Copper Manufacturing Process - peg-az.compeg-az.com/wp-content/uploads/2012/05/Copper-process.pdf · copper.xls 03/08/00 13:26 Sulzer Pumps Finland Oy Pump Lifetime Costs Profile

Copper ManufacturingProcess

V00664/01 (10.2000) Copyright © Sulzer Pumps Finland Oy 8

Copper anodes

Copper cathodes

Copper

Anode casting

Anode slimetreatment

Preciousmetals

NiSO4

Cu solids

CuSO4

Anode scraps

ElectrolysisElectrolytepurification

Electrolyte

Melting andcasting

Anode shaftfurnace

SO2

Slag

SO2

SlagConverting

Roasting

Smelting

Concentrate

General Flowsheet of Process

Copper Manufacturing Process


Pumps in Copper Electrolyse Process

Starting sheets

Electrolyte frompurification

Anode scrapsCopper cathodes tomelting and casting

Electrolyte topurification

Anodes

Cells

Cells

Cells

1.APP/T 2.APP/T

4.WPP/T

Electrorefining

Circulating liquor tank

Filtration

Anode slime to treating

Liquid

+ –

–

–

+

+

3.WSP/T or WKP/T

3 Liquid pH Solids Temp. Density Typical Pump Impeller Seal type Material Dutyo o 3 ( C, F) (kg/m , head type type

3 lb/ft m, ft



Pumps in Copper Electrolyse Process

ElectrolyteH SO 140...180 g/l2 4

Anode slimeH SO 140...180 g/l2 4


Sb, Bi10 mg/l

Cu, Ni,precious metals

Sb, Bi10 mg/l

60/140

60-70/140-158

1230/77

1500/94

1230/77

30/98

35/115

20/66

APP/T

WSP/T/WKP/T

APP/T

Open

1Open

1Open

Singlemechanical

5(ME03)

2Doubl. mech. (MR22) or

Dyn. (DS02)

4654SMO

A890 3A

A890 3A Purification feeder

Anode Slimefrom ElectrolyseCells

Electrolytecirculate

<1

<1

<1

1) Crystallization2) Check always the entraining air through the static seal. The air harms the process3) Material recommendation is only for specified application4) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material5) The shaft seal is not needed with WKP/T6) The floating installation of the pumps in Electrolyse process

1

2

3


Dyn. (DS02)

4 Anode slimeH SO 140...180 g/l2 4

<1Cu, Ni,

precious metals 60/140

1500/94

35/115

WPP/T Open2Doubl. mech.

(MR22) orDyn. (DS02)

4654SMO Filter feeder toprecious metals

60-70/140-158



Electrolyte from electrolysis

CuSO -4

sedimentation

CuSO -crystals4

To Cu removal(electrolysis)

Crystallization

Water

Mother liquor

Mother liquor separation(centrifuge)

Steam

1.APP/T

2.APP/T

3.APP/T

4.APP/T

Pumps in CuSO Crystallization Process4




3 lb/ft ) m, ft


Sb, Bi10 mg/l

60/140

50/122

50/122

50/122

1230/77

1340/84

1560/97

1340/84

18/59

17/56

20/66

20/66

APP/T 1Open A890 3A

A890 3A

A890 3A

Circulation

Crystallizer discharger

Cu removalfeeder

Crystallizer feeder<1

1) Crystallization2) Check always the entraining air through the static seal. The air harms the process3) Material recommendation is only for specified application

1

Cu-solutionH SO 140...180 g/l2 4

CuSO -solution4

H SO 140...180 g/l2 4

Cu-solutionH SO 250 g/l2 4

Cu, Ni

Cu, Ni

Cu, Ni

APP/T

APP/T

1Open

1Open

Double mech.(MR22)

<1

<1

<1

2

3

4

Pumps in CuSO Crystallization Process4


Dyn. (DS02)


Dyn. (DS02)

APP/T 1Open Double mech.

(MR22)A890 3A



4.APP/T

Electrolyte fromCuSO -crystallization4

Cu-solids Cu-solids

Storage

Electrolyte toevaporation

Cu-solids

1.APP/T

2.APP/T 3.APP/T

I Cells –+ III Cells –+II Cells –+

Pumps in Cu Removal by Electrolyse Process




3 lb/ft ) m, ft

Cu solutionH SO 250 g/l2 4

Cu, Ni 50-60/122-140

1230-1340/77-84

15/49

15/49

15/49

15/49

APP/T 1Open A890 3A

A890 3A

A890 3A

A890 1B

2nd stage cellspumping tank

3rd stage cellspumping tank

Evaporator feed

1st stage cells pumping tank feeder

<11



Cu free solutionH SO 250 g/l2 4

Cu, Ni

Ni, Cu

Cu ~ 2 g/l

APP/T

APP/T

APP/T

1Open

1Open

1Open

<1

<1

<1

2

3

4

Pumps in Cu Removal By Electrolyse Process


Dyn. (DS02)2Doubl. mech.



Dyn. (DS02)2Doubl. mech.


1) Crystallization2) Check always the entraining air through the static seal. The air harms the process3) Material recommendation is only for specified application

50-60/122-140

50-60/122-140

50-60/122-140

1230-1340/77-84

1230-1340/77-84

1230-1340/77-84



Electrolyte from Cu removal(electrowinning)

Evaporator

Dropletseparator

Condensate

Condensate

Condensate

Sulphuric acidto process

Filtration NiSO4

Steam

Filtratetank

Heater

1.APP/T

2.APP/T

4.APP/T3.

6.

5.

Pumps in Electrolyte Evaporation Process




3 lb/ft ) m, ft

Cu freeH SO 250 g/l2 4

Ni 1 mg/l

60/140

50/122

120/248

90/194

70/158

60/140

1230/77

1000/62

1500/94

1000/62

1500/94

1600/100

20/66

15/49

3.5/11,5

30/98

20/66

25/82

APP/T Closed 3654SMO

A890 3A

Si-iron

A890 3A

_

_

Condensate

Circulation

Condensate

Filter feeder

NiSO filtrate4

Feeder<11

CondensateH SO 60 g/l2 4

Ni-solutionH SO 300 g/l2 4

H O 2

NiSO4

H SO 300 g/l2 4

H SO 300 g/l2 4

–

Ni5 mg/l

–

Ni5 mg/l

–

APP/T

– – –

APP/T

_

_

Closed

Closed

_

_

Dynamic seal(DS01)

_

_

<1

<1

7

<1

<1

2

3

4

5

6

Pumps in Electrolyte Evaporation Process

Dynamic seal(DS01)


Dyn. (DS02)

1) Material recommendation is only for specified application2) Check always the entraining air through the static seal. The air harms the process3) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material



Anode slime from electrolyse

Autoclave

Filtration

Se solids

Roasting furnace

Convertingand casting

Filtration Filtration

Precipitation

Precipitation

Electrolysis

Leaching Cementation

Ag solids

Te solids

Au solids

Au solids

FiltrationPrecipitation

Solution

Rh solids

Liquid

Pt solids

Waste solution

1.WPP/T

2.WPP/T

6.

4.

5.

7.

3.APP/T

8.

–+

Pumps in Anode Slime Treatment Process



3 lb/ft ) m, ft

Anode slimeH SO ~200 g/l2 4

80/176

80/176

50/122

80/176

70/158

70/158

60/140

50/122

1500/94

1400/88

1300/81

1400/88

1500/94

1700/106

1700/106

1000/62

20/66

20/66

30/99

30/99

15/49

20/66

20/66

20/66

<11

Te-solutionH SO ~200 g/l2 4

Rh freeH SO ~1300 g/l2 4

Te freeH SO ~200 g/l2 4

Ag freeHCl ~200 g/l

Ag freeH SO ~1300 g/l2 4

Au freeHCl ~200 g/l

Noble metal freeHCl ~200 g/l

Se, Ag, Te

–

–

–

Ag

–

–

<1

<1

<1

<1

<1

<1

<1

2

5

3

6

4

7

8

Pumps in Anode Slime Treatment Process

Se,Te,BaSO , 4

PbSO4

9 1400/87 36/118

WPP/T

WPP/T

APP/T

–

–

–

–

–

Closed

Closed

Closed

–

–

–

–

–

2654SMO

2654SMO

–

–

–

–

–

2654SMODouble mech. (MR22)

Double mech. (MR22)

Dynamic seal (DS01)

Treatment feeder

Te filter

Electrolytepurification

Precipitation

Process circulation

Feed 2nd stageAu separation

Pt filter

Waste solution

–

–

–

–

–

V00664/11 (10.2000) Copyright © Sulzer Pumps Finland Oy

1) Material recommendation is only for specified application2) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material

H2SO4 and Sesolids mixture

<1 1 - 2 % 80/176 APP/T Closed Double mech.

(MR22)Hastelloy E8

Se roasting fuurnaceliquid

ApplicationReport

1(1)

N03845 / Metal, Copper en (12.2001), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with ourproducts. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Copper cathodes tomelting and casting


AHLSTAR™ APP for Electrolyte Pumping

+ –

–

–

+

+


Starting sheetsAnodes

Anode scrapsCells

Cells

Cells

Anode slime to treatment

Filtration

APP22-80

AHLSTAR™ APP in Copper Electrolysis Process.

Pump......................... APP22-80Impeller..................... Special open impellerType.......................... APP Process pumpMotor.......................... 15 kW (20 hp)Speed....................... 1740 rpmMaterial..................... ASTM890 Grade3ASealing...................... Double mechanical seal

Pump Data

Q............................... 33.3 l/s (528 USGPM)H............................... 15 m (49 ft)Liquid........................ ElectrolytepH............................. 1Temperature.............. 60 oC (140 oF)H

2SO

4 content .......... 13 %

Density...................... 1400 kg/m3 (88 lb/ft3)

Process Data

An APP31-125 pump was installed to pumpelectrolyte from the filtration of anode slime toback to electrorefining. The pump is equippedwith a seal which prevents access of air intothe pumped liquid.

ApplicationReport

1(1)

Copper cathodes tomelting and casting



+ –

–

–

+

+


Cells

Cells

Anode scraps

Filtration


AnodesStarting sheets

APP31-125



Pump......................... APP 31-125Impeller..................... OpenType.......................... APP Process pumpMotor......................... 22 kW (16.4 hp)Speed....................... 1460 rpmMaterial..................... ASTM 743 CF-8MSealing...................... Double mechanical seal

Pump Data

Q................................ 42 l/s (667 USGPM)H................................ 20 m (66 ft)Liquid......................... ElectrolytepH.............................. 1Temperature.............. 70 oC (158 oF)H2SO4 content .......... 14.5 %Density...................... 1230 kg/m3 (77 lb/ft3)

Process Data

An APP31-125 pump was installed to pumpelectrolyte from a circulating liquor tank back toelectrorefining. The pump has been running inthis position for 14 years without bigger prob-lems. The pump is equipped with a seal whichprevents acces of air into the pumped liquid.

ApplicationReport

1(1)

Pump......................... APP11-32Impeller..................... Closed impellerType.......................... APP Process pumpMotor......................... 4 kW (3 hp)Speed....................... 2905 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 1 l/s (16 USGPM)H............................... 30 m (98 ft)Liquid........................ ElectrolytepH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 14.6 %Density...................... 1230 kg/l (77 lb/ft3)

Process Data



An APP11-32 pump was installed to pump elec-trolyte from a circulating liquor tank to purifica-tion. The application is quite corrosive and con-tains many kind of impurities. Duplex stainlesssteel was chosen to manage the corrosion.


+ –

–

–

+

+


Cells

Cells

Anode scrapsCopper cathodes tomelting and casting

Filtration


AnodesStarting sheets

APP11-32


ApplicationReport

1(1)


Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed......................... 1500 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 2.8 l/s (44 USGPM)H............................... 18 m (59 ft)Liquid........................ ElectrolytepH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 14.6 %Density...................... 1230 kg/m3 (77 lb/ft3)

Process Data

An APP11-32 pump was installed to pump elec-trolyte to crystallization. The application is quitecorrosive and contains many kinds of impuri-ties. Duplex stainless steel was chosen to man-age the corrosion and solids in the pumped liq-uid.



CrystallizationElectrolyte fromelectrolysis

Steam

CuSO4Sedimentation

Mother liquor separation (centrifuge)Water

Mother liquor

CuSO4 crystalsAHLSTAR™ APP in CuSO

4 Crystallization Process.

APP22-32

ApplicationReport

1(1)


Pump......................... APP31-100Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 22 kW (16.4 hp)Speed....................... 1470 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 42 l/s (667 USGPM)H............................... 17 m (56 ft)Liquid........................ Cu solution with solidspH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 14.6 %Density...................... 1340 kg/m3 (84 lb/ft3)

Process Data


Steam

CuSO4Sedimentation


Mother liquor


CuSO4 crystals

APP31-100

AHLSTAR™ APP in CuSO4 Crystallization Process.

AHLSTAR™ APP for Cu Solution Pumping

An APP31-100 pump was installed to circulateCu solution in a crystallizer. The pumped liquidcontains crystallizable solids which can crys-tallize inside the pump. This means that the shaftseal should be selected very carefully. Ready-fitted non-flowing double mechanical seal wasselected because of a higher operating temper-ature in the seal faces on the product side.

ApplicationReport

1(1)



AHLSTAR™ APP for CuSO4 Solution Pumping

Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kw (2.2 hp)Speed....................... 1430 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 0.5 l/s (8 USGPM)H............................... 20 m (66 ft)Liquid........................ CuSO4 solution with solidspH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 14.4 %Density...................... 1560 kg/m3 (97 lb/ft3)

Process Data


Steam

CuSO4Sedimentation


Mother liquor

CuSO4 crystalsAHLSTAR™ APP in CuSO4 Crystallization Process.

An APP22-32 pump pumps crystallized CuSO4

to sedimentation. The solids content is about16 % and crystallization is still going on insidethe pump. The shaft seal has to be selectedvery carefully. Ready-fitted non-flowing doublemechanical seal was selected because of ahigher operating temperature in the seal faceson the product side.

APP22-32

ApplicationReport

1(1)


Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed....................... 1430 r/minMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Process Data



Q............................... 1.4 l/s (22 USGPM)H............................... 15 m (49 ft)Liquid........................ Cu solutionpH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 19 %Density...................... 1340 kg/m3 (84 lb/ft3)

An APP22-32 pump pumps Cu solution back to

sedimentation. The sulphuric acid concentrationis quite high in this application, about 19 %. Ifthe temperature rises about 15 to 20 oC, thensuper duplex stainless steel should be select-ed. APP22-32 from normal duplex stainlesssteel has been working for about six years with-out having to replace the volute casing.


Steam

CuSO4Sedimentation


Mother liquor

CuSO4 crystals

APP22-32

AHLSTAR™ APP in CuSO4 Crystallization Process.

ApplicationReport

1(1)


Pump......................... APP11-32Impeller..................... Closed impellerType.......................... APP Process pumpMotor........................ 7.5 kW (5.6 hp)Speed....................... 2950 r/minMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 1.4 l/s (22 USGPM)H............................... 50 m (164 ft)Liquid........................ Cu solutionpH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 19 %Density...................... 1340 kg/m3 (84 lb/ft3)

Process Data


An APP11-32 pump pumps Cu solution to elec-

trolysis cells to crystallize Cu to solids. Thepump has been running for 12 years now. Thevolute casing of the pump was replaced after 8years of operation. Air is not permitted in theelectrolysis process step. This is why a ready-fitted non-flowing double mechanical seal wasselected.

Electrolyte from CuSO4 crystallization

Cu solids Cu solids Cu solids

I Cells II Cells III Cells

Storage


APP11-32

–+ –+–+

AHLSTAR™ APP in Cu Removal by Electrolysis

ApplicationReport

1(1)


Pump......................... APP22-40Impeller..................... Closed impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed....................... 1440 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 6 l/s (95 USGPM)H............................... 15 m (49 ft)Liquid........................ Cu solutionpH............................. 1Temperature.............. 60 oC (140 oF)H

2SO

4 content .......... 19 %

Density...................... 1340 kg/m3 (84 lb/ft3)

Process Data


An APP11-32 pump pumps Cu solution to elec-

trolysis cells to crystallize Cu to solids. Air isnot permitted in the electrolysis process step.This is why a ready-fitted non-flowing doublemechanical seal was selected.




Storage


APP22-40

AHLSTAR™ APP in Cu Removal by Electrolysis

–+ –+–+

ApplicationReport

1(1)

N15393 / Metal, Copper en (12.2003), Copyright © Sulzer Pumps Finland Oy. This report is a general product presentation. It does notprovide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products.Directions for use and safety will be given separately. All information herein is subject to change without notice.

Pump......................... WKP23-50Impeller..................... Open impellerType.......................... WKP Wear resistant

cantilever pumpMotor........................ 11 kW (15 hp)Speed....................... 1450 r/minMaterial..................... ASTM 890 Grade 3A

Pump Data

Q............................... 5.5 l/s (87 USGPM)H............................... 28 m (92 ft)Liquid........................ Floor waterpH............................. 7Temperature.............. 20 oC (68 oF)Solids content .......... 1 - 5 %Density...................... 1050 kg/m3 (66 lb/ft3)

Process Data

AHLSTAR™ WKP Cantilever for Floor Water Pumping

A WKP wear resistant cantilever pump was in-stalled to pump floor water in Cu removal byelectrolysis. The pump has been running for 4years now. The volute casing of the pump is thesame after 4 years’ operation. The pump doesn’tneed shaft seal or support bearings at the bot-tom side.




Storage


To watertreatment

–+ –+–+

AHLSTAR™ WKP in Cu Removal by ElectrolysisWKP23-250

ApplicationReport

1(1)


AHLSTAR™ APP for Cu-Free Solution Pumping

Condensate

Condensate

Sulphuric acid to process

NiSO4

Pump......................... APP22-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 3 kW (2.2 hp)Speed....................... 1430 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 1.4 l/s (22 USGPM)H............................... 20 m (66 ft)Liquid........................ Cu-free solutionpH............................. 1Temperature.............. 60 oC (140 oF)H2SO4 content .......... 19 %Density...................... 1230 kg/m3 (77 lb/ft3)

Process Data


Evaporator

Dropletseparator

Steam

Heater

Filtration

Filtrate tank

APP22-32

AHLSTAR™ APP in Electrolyte Evaporation

An APP22-32 pump pumps Cu-free solution toelectrolyte evaporation. The pump has been run-ning for about 6 years without having to changethe volute casing.

ApplicationReport

1(1)


AHLSTAR™ APP for Condensate Pumping

Pump......................... APP11-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 4 kW (3 hp)Speed....................... 2880 rpmMaterial..................... ASTM 890 Grade3ASealing...................... Double mechanical seal

Pump Data

Q............................... 0.8 l/s (13 USGPM)H............................... 30 m (99 ft)Liquid........................ CondensatepH............................. 7Temperature.............. 90 oC (194 oF)Solids content .......... 0 %Density...................... 1000 kg/m3 (62 lb/ft3)

Process Data


Evaporator

Dropletseparator

Steam

Heater

Filtration NiSO4

Filtrate tank

APP11-32


Condensate

Condensate


An APP11-32 pump pumps condensate fromelectrolyte evaporation step in a Cu manufac-turing process. Duplex stainless steel and dou-ble mechanical seal were selected. The pumphas been running for 6 years without bigger prob-lems.

ApplicationReport

1(1)


AHLSTAR™ APP for Condensate Pumping

Steam

Pump......................... APP11-32Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 2.20 kW (1.6 hp)Speed....................... 1425 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Single mechanical seal

Pump Data

Process Data


Evaporator

Dropletseparator

Heater

Filtration NiSO4

Filtrate tank

APP11-32


Condensate

Condensate


Q............................... 0.13 l/s (2 USGPM)H............................... 15 m (49 ft)Liquid........................ CondensatepH............................. 1Temperature.............. 50 oC (122 oF)H2SO4 content .......... 6 %Density...................... 1100 kg/m3 (68 lb/ft3)

An APP11-32 pump pumps condensate fromelectrolyte evaporation step in a Cu manufac-turing process. The pumped liquid contains 6 %of sulphuric acid. Duplex stainless steel and sin-gle mechanical seal were selected. The pumphas been running for 6 years without bigger prob-lems.

–+

ApplicationReport

1(1)

Pump......................... APP11-40Impeller..................... Open impellerType.......................... APP Process pumpMotor......................... 15 kW (11 hp)Speed....................... 2920 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 5.5 l/s (87 USGPM)H............................... 50 m (164 ft)Liquid........................ Te solution with solidspH............................. 1Temperature.............. 90 oC (198 oF)H2SO4 content .......... 14 %Density...................... 1400 kg/m3 (88 lb/ft3)

Process Data


Anode slime fromelectrolysis

Autoclave

Filter Precipitation Filter

Se solidsRoastingfurnace


Ag solids

Au solids

Rh solids

LiquidAPP11-40

AHLSTAR™ APP for Te Solution Pumping

AHLSTAR™ APP in Anode Slime Treatmement Process

An APP11-40 pump pumps Te solution to Tesolids filtration. The pumped liquid contains 14%of sulphuric acid and Te solids, also Cu and Nisolids. Duplex stainless steel and double me-chanical seal were selected. The pump hasbeen running for 5 years.

ApplicationReport

1(1)


AHLSTAR™ APT for Anode Slime Pumping

Pump......................... APT55-12Impeller..................... Open impellerType.......................... APT Process pumpMotor.......................... 400 hp (298 kW)Speed....................... 1180 rpmMaterial..................... ASTM 890 Grade 3ASealing...................... Double mechanical seal

Pump Data

Q............................... 7700 USGPM (485 l/s)H............................... 150 ft (46 m)Liquid........................ Anode slimepH............................. 1Temperature.............. 120 oF (49 oC)H2SO4 content .......... 13 %Density...................... 94 lb/ft3 (1500 kg/m3)

Process Data

AHLSTAR™ APT in Anode Slime Treatmement Process

An APT pump pumps anode slime slurry to fil-tration. The pumped liquid contains 14% of sul-phuric acid and different kinds of solids, about30%. Duplex stainless steel and double mechan-ical seal were selected. The pump has been run-ning for 10 years.

–+

Anode slime fromelectrolysis

Autoclave

Filter Precipitation Filter

Se solidsRoastingfurnace


Ag solids

Au solids

Rh solids

Liquid

APT55-12

ApplicationReport

1(1)


AHLSTAR™ APP for Anode Slime Pumping

Pump......................... APP32-80Impeller..................... Open impellerType.......................... APP Process pumpMotor.......................... 2230 kW (30 hp)Speed....................... 1460 rpmMaterial..................... Hastelloy E8Sealing...................... Double mechanical seal

Pump Data

Q............................... 17 l/s (269 USGPM)H............................... 36 m (118 ft)Liquid........................ Sulphuric acidpH............................. 1Temperature.............. 80 oC ( 176 oF)H2SO4 content .......... 25 - 30 %Density...................... 1400 kg/m3 (87 lb/ft3)

Process Data

AHLSTAR™ APP in Anode Slime Treatment Process

Anode slime from electrolyse

Autoclave

Filtration

Se solidsRoasting

furnace


Filtration Filtration

Precipitation

Precipitation

Electrolysis

Leaching Cementation

Ag solids

Te solids

Au solids

Au solids

FiltrationPrecipitation

Solution

Rh solids

Liquid

Pt solidsWaste solution

–+

Ejector Gas

APP32-80

Se Filter

–+

Gas from Selenium roasting furnace mixed withsulphuric acid and water was pumped with AHL-STARTM APP process pump. The first materialselection was Hastelloy B type material whichwas lost in couple of months. Hastelloy B mate-rial was tested first because of good experiencein other process equipments. Hastelloy B waschanged to Hastelloy E8 type of material whichis nickel alloyed material also. The pump isequipped with double mechanical seal. APPpump from Hastelloy E8 material has been run-ning three years without problems. The pump isstill running.

copper.xls 03/08/00 13:26

Sulzer Pumps Finland OyPump Lifetime Costs Profile

Industry Copper

Segment 2744

No. of pumps 25 (150) Pump average lifetime (yr) 11,8

Pump types APP, WPP

Volute Casing Impeller Casing Cover Seal Average Liftime Number of pumps Remarks

ELECTROLYSE 9 yr. 5,3 yr. 5,3 yr. 2 yr. 9 yr. 3 Because of low voltage level in electrolyse, avoid

electrical corrosion

Cu REMOVAL by 11,5 yr. 8,8 yr. 8,8 yr. 2 yr. 11,5 yr. 4 Copper sulfate is reason for wearing

ELECTROLYSE

ELECTROLYTE 13,8 yr. 12,4 yr. 12,4 yr. 3,2 yr. 13,8 yr. 6 Some applications are very wearing because of high

EVAPORATION acid and temperature values.

CuSO4 16 yr. 13 yr. 13 yr. 2,3 yr. 16 yr. 4 Crystallized particles makes wearing in some

CRYSTALLIZATION applications

ANODE SLIME 8,7 yr. 5,7 yr. 5,7 yr. 2 yr. 8,7 yr. 8 Low pH, high temperature and solid particles make

TREATMENT some wearing

ADDITIONAL INFO Solid particles (Antimony, Bismuth and Arsenic) are cathered to the inside of pipelines and at least once a year the solid matter has to be removed off by

high pressure washing.

The motor and baseplate have to be protected by cover to avoid external corrosion in case if pumped liquid has got outside.

Documents

Copper Manufacturing Process - peg-az.compeg-az.com/wp-content/uploads/2012/05/Copper-process.pdf · copper.xls 03/08/00 13:26 Sulzer Pumps Finland Oy Pump Lifetime Costs Profile