliden8Port Kembla15Huttenwerke Kayser315350Birla Copper31595Automatic craneHibi KyodoLiberatorChelating resinNiSO4 plant,
Hibi Kyodo308STERLITE32196Port Kembla8STERLITE15Union Miniere330355CRL30095Automatic craneLG MetalsLiberatorNiSO4 plant
Huttenwerke Kayser315Hibi Kyodo30896.5Kennecott Utah9.7CRL16Port Kembla274359Norddeutsche Affinerie33096Automatic craneAtlantic copperLiberatorNiSO4 plant
Birla Copper315Huttenwerke Kayser31597Falcon Bridge10Mexicana De Cobra16Mexicana De Cobra280362PT Smelting28596Automatic craneBolidenLiberatorNiSO4 plant
Cyprus Miami320Norddeutsche Affinerie33097Huttenwerke Kayser12Kennecott Utah16Atlantic copper332370Huttenwerke Kayser31597Automatic craneBirla CopperDirect Neutralisation
STERLITE321Atlantic copper33297Union Miniere12Hibi Kyodo17.5STERLITE321377Hibi Kyodo30897Automatic craneKennecott UtahLiberatorTo other plant
Union Miniere330Birla Copper31597Atlantic copperBoliden20Birla Copper315392Atlantic copper33297Automatic craneSTERLITELiberatorAcid purification unitETP
Norddeutsche Affinerie330Mexicana De Cobra28098Birla CopperCyprus Miami20Norddeutsche Affinerie330Mexicana De Cobra280--
Atlantic copper330LG Metals29098Norddeutsche AffinerieFalcon Bridge27Boliden300Boliden300
Sheet3
..ELECTROLYTE
Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/449595Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring,Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring,Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring,Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring,Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring,Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring,Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring,Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100Direct neutralisation31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring,Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
Chart1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Refinery Name
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
Chart2
28593
28094
27495
33095
32095
30096
28096
30096
32196
30896.5
31597
33097
33297
31597
28098
29098
Current Density
Current Efficiency,%
Refinery
CE. %
Current Efficiencies
Chart4
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Scrap Gen., %
REFINERY
Chart5
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12.5
Slime fall, Kg/MT
Slime fall, Kg/MT
Refinery
Chart6
245
280
295
310
320
325
342
350
350
359
362
370
377
392
Power Cons. Units/MT
Chart7
280245
320280
300295
285310
280320
290325
308342
330350
315350
274359
280362
332370
321377
315392
Current Density
Power Cons. Units/MT
Refinery
Power Consumption, Units/MT
Power Consumption, Units/MT
Sheet2
Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m
CRL461706325
Port Kembla451806230
Union Miniere401706330
Falcon Bridge4218065550(JUMBO)
Huttenwerke Kayser451656525
Norddeutsche Affinerie46170-2006325
PT Smelting451806335
Hibi Kyodo48.91926530
Mexicana De Cobra451806525
LG Metals421556430
Atlantic copper451806420
Boliden471756520
Cyprus Miami451756440
Birla Copper461726525
Kennecott Utah451706620
STERLITE501656525
JHAGADIA COPPER45160-17062-6427-30
Sheet3
Reagent addition and control....
Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/449595Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring,Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring,Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring,Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring,Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring,Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring,Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring,Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100Direct neutralisation31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring,Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
Chart1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Refinery Name
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
Chart2
28593
28094
27495
33095
32095
30096
28096
30096
32196
30896.5
31597
33097
33297
31597
28098
29098
Current Density
Current Efficiency,%
Refinery
CE. %
Current Efficiencies
Chart4
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Scrap Gen., %
REFINERY
Chart5
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12.5
Slime fall, Kg/MT
Slime fall, Kg/MT
Refinery
Chart6
245
280
295
310
320
325
342
350
350
359
362
370
377
392
Power Cons. Units/MT
Chart7
280245
320280
300295
285310
280320
290325
308342
330350
315350
274359
280362
332370
321377
315392
Current Density
Power Cons. Units/MT
Refinery
Power Consumption, Units/MT
Power Consumption, Units/MT
Sheet2
Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing
CRL41774645Reatrol
Port Kembla5080042No
Union Miniere9060050Yes
Falcon Bridge11045040Colamat
Huttenwerke Kayser8080060No
Norddeutsche Affinerie----Colamat
PT Smelting40-6060-905-1030-40No
Hibi Kyodo1168635No
Mexicana De Cobra77654935No
LG Metals7180040No
Atlantic copper6464030Yes
Boliden4590050No
Cyprus Miami5065735Yes
Birla Copper83811545-
Kennecott Utah7565045No
STERLITE5560050No
JHAGADIA COPPER85-9072-8040-45No
Sheet3
CELL INSPECTION METHODS
]Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/4495952Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring, Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring, Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring, Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring, Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring, Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring, Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring, Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100--31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring, Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
]Chart1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Refinery Name
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
]Chart2
28593
28094
27495
33095
32095
30096
28096
30096
32196
30896.5
31597
33097
33297
31597
28098
29098
Current Density
Current Efficiency,%
Refinery
CE. %
Current Efficiencies
]Chart4
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Scrap Gen., %
REFINERY
]Chart5
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12.5
Slime fall, Kg/MT
Slime fall, Kg/MT
Refinery
]Chart6
245
280
295
310
320
325
342
350
350
359
362
370
377
392
Power Cons. Units/MT
]Chart7
280245
320280
300295
285310
280320
290325
308342
330350
315350
274359
280362
332370
321377
315392
Current Density
Power Cons. Units/MT
Refinery
Power Consumption, Units/MT
Power Consumption, Units/MT
]Sheet2
Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightRefinery NameNo. of cellsAnode/cathode per cellAnode gap, mmRefinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT
Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150Port Kembla48053/52100Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250Cyprus Miami50461/60102Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60Falcon Bridge51245/4484Birla Copper12.6CRL2.6CRL300295
LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265LG Metals512-98PT Smelting13.2STERLITE2.7PT Smelting285310
STERLITESilvassaIndiaISA165000Port Kembla3445021/7357STERLITE51855/54100Union Miniere14Mexicana De Cobra3Kennecott Utah280320
Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76Boliden58844/43100LG Metals14LG Metals3.3LG Metals290325
Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250Hibi Kyodo63154/53-Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5PT Smelting65459/58103.5Port Kembla15Port Kembla8Union Miniere330350
Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370Birla Copper68854/53100STERLITE15Boliden8Huttenwerke Kayser315350
PT SmeltingGresikIndonesiaISA200000CRL3705021/7355Huttenwerke Kayser80039/3898CRL16Kennecott Utah9.7Port Kembla274359
Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250Union Miniere91161/6098Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
CRLTownsvilleAustraliaISA270000LG Metals3805521/7350CRL106045/4495Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355Norddeutsche Affinerie108057/5695Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73Mexicana De Cobra111558/57105Boliden20Norddeutsche AffinerieBirla Copper315392
Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365Atlantic copper112040/3998Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50Kennecott Utah140047/4698Falcon Bridge27Birla CopperBoliden300
*Under Trail* 56 anodes per cell is under trail
* 56 anodes per cell is under trail
Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m
CRL461706325
Port Kembla451806230
Union Miniere401706330
Falcon Bridge4218065-
Huttenwerke Kayser451656525
Norddeutsche Affinerie46170-20063-
PT Smelting451806335
Hibi Kyodo48.91926530
Mexicana De Cobra451806525
LG Metals421556430
Atlantic copper451806420
Boliden471756520
Cyprus Miami451756440
Birla Copper461726525
Kennecott Utah451706620
STERLITE501656525
Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing
CRL41774645Reatrol
Port Kembla5080042No
Union Miniere9060050Yes
Falcon Bridge11045040Colamat
Huttenwerke Kayser8080060No
Norddeutsche Affinerie----Colamat
PT Smelting40-6060-905-1030-40No
Hibi Kyodo1168635No
Mexicana De Cobra77654935No
LG Metals7180040No
Atlantic copper6464030Yes
Boliden4590050No
Cyprus Miami5065735-
Birla Copper83811545-
Kennecott Utah7565045No
STERLITE5560050No
Refinery NameCell inspection/dayMethods
CRL2Infrared camera, Cell voltage monitoring
Port Kembla1Infrered camera, Gaussmeter
Union Miniere1Infrared Camera, Cell voltage monitoring
Falcon Bridge1Infrared Camera, Cell voltage monitoring
Huttenwerke Kayser3Infrared Camera, Cell voltage monitoring
Norddeutsche Affinerie1.5Infrared Camera, Cell voltage monitoring, Gauss meter
PT Smelting1 to 2Cell voltage monitoring, Gauss meter
Hibi Kyodo2 or 3Cell voltage monitoring, Gauss meter
Mexicana De Cobra3Cell voltage monitoring, Gauss meter
LG Metals1Infrared Camera, Gauss meter
Atlantic copper2Infrared Camera, Cell voltage monitoring, Gauss meter
Boliden3Cell voltage monitoring, Gauss meter
Cyprus Miami2Infrared Camera, Cell voltage monitoring, Gauss meter
Birla Copper--
Kennecott Utah1Infrared Camera, Cell voltage monitoring
STERLITE3Cell voltage monitoring, Gauss meter
Jhagadia Copper2Cell voltage monitoring, Gauss meter
]Sheet3
ELECTROLYTE PURIFICATION METHODS
]Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/4495952Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring, Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring, Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring, Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring, Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring, Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring, Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring, Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100--31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring, Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
]CD
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
330
STERLITE
BIRLA
Current Density
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
]CE
93
94
95
95
95
96
96
96
96
96.5
97
97
97
97
98
98
STERLITE
BIRLA
Current Efficiency,%
Refinery
Current efficiency, %
Current Efficiency, %
]slime fall
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12
STERLITE
Slime fall, Kg/MT
Refinery
Slime fall, Kg/MT
]SCRAP
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Refinery
Scrap Gen., %
Scrap Generation., %
]Sheet2
Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightRefinery NameNo. of cellsAnode/cathode per cellAnode gap, mmRefinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT
Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150Port Kembla48053/52100Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250Cyprus Miami50461/60102Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60Falcon Bridge51245/4484Birla Copper12.6CRL2.6CRL300295
LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265LG Metals512-98PT Smelting13.2STERLITE2.7PT Smelting285310
STERLITESilvassaIndiaISA165000Port Kembla3445021/7357STERLITE51855/54100Union Miniere14Mexicana De Cobra3Kennecott Utah280320
Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76Boliden58844/43100LG Metals14LG Metals3.3LG Metals290325
Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250Hibi Kyodo63154/53-Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5PT Smelting65459/58103.5Port Kembla15Port Kembla8Union Miniere330350
Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370Birla Copper68854/53100STERLITE15Boliden8Huttenwerke Kayser315350
PT SmeltingGresikIndonesiaISA200000CRL3705021/7355Huttenwerke Kayser80039/3898CRL16Kennecott Utah9.7Port Kembla274359
Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250Union Miniere91161/6098Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
CRLTownsvilleAustraliaISA270000LG Metals3805521/7350CRL106045/4495Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355Norddeutsche Affinerie108057/5695Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73Mexicana De Cobra111558/57105Boliden20Norddeutsche AffinerieBirla Copper315392
Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365Atlantic copper112040/3998Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50Kennecott Utah140047/4698Falcon Bridge27Birla CopperBoliden300
*Under Trail* 56 anodes per cell is under trail
* 56 anodes per cell is under trail
Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m
CRL461706325
Port Kembla451806230
Union Miniere401706330
Falcon Bridge4218065-
Huttenwerke Kayser451656525
Norddeutsche Affinerie46170-20063-
PT Smelting451806335
Hibi Kyodo48.91926530
Mexicana De Cobra451806525
LG Metals421556430
Atlantic copper451806420
Boliden471756520
Cyprus Miami451756440
Birla Copper461726525
Kennecott Utah451706620
STERLITE501656525
Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing
CRL41774645Reatrol
Port Kembla5080042No
Union Miniere9060050Yes
Falcon Bridge11045040Colamat
Huttenwerke Kayser8080060No
Norddeutsche Affinerie----Colamat
PT Smelting40-6060-905-1030-40No
Hibi Kyodo1168635No
Mexicana De Cobra77654935No
LG Metals7180040No
Atlantic copper6464030Yes
Boliden4590050No
Cyprus Miami5065735-
Birla Copper83811545-
Kennecott Utah7565045No
STERLITE5560050No
Refinery NameCell inspection/dayMethods
CRL2Infrared camera, Cell voltage monitoring
Port Kembla1Infrered camera, Gaussmeter
Union Miniere1Infrared Camera, Cell voltage monitoring
Falcon Bridge1Infrared Camera, Cell voltage monitoring
Huttenwerke Kayser3Infrared Camera, Cell voltage monitoring
Norddeutsche Affinerie1.5Infrared Camera, Cell voltage monitoring, Gauss meter
PT Smelting1 to 2Cell voltage monitoring, Gauss meter
Hibi Kyodo2 or 3Cell voltage monitoring, Gauss meter
Mexicana De Cobra3Cell voltage monitoring, Gauss meter
LG Metals1Infrared Camera, Gauss meter
Atlantic copper2Infrared Camera, Cell voltage monitoring, Gauss meter
Boliden3Cell voltage monitoring, Gauss meter
Cyprus Miami2Infrared Camera, Cell voltage monitoring, Gauss meter
Birla Copper--
Kennecott Utah1Infrared Camera, Cell voltage monitoring
STERLITE3Cell voltage monitoring, Gauss meter
Electrolyte Purification
Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameSlime fall, Kg/MTRefinery NameScrap Gen., %Refinery NameCurrent DensityPower Cons. Units/MTRefinery NameCurrent DensityTime Efficiency, %EquipmentsRefinery NameStep-1Step-2Step-3
Port Kembla274PT Smelting28593Cyprus Miami1.6Norddeutsche Affinerie11Falcon Bridge280245Kennecott Utah28092Automatic craneCRLLiberatorArsenic extractionNiSO4 plant
Falcon Bridge280Kennecott Utah28094PT Smelting2.4Huttenwerke Kayser12Cyprus Miami320360Falcon Bridge28094Automatic cranePort KemblaLiberatorNiSO4 plant
Mexicana De Cobra280Port Kembla27495CRL2.6Birla Copper12.6CRL300345STERLITE32194Manual craneUnion MiniereBleeding to chemical plant
Kennecott Utah280Union Miniere33095STERLITE2.7PT Smelting13.2PT Smelting285310Port Kembla27495Automatic craneFalcon BridgeLiberatorAcid purification unitETP
PT Smelting285Cyprus Miami32095Mexicana De Cobra3Union Miniere14Kennecott Utah280320Union Miniere33095Automatic craneHuttenwerke KayserCuSO4 plantLiberatorNiSO4 plant
LG Metals290CRL30096LG Metals3.3LG Metals14LG Metals290325LG Metals29095Automatic craneNorddeutsche AffinerieLiberatorNi,Fe,As removal
CRL300Falcon Bridge28096Hibi Kyodo6Atlantic copper14Hibi Kyodo308342Cyprus Miami32095Automatic cranePT SmeltingLiberatorNiSO4 plant
Boliden300Boliden30096Boliden8Port Kembla15Huttenwerke Kayser315350Birla Copper31595Automatic craneHibi KyodoLiberatorChelating resinNiSO4 plant,
Hibi Kyodo308STERLITE32196Port Kembla8STERLITE15Union Miniere330355CRL30095Automatic craneLG MetalsLiberatorNiSO4 plant
Huttenwerke Kayser315Hibi Kyodo30896.5Kennecott Utah9.7CRL16Port Kembla274359Norddeutsche Affinerie33096Automatic craneAtlantic copperLiberatorNiSO4 plant
Birla Copper315Huttenwerke Kayser31597Falcon Bridge10Mexicana De Cobra16Mexicana De Cobra280362PT Smelting28596Automatic craneBolidenLiberatorNiSO4 plant
Cyprus Miami320Norddeutsche Affinerie33097Huttenwerke Kayser12Kennecott Utah16Atlantic copper332370Huttenwerke Kayser31597Automatic craneBirla CopperDirect Neutralisation
STERLITE321Atlantic copper33297Union Miniere12Hibi Kyodo17.5STERLITE321377Hibi Kyodo30897Automatic craneKennecott UtahLiberatorTo other plant
Union Miniere330Birla Copper31597Atlantic copperBoliden20Birla Copper315392Atlantic copper33297Automatic craneSTERLITELiberatorAcid purification unitETP
Norddeutsche Affinerie330Mexicana De Cobra28098Birla CopperCyprus Miami20Norddeutsche Affinerie330Mexicana De Cobra280--Jhagadia CopperLiberatorETP
Atlantic copper330LG Metals29098Norddeutsche AffinerieFalcon Bridge27Boliden300Boliden300
]Sheet3
Chart2
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
330
265
Current Density
sheet1
Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightRefinery NameNo. of cellsAnode/cathode per cellAnode gap, mmRefinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT
Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150Port Kembla48053/52100Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250Cyprus Miami50461/60102Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60Falcon Bridge51245/4484Birla Copper12.6CRL2.6CRL300295
LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265LG Metals512-98PT Smelting13.2STERLITE2.7PT Smelting285310
STERLITESilvassaIndiaISA165000Port Kembla3445021/7357STERLITE51855/54100Union Miniere14Mexicana De Cobra3Kennecott Utah280320
Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76Boliden58844/43100LG Metals14LG Metals3.3LG Metals290325
Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250Hibi Kyodo63154/53-Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5PT Smelting65459/58103.5Port Kembla15Port Kembla8Union Miniere330350
Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370Birla Copper68854/53100STERLITE15Boliden8Huttenwerke Kayser315350
PT SmeltingGresikIndonesiaISA200000CRL3705021/7355Huttenwerke Kayser80039/3898CRL16Kennecott Utah9.7Port Kembla274359
Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250Union Miniere91161/6098Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
CRLTownsvilleAustraliaISA270000LG Metals3805521/7350CRL106045/4495Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355Norddeutsche Affinerie108057/5695Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73Mexicana De Cobra111558/57105Boliden20Norddeutsche AffinerieBirla Copper315392
Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365Atlantic copper112040/3998Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50Kennecott Utah140047/4698Falcon Bridge27Birla CopperBoliden300
*Under Trail* 56 anodes per cell is under trail
* 56 anodes per cell is under trail
Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m
CRL461706325
Port Kembla451806230
Union Miniere401706330
Falcon Bridge4218065-
Huttenwerke Kayser451656525
Norddeutsche Affinerie46170-20063-
PT Smelting451806335
Hibi Kyodo48.91926530
Mexicana De Cobra451806525
LG Metals421556430
Atlantic copper451806420
Boliden471756520
Cyprus Miami451756440
Birla Copper461726525
Kennecott Utah451706620
STERLITE501656525
Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing
CRL41774645Reatrol
Port Kembla5080042No
Union Miniere9060050Yes
Falcon Bridge11045040Colamat
Huttenwerke Kayser8080060No
Norddeutsche Affinerie----Colamat
PT Smelting40-6060-905-1030-40No
Hibi Kyodo1168635No
Mexicana De Cobra77654935No
LG Metals7180040No
Atlantic copper6464030Yes
Boliden4590050No
Cyprus Miami5065735-
Birla Copper83811545-
Kennecott Utah7565045No
STERLITE5560050No
Refinery NameCell inspection/dayMethods
CRL2Infrared camera, Cell voltage monitoring
Port Kembla1Infrered camera, Gaussmeter
Union Miniere1Infrared Camera, Cell voltage monitoring
Falcon Bridge1Infrared Camera, Cell voltage monitoring
Huttenwerke Kayser3Infrared Camera, Cell voltage monitoring
Norddeutsche Affinerie1.5Infrared Camera, Cell voltage monitoring, Gauss meter
PT Smelting1 to 2Cell voltage monitoring, Gauss meter
Hibi Kyodo2 or 3Cell voltage monitoring, Gauss meter
Mexicana De Cobra3Cell voltage monitoring, Gauss meter
LG Metals1Infrared Camera, Gauss meter
Atlantic copper2Infrared Camera, Cell voltage monitoring, Gauss meter
Boliden3Cell voltage monitoring, Gauss meter
Cyprus Miami2Infrared Camera, Cell voltage monitoring, Gauss meter
Birla Copper--
Kennecott Utah1Infrared Camera, Cell voltage monitoring
STERLITE3Cell voltage monitoring, Gauss meter
Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%
Port Kembla274PT Smelting28593
Falcon Bridge280Kennecott Utah28094
Mexicana De Cobra280Port Kembla27495
Kennecott Utah280Union Miniere33095
PT Smelting285Cyprus Miami32095
LG Metals290CRL30096
CRL300Falcon Bridge28096
Boliden300Boliden30096
Hibi Kyodo308STERLITE32196
Huttenwerke Kayser315Hibi Kyodo30896.5
Birla Copper315Huttenwerke Kayser31597
Cyprus Miami320Norddeutsche Affinerie33097
STERLITE321Atlantic copper33297
Union Miniere330Birla Copper31597
Norddeutsche Affinerie330Mexicana De Cobra28098
Atlantic copper330LG Metals29098
Jhagadia Copper265
Chart1
93
94
95
95
95
96
96
96
96
96.5
97
97
97
97
98
98
97.5
Current Efficiency,%
Chart2
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
330
265
Current Density
sheet1
Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightRefinery NameNo. of cellsAnode/cathode per cellAnode gap, mmRefinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT
Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150Port Kembla48053/52100Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250Cyprus Miami50461/60102Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60Falcon Bridge51245/4484Birla Copper12.6CRL2.6CRL300295
LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265LG Metals512-98PT Smelting13.2STERLITE2.7PT Smelting285310
STERLITESilvassaIndiaISA165000Port Kembla3445021/7357STERLITE51855/54100Union Miniere14Mexicana De Cobra3Kennecott Utah280320
Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76Boliden58844/43100LG Metals14LG Metals3.3LG Metals290325
Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250Hibi Kyodo63154/53-Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5PT Smelting65459/58103.5Port Kembla15Port Kembla8Union Miniere330350
Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370Birla Copper68854/53100STERLITE15Boliden8Huttenwerke Kayser315350
PT SmeltingGresikIndonesiaISA200000CRL3705021/7355Huttenwerke Kayser80039/3898CRL16Kennecott Utah9.7Port Kembla274359
Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250Union Miniere91161/6098Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
CRLTownsvilleAustraliaISA270000LG Metals3805521/7350CRL106045/4495Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355Norddeutsche Affinerie108057/5695Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73Mexicana De Cobra111558/57105Boliden20Norddeutsche AffinerieBirla Copper315392
Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365Atlantic copper112040/3998Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50Kennecott Utah140047/4698Falcon Bridge27Birla CopperBoliden300
*Under Trail* 56 anodes per cell is under trail
* 56 anodes per cell is under trail
Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m
CRL461706325
Port Kembla451806230
Union Miniere401706330
Falcon Bridge4218065-
Huttenwerke Kayser451656525
Norddeutsche Affinerie46170-20063-
PT Smelting451806335
Hibi Kyodo48.91926530
Mexicana De Cobra451806525
LG Metals421556430
Atlantic copper451806420
Boliden471756520
Cyprus Miami451756440
Birla Copper461726525
Kennecott Utah451706620
STERLITE501656525
Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing
CRL41774645Reatrol
Port Kembla5080042No
Union Miniere9060050Yes
Falcon Bridge11045040Colamat
Huttenwerke Kayser8080060No
Norddeutsche Affinerie----Colamat
PT Smelting40-6060-905-1030-40No
Hibi Kyodo1168635No
Mexicana De Cobra77654935No
LG Metals7180040No
Atlantic copper6464030Yes
Boliden4590050No
Cyprus Miami5065735-
Birla Copper83811545-
Kennecott Utah7565045No
STERLITE5560050No
Refinery NameCell inspection/dayMethods
CRL2Infrared camera, Cell voltage monitoring
Port Kembla1Infrered camera, Gaussmeter
Union Miniere1Infrared Camera, Cell voltage monitoring
Falcon Bridge1Infrared Camera, Cell voltage monitoring
Huttenwerke Kayser3Infrared Camera, Cell voltage monitoring
Norddeutsche Affinerie1.5Infrared Camera, Cell voltage monitoring, Gauss meter
PT Smelting1 to 2Cell voltage monitoring, Gauss meter
Hibi Kyodo2 or 3Cell voltage monitoring, Gauss meter
Mexicana De Cobra3Cell voltage monitoring, Gauss meter
LG Metals1Infrared Camera, Gauss meter
Atlantic copper2Infrared Camera, Cell voltage monitoring, Gauss meter
Boliden3Cell voltage monitoring, Gauss meter
Cyprus Miami2Infrared Camera, Cell voltage monitoring, Gauss meter
Birla Copper--
Kennecott Utah1Infrared Camera, Cell voltage monitoring
STERLITE3Cell voltage monitoring, Gauss meter
Refinery NameCurrent DensityRefinery NameCurrent Efficiency,%
Port Kembla274PT Smelting93
Falcon Bridge280Kennecott Utah94
Mexicana De Cobra280Port Kembla95
Kennecott Utah280Union Miniere95
PT Smelting285Cyprus Miami95
LG Metals290CRL96
CRL300Falcon Bridge96
Boliden300Boliden96
Hibi Kyodo308STERLITE96
Huttenwerke Kayser315Hibi Kyodo96.5
Birla Copper315Huttenwerke Kayser97
Cyprus Miami320Norddeutsche Affinerie97
STERLITE321Atlantic copper97
Union Miniere330Birla Copper97
Norddeutsche Affinerie330Mexicana De Cobra98
Atlantic copper330LG Metals98
Jhagadia Copper265Jhagadia Copper97.5
sheet1
Current Efficiency,%
]Sheet1
Refinery NameLocationCountryProcessCapacity, MTAAnode Wt. KgsAnode/ cathode cycleNo. of cropsScrap Gen., %Slime fall, Kg/MTNo. of cellsAnode/cathode per cellAnode gap, mmBusbar Current density, Amps/mm2Cell inspection/dayMethodsCurrent DensityCurrent Efficiency,%Power Cons. Units/MTTime Efficiency, %Electrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/mElectrolyte FiltrationElectrolyte PurificationGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensingCathode WeightProductivity, MT/MannhrCSM speedSteam Cons. Kg/MTWashingStrippingStackingSamplingWeighingStrapping
CRLTownsvilleAustraliaISA27000037021/73162.6106045/4495952Infrared camera, Cell voltage monitoring30096295461706325100%As SX, NiSO4 Evaporative Crystallisation41774645Reatrol50520YesYesYesYesYesYes
Port KemblaPort KemblaAustraliaISA12000034421/7315848053/521000.961Infrered camera, Gaussmeter2749535995451806230100%Liberatore, NiSO4 Evaporation5080042No500.55500YesYesYesYesYesYes
Union MiniereOlenBelgiumISA35000040021/73141291161/60981Infrared Camera, Cell voltage monitoring3309535595401706330100%Bleeding to chemical plant9060050Yes50-600.42600220YesYesYesYesYesYes
Falcon BridgeKidd creekCanadaKidd1300001739/91271051245/44841.051Infrared Camera, Cell voltage monitoring28096245944218065-100%Liberators, APU,ETP11045040Colamat650.75450YesYesYesYesYesYes
Huttenwerke KayserLunenGeramnyISA18000039421/73121280039/38980.93Infrared Camera, Cell voltage monitoring3159735097451656525-CuSO4 production, Liberator, NiSO4 Prodcution8080060No570.42380YesYesYesYesYesYes
Norddeutsche AffinerieHamburgGermanyISA37000040621/7311108057/56951.5Infrared Camera, Cell voltage monitoring, Gauss meter330979646170-20063-Liberators, Ni,Fr,As removalColamat40-760.4500YesYesYesYes
PT SmeltingGresikIndonesiaISA20000035721/14/7213.22.465459/58103.50.431 to 2Cell voltage monitoring, Gauss meter2859331096451806335PartLiberators40-6060-905-1030-40No500.34500YesYesYesYesYesYes
Hibi KyodoTamanoJapanISA19100037119/9217.5663154/53-0.992 or 3Cell voltage monitoring, Gauss meter30896.53429748.91926530YesLiberator, NiSO4 evaporation, Chelating resin1168635No78.50.26230YesYesYes
Mexicana De CobraNacozoriMexicoKidd30000034220/102163111558/571053Cell voltage monitoring, Gauss meter28098362-451806525Yes-77654935No701.38450YesYesYesYesYesYes
LG MetalsOnsanS.KoreaKidd16000038021/73143.35129811Infrared Camera, Gauss meter2909832595421556430YesLiberatore, NiSO4 Evaporation7180040No550.5450YesYesYesYesYesYes
Atlantic copperHuelvaSpainISA25000035018/6314112040/399812Infrared Camera, Cell voltage monitoring, Gauss meter3329737097451806420YesLiberator, filtration6464030Yes500.45450YesYesYesYesYesYes
BolidenSweedenSweedenISA14000027014/7220858844/431001.63Cell voltage monitoring, Gauss meter30096471756520YesLiberatore, NiSO4 Evaporation4590050No500.7YesYesYesYesYesYes
Cyprus MiamiMiamiUSAISA19000036921/73201.650461/601021.062Infrared Camera, Cell voltage monitoring, Gauss meter3209528095451756440Yes506573555450YesYesYesYesYesYes
Birla CopperDahejIndiaISA18000036521/7312.668854/53100--31597392954617265258381
Kennecott UtahMagmaUSAKidd28100033021/102169.7140047/46980.551Infrared Camera, Cell voltage monitoring280943209245170662070%Liberator, To other plant7565045No650.56500YesYesYesYesYesYes
STERLITESilvassaIndiaISA165000346/36519/73152.751855/541000.553Cell voltage monitoring, Gauss meter321963779450165652533%Liberator, To other plant5560050No40-500.69500YesYesYesYesYesYes
]CD
274
280
280
280
285
290
300
300
308
315
315
320
321
330
330
330
STERLITE
BIRLA
Current Density
Refinery
Current Density, Amps/m2
Current Density, Amps/m2
]CE
93
94
95
95
95
96
96
96
96
96.5
97
97
97
97
98
98
STERLITE
BIRLA
Current Efficiency,%
Refinery
Current efficiency, %
Current Efficiency, %
]slime fall
1.6
2.4
2.6
2.7
3
3.3
6
8
8
9.7
10
12
12
STERLITE
Slime fall, Kg/MT
Refinery
Slime fall, Kg/MT
]SCRAP
11
12
12.6
13.2
14
14
14
15
15
16
16
16
17.5
20
20
27
Scrap Gen., %
Refinery
Scrap Gen., %
Scrap Generation., %
]Sheet2
Refinery NameLocationCountryProcessCapacity, MTARefinery NameAnode Wt. KgsCathode WeightAnode/ cathode cycleNo. of cropsCathode WeightRefinery NameNo. of cellsAnode/cathode per cellAnode gap, mmRefinery NameScrap Gen., %Refinery NameSlime fall, Kg/MTRefinery NameCurrent DensityPower Cons. Units/MT
Port KemblaPort KemblaAustraliaISA120000Falcon Bridge173659/9150Port Kembla48053/52100Norddeutsche Affinerie11Cyprus Miami1.6Falcon Bridge280245
Falcon BridgeKidd creekCanadaKidd130000Boliden2705014/7250Cyprus Miami50461/60102Huttenwerke Kayser12PT Smelting2.4Cyprus Miami320280
BolidenSweedenSweedenISA140000Kennecott Utah3306521/10250-60Falcon Bridge51245/4484Birla Copper12.6CRL2.6CRL300295
LG MetalsOnsanS.KoreaKidd160000Mexicana De Cobra3427020/10265LG Metals512-98PT Smelting13.2STERLITE2.7PT Smelting285310
STERLITESilvassaIndiaISA165000Port Kembla3445021/7357STERLITE51855/54100Union Miniere14Mexicana De Cobra3Kennecott Utah280320
Huttenwerke KayserLunenGeramnyISA180000Atlantic copper3505018/6340-76Boliden58844/43100LG Metals14LG Metals3.3LG Metals290325
Birla CopperDahejIndiaISA180000PT Smelting3575021/14/7250Hibi Kyodo63154/53-Atlantic copper14Hibi Kyodo6Hibi Kyodo308342
Cyprus MiamiMiamiUSAISA190000Birla Copper36540-5021/7378.5PT Smelting65459/58103.5Port Kembla15Port Kembla8Union Miniere330350
Hibi KyodoTamanoJapanISA191000Cyprus Miami3695521/7370Birla Copper68854/53100STERLITE15Boliden8Huttenwerke Kayser315350
PT SmeltingGresikIndonesiaISA200000CRL3705021/7355Huttenwerke Kayser80039/3898CRL16Kennecott Utah9.7Port Kembla274359
Atlantic copperHuelvaSpainISA250000Hibi Kyodo37178.519/9250Union Miniere91161/6098Mexicana De Cobra16Falcon Bridge10Mexicana De Cobra280362
CRLTownsvilleAustraliaISA270000LG Metals3805521/7350CRL106045/4495Kennecott Utah16Huttenwerke Kayser12Atlantic copper332370
Kennecott UtahMagmaUSAKidd281000Huttenwerke Kayser3945721/7355Norddeutsche Affinerie108057/5695Hibi Kyodo17.5Union Miniere12.5STERLITE321377
Mexicana De CobraNacozoriMexicoKidd300000Union Miniere40050-6021/73Mexicana De Cobra111558/57105Boliden20Norddeutsche AffinerieBirla Copper315392
Union MiniereOlenBelgiumISA350000Norddeutsche Affinerie40640-7621/7365Atlantic copper112040/3998Cyprus Miami20Atlantic copperNorddeutsche Affinerie330
Norddeutsche AffinerieHamburgGermanyISA370000STERLITE346/36540-5019/7340-50Kennecott Utah140047/4698Falcon Bridge27Birla CopperBoliden300
*Under Trail* 56 anodes per cell is under trail
* 56 anodes per cell is under trail
Refinery NameElectrolyte Copper, gplElectrolyte Acid, gplElectrolyte Temperature, Deg. CElectrolyte flow/cell, L/m
CRL461706325
Port Kembla451806230
Union Miniere401706330
Falcon Bridge4218065-
Huttenwerke Kayser451656525
Norddeutsche Affinerie46170-20063-
PT Smelting451806335
Hibi Kyodo48.91926530
Mexicana De Cobra451806525
LG Metals421556430
Atlantic copper451806420
Boliden471756520
Cyprus Miami451756440
Birla Copper461726525
Kennecott Utah451706620
STERLITE501656525
Refinery NameGlue, Kg/MTThiourea, Kg/MTAvitone, Kg/MTChloride LevelAutosensing
CRL41774645Reatrol
Port Kembla5080042No
Union Miniere9060050Yes
Falcon Bridge11045040Colamat
Huttenwerke Kayser8080060No
Norddeutsche Affinerie----Colamat
PT Smelting40-6060-905-1030-40No
Hibi Kyodo1168635No
Mexicana De Cobra77654935No
LG Metals7180040No
Atlantic copper6464030Yes
Boliden4590050No
Cyprus Miami5065735-
Birla Copper83811545-
Kennecott Utah7565045No
STERLITE5560050No
Refinery NameCell inspection/dayMethods
CRL2Infrared camera, Cell voltage monitoring
Port Kembla1Infrered camera, Gaussmeter
Union Miniere1Infrared Camera, Cell voltage monitoring
Falcon Bridge1Infrared Camera, Cell voltage monitoring
Huttenwerke Kayser3Infrared Camera, Cell voltage monitoring
Norddeutsche Affinerie1.5Infrared Camera, Cell voltage monitoring, Gauss meter
PT Smelting1 to 2Cell voltage monitoring, Gauss meter
Hibi Kyodo2 or 3Cell voltage monitoring, Gauss meter
Mexicana De Cobra3Cell voltage monitoring, Gauss meter
LG Metals1Infrared Camera, Gauss meter
Atlantic copper2Infrared Camera, Cell voltage monitoring, Gauss meter
Boliden3Cell voltage monitoring, Gauss meter
Cyprus Miami2Infrared Camera, Cell voltage monitoring, Gauss meter
Birla Copper--
Kennecott Utah1Infrared Camera, Cell voltage monitoring
STERLITE3Cell voltage monitoring, Gauss meter
Refinery NameCurrent DensityRefinery NameCurrent DensityCurrent Efficiency,%Refinery NameSlime fall, Kg/MTRefinery NameScrap Gen., %Refinery NameCurrent DensityPower Cons. Units/MTRefinery NameCurrent DensityTime Efficiency, %Equipments
Port Kembla274PT Smelting28593Cyprus Miami1.6Norddeutsche Affinerie11Falcon Bridge280245Kennecott Utah28092Automatic crane
Falcon Bridge280Kennecott Utah28094PT Smelting2.4Huttenwerke Kayser12Cyprus Miami320360Falcon Bridge28094Automatic crane
Mexicana De Cobra280Port Kembla27495CRL2.6Birla Copper12.6CRL300345STERLITE32194Manual crane
Kennecott Utah280Union Miniere33095STERLITE2.7PT Smelting13.2PT Smelting285310Port Kembla27495Automatic crane
PT Smelting285Cyprus Miami32095Mexicana De Cobra3Union Miniere14Kennecott Utah280320Union Miniere33095Automatic crane
LG Metals290CRL30096LG Metals3.3LG Metals14LG Metals290325LG Metals29095Automatic crane
CRL300Falcon Bridge28096Hibi Kyodo6Atlantic copper14Hibi Kyodo308342Cyprus Miami32095Automatic crane
Boliden300Boliden30096Boliden8Port Kembla15Huttenwerke Kayser315350Birla Copper31595Automatic crane
Hibi Kyodo308STERLITE32196Port Kembla8STERLITE15Union Miniere330355CRL30095Automatic crane
Huttenwerke Kayser315Hibi Kyodo30896.5Kennecott Utah9.7CRL16Port Kembla274359Norddeutsche Affinerie33096Automatic crane
Birla Copper315Huttenwerke Kayser31597Falcon Bridge10Mexicana De Cobra16Mexicana De Cobra280362PT Smelting28596Automatic crane
Cyprus Miami320Norddeutsche Affinerie33097Huttenwerke Kayser12Kennecott Utah16Atlantic copper332370Huttenwerke Kayser31597Automatic crane
STERLITE321Atlantic copper33297Union Miniere12Hibi Kyodo17.5STERLITE321377Hibi Kyodo30897Automatic crane
Union Miniere330Birla Copper31597Atlantic copperBoliden20Birla Copper315392Atlantic copper33297Automatic crane
Norddeutsche Affinerie330Mexicana De Cobra28098Birla CopperCyprus Miami20Norddeutsche Affinerie330Mexicana De Cobra280--
Atlantic copper330LG Metals29098Norddeutsche AffinerieFalcon Bridge27Boliden300Boliden300
Jhagadia Copper26595Automatic crane
]Sheet3
Bench marking Parameters Put actual figs for last three months and what is target for Business Plan
Sl. No.
Parameter
Present Value
Target value
1
Operating current density
265 Amps/m2
280 Amps/m2
2
Current efficiency
97.5 %
98 %
3
Time efficiency
92 %
95 %
4
Scrap generation
12.5 %
12 %
5
Slime fall
4-6 Kg/MT
< 4 Kg/MT
6
DC Power Consumption
400 Units/MT
350 Units/MT
7
Steam Consumption
704 Kg/MT
300 Kg/MT
Cathode Quality
Sl. No.
Parameter
Present Value, ppm
Target value, ppm
1
Silver
8-9
< 6
2
Bismuth
0.6-1.0
0.3
3
Antimony
1-2
ELECTROLYTE QUALITY
Sl. No.
Parameter
Present Value, gpl
Target value, gpl
1
Nickel
8-10
< 15
2
Iron
0.01-0.02
< 1
3
Bismuth
25 PPM
CHEMICALS CONSUMPTIONToo much additives ?????
slime fall
1.6
2.6
2.7
2.7
3
3
3.1
3.3
6
6
6
7
7
7
8
8
8.3
9.7
10
12
12
Sterlite
Slime fall , kg/MT of cathode
scarp %
23
20
20
18
18
18
17.5
17
16
16
16
15
15
15
15
14
14
14
14
12.6
12
11
Sterlite
Birla
Scrap %
TE
91
92
92
94
94
94
94
95
95
95
95
95
95.6
96
96
96.7
97
97
97
97
Sterlite
Birla
Time efficiency, %
CD
231
274
274
280
280
280
280
290
300
300
300
305
308
312.5
315
315
320
325
328
330
330
330
Sterlite
Birla
CURRENT DENSITY, Amps/m2
PLANT CAPACITY
15000
30000
31000
37000
40000
50000
50
Recommended