The base metals industry faces continuing challenges in the current environment of difficult economic circumstances and uncertainties about the future costs and availability of power. In the case of base metals electrowinning, there is continuing pressure to increase energy efficiency and maximise capital intensity without compromising product quality or the health of employees and the environment. The objectives of the project are to create knowledge relevant to improving energy efficiency and capital intensity that sponsor companies can exploit in their electrowinning businesses.
The project comprises a modular structure with four concurrent modules to be undertaken within the overall research program:

Module 1: Advancing Anode Processes and Energy Efficiency

Improve performance of plants by reducing operating (particularly energy) costs and maximizing the use of capital without compromising the health of employees and the environment.

Drawing upon the knowledge gained by the team over the past six years, a major component of this module will be assessment of alternative anode materials including non-lead anode options. Comparisons with existing anodes will be made by building upon and extending the team’s expertise in fundamental laboratory studies of the electrochemical characteristics and corrosion performance.  Another outcome from this module will be further improved understandings of anode degradation mechanisms leading to recommendations for best practice for anode management. Pilot-plant scale testing of new anodes is outside the immediate scope of the project.  Specific pilot plant programs can be designed and costed should the sponsor companies individually or collectively decide to do so.

Project Leader
Professor Mike Nicol

Project Duration
3 years, commencing April 2010

Module 2: Advancing Cathode Processes and Product Quality

Identify viable low-capital options for plants to increase throughput without compromising cathode quality or harming employees and the environment.

Issues to do with operating at increased current density will be the focus for this module.  One aspect will be to study the role of additives including the fundamentals of how they work (which will identify better future options), the optimum concentrations in electrolyte and the options for real-time control of dosage rates.  The interactions between additives and standard mist suppressant reagents will also be examined.  A second aspect for this module will be to study issues such as the effect of current density on the adhesion and stripping of cathodes. Ideas for semi-permanent alternatives to edge strips will also be investigated.

Project Sponsors

Anglo American

BHP Billiton

Freeport McMoran

Hatch Associates

Industrie De Nora

Inppamet

Outotec

RSR Technologies

TeckCominco Metals

Vale Inco

Votorantim Metais

For further information contact:

Terry Braden
Research Director & Regional Manager North America
AMIRA International
PO Box 461028
Aurora, Colorado, 80046
USA
Phone +1 (303) 400-3982
Fax +1 (303) 680-0523
Email:

terry.braden@amirainternational.com

Module 3: Cell and Tankhouse Optimization

Develop simulation models for mass transport and current distribution that can be used to optimise energy efficiency and capital intensity.

This Module will further develop and extend the CFD models produced in the P705A project for copper electrowinning and electrorefining cells.  The predicted bulk electrolyte flow will be validated by measurements made in a pilot scale cell and then on-site.  The CFD model will be extended to include mass transport close to the cathode surface, for both Cu and Zn deposition. This will enable the rate limiting nature of mass transfer particularly at high current densities to be fully characterized, thereby allowing for the estimation of the mass transfer of metal ions, impurities and additives to the cathode surface under various conditions.

In addition, the macroscopic current distribution on individual cathodes will be modeled by the use of advanced CFD simulations.

Module 4: Technology Transfer

Maximize the opportunities for the benefits from the project to be transferred to sponsor companies

A particular focus will be on delivering to sponsor company sites the outcomes of the project (including knowledge developed in P705 and P705A). During visits to sponsor nominated sites, Information will be delivered in a way that allows plant personnel to apply the information in an efficient and timely fashion. In addition, detailed operating information will be gathered that will assist sponsors to benchmark their operations against others in the same industry and across industries.  There will also be the opportunity for staff training courses during site and regional visits.