Copper SX-EW technology

Our solution for leaching, solvent

extraction and electrowinning
Outotec offers optimised solutions and complete plants
for the production of high-quality copper cathodes
through innovative leaching, solvent extraction and
electrowinning technologies.

Our technology package for leaching-SX–EW plants

may contain basic and/or detailed engineering as
well as proprietary and key equipment supply.
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A complete technology solution

from a single partner
Outotec's early involvement in a project makes it possible to fi nd the
The Outotec difference most profi table metallurgical solution from mine to metal production.
We provide world leading technologies, technology selection expertise,
The Outotec difference is the
feasibility studies, basic and detailed engineering, equipment supply,
competitive advantage we give
training, erection supervision and start-up assistance, as well as follow-
our customers by helping them
up and technical support services. This comprehensive involvement
enhance the performance of their
enables Outotec to guarantee process performance for the whole
processes, products and services.
production line.
It is a factor our customers rely
Outotec is in the unique position of being able to provide
on to help them overcome even
solutions for the whole copper production chain. From cost effective,
the most demanding challenges;
environmentally friendly leaching, through state-of-the-art solvent
giving them the edge in business.
extraction to highly reliable automated electrowinning, Outotec has the
entire mine to metal process covered.

Outotec offers: Extensive research and development

n Innovative technologies for Outotec's long history in the operation and development of hydrometal-
leaching-SX–EW plants lurgical solutions for leaching, solvent extraction and electrowinning
n Feasibility studies processes has made us a world leader in these fi elds. All processes
n Basic and detailed engineering have been developed with a view to improve production effi ciency and to
n Proprietary and key equipment maximize profi tability. We also pay special attention to health and safety
supply issues and the minimization of environmental impact of our technolo-
n Commissioning and start-up gies. With extensive research facilities and resources, we ensure that
services the latest advances in technology are available when needed – and when
n Spare parts and maintenance they benefi t you most.
services
n Plant audits, retrofi ts and
machine upgrades
n Tailor-made process solutions
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Outotec packages include:

Leaching:
n Leaching process with pro-
prietary equipment

VSF™ solvent extration:

n Dispersion Overfl ow Pumps
(DOP ®)
n SPIROK® mixers
n Outotec settlers with DDG ®
fences and launders
Escondida plant, Chile.
n Loaded organic tank, rich
electrolyte after settler as
coalescer units
Considerable savings in Leaching: the start of the process
n Organic treatment units
operating costs
A number of leaching process Tankfarm with proprietary
When a single technology partner options are available for the equipment:
provides a combined leaching-SX– hydrometallurgical treatment of n Electrolyte circulation and
EW plant, the unit processes can be ores and concentrates. composition control system
integrated and optimized to provide Our solution may include
Tankhouse:
a reliable and economical process. mineral processing, innovative
n Cathode stripping machines
The design of the plant is reactor and process technology
n Permanent cathodes
compact and the layout is effi cient, for atmospheric leaching either
n Lead anodes
leading to lower construction and in sulphate or chloride media and
n Tankhouse cranes and bales
operating costs and a shorter start-up pressure leaching, depending on
n Polymer concrete cells
time. We provide guarantees for the the raw materials. This may be
n Busbar systems
plant’s capacity, the quality of the followed by Outotec's SX and EW
n Acid mist capture systems
produced copper and operational technology.
n CellSenseTM systems
parameters for the process equipment. A total process design by
n Process automation
Our long-term commitment to customer Outotec facilitates economical copper
service minimizes operating risks production, especially from low-
throughout the lifetime of the plant. grade deposits that would not
otherwise be viable using traditional
metallurgical processes.

Solvent
Electro-
Extraction
winning

Tankfarm

Cathode copper
Sulfidic/oxidic
Leaching
copper ore

Outotec is the only company to offer a complete solution for the

whole copper production chain, from mine to metal.
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Optimized solvent extraction

In the solvent extraction phase of the process, incoming pregnant leach solution (PLS) is

concentrated and purified, and a pure electrolyte is then used in electrowinning to produce

chemically and physically high quality copper cathodes.

A history of dedicated research and development Since launching the VSF TM technology for copper
applications more than a decade ago, Outotec has
For nearly 30 years, Outotec has been developing its gained a leading market share of new copper solvent
wide range of solvent extraction technologies, delivering extraction capacity.
both equipment and processes to its customers in the
metals processing industries. This long history of The VSF TM Solvent Extraction technology
dedicated research and development began in response
to increasing demands for lower operation and invest- VSF TM technology is the result of the continuous
ment costs, together with more reliable and stable development of mixer-settler technology. It has been
production where health & safety issues are given designed to run at minimum operating costs, ensuring
high priority in plant design. The results have been high profitability even during times of copper price
impressive, and today the plants that use our ground- fl uctuations. The scalability of this technology makes
breaking Vertical Smooth Flow (VSF TM) mixer-settler it exceptionally well suited for both larger and smaller
technology are among the most profi table in the world. plants, as it enables low entrainment values and very
stable performance even with fl uctuating fl ow rates.

SX pilot unit.
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A further benefi t of the scalable

nature of VSF TM solvent extraction
technology is that it leads to a more
compact plant layout and a reduced
need for organic fi rst fi ll inventory,
as often only one VSF TM train is
required. This leads to signifi cant
savings in investment and operating
costs.
In the VSF TM technology,
pumping and mixing are carried out
as separate processes. The VSF TM VSF™ stands for Vertical Smooth Flow, which describes the operation of a SPIROK® helical
tube agitator in a mixing tank. An extremely high agitator/tank volume ratio requires less
technology has three key elements: energy and ensures a smooth flow pattern with uniform mixing conditions.
a Dispersion Overflow Pump (DOP®),
a set of two SPIROK® mixers, and a
proprietary settler design including High-stability mixing
DDG ® fences. The main benefit of the VSFTM
The basic idea behind the technology is that minimal Mixing has been a crucial element
TM
VSF technology is to have smooth entrainment levels can be in VSF TM technology’s development.
agitation throughout the SX plant achieved without compromising The SPIROK® mixing technology
to avoid oxidation of organic and reaction and settling rates. This enables mixers to operate with
development of overly small droplet brings value in terms of minimal mixing energy and pumping
size in dispersion. These principles function, ensuring gentle, uniform
n Low investment costs, due to
give Outotec's SX plant the flexibility mixing and minimal crud formation.
smaller settler sizes and
to run in widely varying conditions The VSF TM mixing unit typically
less organic inventory
and to have high trough output with consists of two cylindrical mixer
n Low operating costs, due to
very little organic losses and crud tanks, baffl ed and equipped with
low copper and reagent
formation. double helical SPIROK® stirrers.
losses
n Flexibility, enabling constant
Maximum pumping efficiency Flexible and efficient settling
cash fl ow during varying
leaching conditions
Outotec's dispersion overflow pump Outotec's deep-dense-dispersion
(DOP ®) is the heart of the extraction (3D) settlers are typically equipped
unit. It is specially designed to pump with DDG ® fences, as well as a
high flow rates of aqueous and organic guiding fence at the feed end of the
solutions with relatively low head settler. The 3D settler technology
and generate the dispersion with enables high feed flows, low organic
optimized and controlled droplet inventory and extremely low en-
size. The impact of the DOP ® unit trainments.
on stage effi ciency is considerable, The VSF TM technology has
with performance fi gures typically proved its value from laboratory
approaching 100% found in any ® scale to large high capacity heap
SPIROK maintains smooth mixing with
VSF TM design. optimal reaction surface. leach SX–EW operations.

Dispersion Overflow Pump generates

optimal droplet distribution.
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Compact design allows maximum

production with low operational costs
In order to minimize the footprint The OutoTrack configuration option
and to simplify the flow sheet of an enables flexible PLS flow rates to even VSFTM with an OutoCompact
SX–EW plant, we use the OutoCompact double by changing from a series to a settler and layout design en-
layout in our process design. In the parallel feed pipeline connection. This hances your productivity with
OutoCompact layout, a loaded organic is an option when the pregnant leach
n Lower investment costs
buffer is held in a loaded organic (LO) solution tenor varies/drops.
n Lower organic inventory
tank that is an active piece of process In certain cases further
and make-up costs
equipment in an SX-track. The wash investment savings can be realised
n Increased health & safety
water circulation and coalescence using our latest settler design, the
n Reduced settler area
gates of the LO tank prevent OutoReverse, with in and out flow
n Reduced plant area with
contaminated aqueous residues connections located on one side of
reduced excavation costs
being carried through the stripping the settler.
n Reduced piping costs
circuit to the electrowinning circuit.
n More flexible configuration
to tolerate process
disturbances
n More stable cash fl ow
over a longer life time

®
DDG technology is replacing picket fences. Centralized pipe runs saves excavation costs.
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Integrated OutoCompact
Tankfarm concept
The OutoCompact Tankfarm concept In the OutoCompact track layout, a This improves the occupational
makes a number of conventional centralized organic treatment unit safety of the tankfarm and reduces
tankfarm operations unnecessary, is located next to the SX tracks to fi re protection investments.
so you no longer need: minimize operations involving
n raffi nate purifi cation units; due organics in the tankfarm.
to the low entrainments of VSF TM
technology An integrated OutoCompact
n loaded organic purifi cation Tankfarm brings savings
units; because VSF TM technology in investment costs and
and the LO-tank in each track guarantees secure and
ensure the purity of organics economical operations.
recycled to the stripping circuit The benefits further
n rich electrolyte coalescer units; include:
as VSF TM technology, combined
n Fewer process units
with rich electrolyte after the
n Less piping
settler, result in extremely low
n Fewer excavations
organic entrainments in the
n Smaller fi re protected area
electrowinning circuit.
Our concept gives you The OutoCompact Tankfarm
signifi cant savings in tankfarm is a link in an integrated plant.
investment costs. The optimal functioning of
each link together allows
outstanding quality and
production guarantees for the
entire SX–EW plant.
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High quality cathodes from advanced

electrowinning plants
For decades, Outotec has been the material handling cranes, cathode
world’s leading developer and sup- stripping machines, electrolytic The value of the
plier of tankhouse machines and as cells, busbars and electrodes. Outotec's Tankhouse
a result, our machines can be found The degree of the machine concept lies in:
in almost all of the world's major and the process automation is
n The high quality of
copper tankhouses. Our continuous optimized to the customer’s
produced copper cathodes
research and development work on requirements. In addition to
n Reliable process
tankhouse equipment and processes, reliable production of the highest
operations and equipment
as well as our own production experi- quality copper, signifi cant savings
functions
ence, has led to a range of impressive in electricity, edge strips, cathodes,
n Savings in investment
new technology developments, spe- maintenance, personnel and
costs
cially designed for high performance investment costs are realized.
n Savings in operation and
and cost efficient copper production. Outotec's compact
maintenance costs
Environmental protection and occu- tankhouse layout minimizes space
pational health and safety have been requirements and maximizes
made important aspects for our production efficiency. Our tankhouse
development work. machines are compatible with
The core of electrowinning other tankhouse technologies
operations is the material handling and are suitable for upgrade and
technology. Outotec's advanced and modernization projects.
proven material handling system We can offer a complete
bridges mechanical equipment, electrowinning plant to provide
automation and engineering expe- reliable and trouble-free operation
rience with experienced process for the entire life cycle of the plant.
metallurgy. Our material handling
systems consist of fully integrated High quality copper cathodes.
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Better for the environment,

better for people

The electrowinning plants designed

by Outotec have a unique and
effective acid mist capture system
using cell hoods.
Our acid mist capture system
includes an off-gas scrubber, which
ensures an excellent atmosphere
in the tankhouse, and the lowest
possible acid emissions to the envi-
Proven process performance. ronment. As a result, it gives lower
operation costs through acid recy-
cling, savings in corrosion-related
World-class tankhouse machines DoubleContact™ busbar system maintenance as well as improved
occupational health and safety. A
Our tailor-made tankhouse machines, With the innovative DoubleContact™ healthier and safer operating atmos-
cathode stripping machines and busbar system, both anodes and phere signifi cantly improves em-
tankhouse crane systems, can be cathodes have an electrical contact ployees' work satisfaction.
used with most existing tankhouse on both sides. The principal benefi t In cool climates, hoods and
technologies, though they are of this technology is a more even scrubbers reduce considerably the
particularly suited to the Outotec's current distribution, which in turn amount of general ventilation gas
process with state-of-the-art leads to reduced energy consumption, fl ows, and therefore investment
permanent cathodes. a more even cathode weight and operation costs. When using
The latest and patented distribution, and fewer short circuits. hoods the surface of the electrolyte
cathode stripping technology maxi- Fewer short circuits mean higher in cells is completely free from
mizes the lifetime of permanent current efficiency and better cathode fl oating beads or balls, which can
cathodes, especially their edge quality, as well as much longer stick on to copper deposit surface.
strips. Only side edge strips are re- insoluble lead anode life as less For easy operation of the system,
quired on cathodes, giving a signifi - damage occurs to the anode's electrode-handling cranes can
cantly reduced replacement costs surface. This also extends cell be equipped with fully automated,
and better trouble-free operation of maintenance cycle times. semi-automated or manual hood-
the plant. handling devices. Our expertise
Tankhouse machines can be brings you long-term safety, work
equipped with numerous automated satisfaction, and confi dence to
options. Manual options are also operate the plant.
available for smaller capacity plants.

Advanced electrowinning
cell concept

The design of Outotec's electrowinning

tankhouse is based on proven 84-
cathode long cell technology. This
results in a smaller tankhouse
area, which in turn leads to lower
construction costs and shorter
construction times. Patented DoubleContact™ busbar system Off-gas scrubber captures tankhouse
ensures more even cathode weigth acid mists.
distribution.
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High performance tankhouse equipment

Accurate and modern tankhouse cranes n suitable levels of automation up to fully
unmanned applications
Accurate and effi cient transportation of electrodes is n features of the Pulling Program, including
an essential task in every tankhouse. Outotec ensures reporting on production fi gures.
that the crane performance, capacity rating and level
of automation are tailored to suit the plant fl exibility Tankhouse cranes can be equipped with cathode and
requirements and the customer’s needs. busbar washing systems, which helps maintain copper
In addition to handling capacity, the high quality, fast electrode handling and minimal manual
positioning accuracy of the electrodes in the electrolytic involvement.
cells ensures high effi ciency and optimal production The tankhouse cranes handle heavy loads with
to meet today’s highest standards. an accuracy of a few millimeters. At the same time,
We work in close cooperation with our partners the cycle time of each motion is minimized in order
to develop the performance of their operating plants. to prevent the cranes becoming bottlenecks in the
This gives us a unique ability to help our customers production process.
to select the most suitable technology, taking into Improved profitability with advanced automation
account requirements such as: Outotec's Advanced Material Management System helps
n reliable operation in challenging working create reports required for plant operation and copper
environments (acid mist, humidity) production.
n electric insulation and other safety issues

Advanced automation user interfaces. State-of-the-art permanent cathodes in laser welding.

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Our CellSense™ system continuously The strong edge strips are designed
monitors your copper production in for a waxless process to reduce Main features of cathode
electrolytic cells and enables detection maintenance requirements and stripping machines:
of short circuits at an early stage. problems in stripping. They are
n Machine capacities of up
As a result the produced copper attached to the vertical sides of the
to 600 blanks per hour
has better quality, together with plate with a patented extrusion-weld
n Only one machine operator
reduced lead anode corrosion and method.
needed
electrical energy costs. Our permanent cathode
n Compact machine layout
Cathode blanks are marked technology ensures reliable and
n Simple to maintain
with ID codes. The performance of effi cient performance for your
n High reliability and low
each cathode blank can be tracked electrorefi ning or electrowinning
maintenance costs
and optimized based on weighing production either in new or existing
n Machine diagnostic
and/or measuring the surface tankhouse operations.
monitoring
quality of individual cathodes with
n Easily synchronized with the
machine vision cameras. Compact cathode stripping
tankhouse cranes and with
machines – a profitable
the plant control system
Long-life permanent cathodes investment

Our permanent cathodes provide Cathode stripping machines are an

superior strength and performance essential and integrated part of
and are designed to maximize the material handling process in Benefits of permanent
productivity and minimize the electrowinning tankhouse. Our cathodes:
maintenance. The suspension bar, cathode stripping machines reliably
with a copper core, has a full-length separate deposited copper from n High mechanical strength

stainless steel jacket, which provides cathode blanks with minimal fl exing n High dimensional accuracy

high mechanical strength and to maximize the lifetime of them and n Only stainless steel to

excellent corrosion resistance. In the edge strips. stainless steel welds

addition, the stainless steel jacket Machine capacities and n High protection against

means that copper is only exposed degree of automation can be selected corrosion

at the busbar contact areas. This according to the customer's n High current effi ciency

design allows the possibility to requirements. Occupational health n Low electrical resistance

replace a damaged plate and reuse and safety aspects have been given
the bar. high priority in the design phase
The large copper cross and our cathode stripping machines Copyright © 2006 Outotec Oyj. All rights
section in the suspension bar fulfi ll all required safety norms. reserved. VSF™, SPIROK ®, DOP ®, DDG ®,
ensures the lowest electrical CellSensor™, CellSense™ and Double
Contact™ are trademarks of Outotec Oyj.
losses throughout the lifetime
Outotec Oyj owns several patents and
of the cathode. patent applications regarding solvent
extraction technology.

Experienced process know-how. Cathode stripping machine in operation. New patented detachment unit separates
copper deposits reliably, and reduces wear of
the edge strips and plate.
 3056EN. Pinta/Libris, Helsinki, Finland. July 2007
Outotec, formerly Outokumpu Technology, is a worldwide technology
leader in minerals and metals processing, providing innovative and
environmentally sound solutions for a wide variety of customers in
minerals processing, iron and steel, aluminum and non-ferrous metals
industries. Outotec Oyj is listed on the Helsinki Stock Exchange.

[email protected]
www.outotec.com

Copyright © 2007 Outotec Oyj. All rights reserved.

Outotec and More out of ore! are registered trademarks of Outotec Oyj.