Leaching and solution purification, followed by electrowinning, is a common and growing route to the production of base metals such as copper, zinc, nickel and cobalt. Typically, the electrowinning stage is the most capital-intensive part of this process and involves the highest component of the operating costs. It is also the most crucial stage in relation to the final product quality.
Innovation in base metals electrowinning can lead to increased throughput in tankhouses, reduced operating costs, and improved product quality. This project is aimed at helping industry to achieve these outcomes.
This project covers an important research program in base metals electrowinning that will lead to benefits to industry. The project offers companies the opportunity to tap into a world class R&D activity at a high leverage of sponsorship investment.
The project comprises a modular structure with three concurrent modules to be undertaken within the overall research program:

Module 1: Advancing Electrode Processes and Cathode Quality

This Module aims to build on the substantial foundation laid in the P705 project. A particular focus will be on delivering to sponsor sites the outcomes of the P705 project. During these visits knowledge gained in the project will be delivered in a way that allows plant personnel to apply the information in an efficient and timely fashion. On-site courses will be also delivered to operating personnel during such visits.
The research program will involve continuing fundamental laboratory studies of the electrochemical characteristics and corrosion performance of existing and new anode materials culminating in the compilation of an Anode Handbook for the use of the industry personnel. Other proposed activities include studies of the role of additives in promoting the formation of high quality cathodes and minimizing acid mist formation in tankhouses, the optimization of the adhesion of electrodeposits to cathode blanks and the role of manganese in the electrowinning of base metals.

Project Leader
Professor Mike Nicol

Project Duration
3 years, commenced August 2006

Module 2: Maximizing Energy Utilization: Enhancing Uniformity of Current Distribution

One of the most prevalent problems in the operation of modern tankhouses is that of current distribution in a uniform way to all cathodes/anodes and to all areas of the cathodes and anodes. Even incremental improvements in this area can lead to substantial savings, improved anode life and consistent cathode quality for all metals. This module will initially build on work initiated during the past year at Murdoch university on the development of a user-friendly model that will simulate the complex problem of current distribution in parallel plate electrochemical cells.

Project Sponsors

Bateman Engineering Pty Ltd 

Hatch Associates Pty Ltd 

Freeport McMoran 

TeckCominco Metals Ltd 

BHP Billiton 

RSR Technologies 

Nyrstar Ltd 

Anglo American Corp 

Oxiana 

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@amira.com.au

Module 3: Improving Electrolytic Cell Technology: Optimizing Electrolyte Flow

Fluid flow plays a critical role in determining product quality, not only through its influence on solution mass transfer, but also through its impact on the suspension of particulate matter (sludge) and hence direct contamination of the product.
Gaining a much more detailed understanding of fluid flow and its effect on mass transfer, process efficiency and product quality will therefore be the focus of research in this module.

Potential benefits of this research project are:

• Reductions in general operating costs at tankhouses, particularly power and labour costs

• Increase in anode life, lower maintenance and cost in existing tankhouses and reductions in the capital cost of new tankhouses

• Improvements to product quality, particularly for nickel, cobalt and zinc cathodes, leading to improved price premiums and increased plant throughputs.