TANKHOUSE EQUIPMENT

Torren 2013-05-24

Outotec Tankhouse Equipment

ANODE PREPARATION MACHINE (APM)
Proven technology Worldwide benchmark

TANKHOUSE CRANE
Multifunctional Bale (Anode+Cathode) Fully Automatic

FULL DEPOSIT ROBOT STRIPPING MACHINE (FDRSM)

Reliable solution Modern technology

ANODE SCRAP WASHING MACHINE (ASWM)

Maximum recovery of slime Low water consumption

PERMANENT CATHODE
Rigid Design Best edgestrip

Robotic Stripping Machines

Outotec is the Worlds leading supplier of robotic supported Cathode Stripping Machines. The total amount of installed robots are now 40 pcs. With the main customers being some of the worlds biggest Cu Refineries.
Site: 1 Caserones, Pan Pacific 2 RCC Novgorod 3 TNMG Tongling 4 Daye NF 5 JNMC Fangchenggang 6 Paranapanema, Caraiba 7 Boliden cathodes 8 Norilsk Nickel 9 Fuchunjiang smelter* 10 China Gold* Total number of robots: Country: Chile Russia China China China Brasil Sweden Russia China China No. Of Robots: 1 2 6 6 6 3 5 6 3 3 40 Copper Production: 45.000 75.000 > 400.000 > 300.000 > 400.000 > 275.000 > 275.000 > 325.000 > 200.000 > 200.000

2. Success Stories
Russia Copper Company wanted to upgrade their old Cathode stripping machine that had low capacity and was considered non safe to the operators. In tuff competition Outotec came up with the safest, most flexible and time efficient solution to the customer. By replacing the old conventional stripping machine Outotec installed two robots and their strip station for Taco/Kidd Cathodes the performance of the stripping went up by more than 50%. Implementation time, Maintenance and Safety has been the key drivers and Outotec fulfilled all of the criteria's set by the client. In 4 weeks the new stripping solution was in place and production up and running a minimum of production losses was achieved!

Building Success together with Clients!

Before..
Low average speed: 140-150 c/h Unsafe frequent incidents Time consuming manual interference due to low strip ability Damaged cathodes (edgestrip and surface)

.After!
Increased sped: 250 c/h Safe No human interference Reduced maintenance Increased interval between cathode maintenance Open solution Easy to keep clean & maintain Fast implementation

The Tongling Case 400.000 tpa

One of Chinas largest producer of cathode copper selected Outotecs robot stripping machines for their new 400.000 tpa. tankhouse By using Only two machines, Outotec was the only one who could meet their production demand in a safe and cost effective way!

The Daye Case 300.000 tpa

Another of the Chinese Copper giants, Daye Nonferrous, selected Outotec for their newly build Copper Refinery Key factors in their chooise was Outotecs local presence, advanced technology, machine data and the capability of doing a record fast installation on site to secure the customers cash flow.

DAYE Tankhouse

FDRSM Stack handling

The Paranapanema Case

An old starting sheet technology based tankhouse that is converting to a full deposit cathode production needed the best available technology Outotec was selected to convert their operation and install Cathodes and a Stripping Machine with a capacity of 700 cathodes/h (630 practical) A doubble strip station solution was selected to strip the Taco/Kidd cathodes in the 275.000 tpa tankhouse

In Feed / Out Feed Robots

The feeding robot transfers the cathode and copper deposit from the wash conveyer to stripping station 1 and stripping station 2 and afterstripping to the discharge conveyor or the optional cathode scanners.. The robot gripper is equipped with a special tool that prevents the copper deposit from pre-stripping during movement.

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Stacking robot
The stacking robot takes the plates from the cathode conveyer and builds a stack of copper plates onto the stack-lifting table. The stacking robot can also place B-grade cathodes in the B-grade storage. The stacking robot also feed the sampling unit. The stacks are even and neath and easy to strapp.

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Stripping Station
The stripping station pre strip and strips the cathodes. When the copper comes loose the strip station tilts the cathode from vertical to horizontal position and releases the copper onto the cathode conveyor. In case of a planned maintenance, stripping station 1 or 2 can be shut off and the stripping machine can still run with just a slightly lower capacity. The frames are manufactured in carbon steel. The carbon steel parts are protected against corrosion by acid resistant epoxy paint.

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Pre-weighing of Cathodes

Performance of each cathode

Automatic selection of A or B grade cathode

Can be combined with TIMS Cell performance (summarizing)

CathodeSense overview
Online Physical Quality Inspection

Cathode deposit (nodules, thickness) Edge strips (missing parts, nodules) Plate straightness
Versatile Classification Criteria

size, count, area, location and type of

defects

Integration with FDSM and TIMS Quality Classification Automatic reject for

Maintenance Historical analysis Quality analysis Troubleshooting

Our FDSM References

1986 Gibraltar Mines 1988 Pinto Valley 1988 Cananea 1991 Cananea 1 1995 Morenci Southside 1998 Morenci Central x2 1999 Tonopha, NV 2000 Cananea 2 2000 Morenci Stargo x2 2007 Safford
1987 Brixlegg 1989 Nord Deutsche 1991 Nord Deutsche 1994 Httenwerke Kaiser 1997 Olen 2007 Cobre Las Cruses 2008 Pirdop 2012 Boliden Rnnskr 1992 Kyshtym 1995 Boliden Rnnskr 1995 Norilsk 2002 ZAO Novgorod 2005 Kyshtym 2007 Pori (Taco) 2008 Assarel Medet 2009 Physma (Taco) 2011 ZAO Novgorod 2012 NICICO Kahtoonabad 2012 Norilsk nickel 2002 Guxi 1-2 2006 Guxi 3-4 2006 Yanggo 1-2 2009 Zijin 1 2009 Jinlong 1 2010 Tongling 1-2 2011 Daye 1-2 2012 FNMC Fangchenggang 1-2 2013 Heding Fuchunjiang 1 2013 China Gold Sanmenxia 1

1993 Cerro Colorado 1993 Minera Escondida 1993 Quebrada Blanca 1993 Chuquicamata 1994 Zaldivar 1994 Lince 1994 Salvadore 1994 Toquepala 1996 Chuquicamata 1997 Cerro Colorado 2001 El Tesoro 2004 Milpillas 2007 Gaby x2 2008 Franke 2009 Tia Maria 2010 Caserones 2011 Caraiba 1 (Paranapanema)

2008 Rustenburg (Nickel) 2010 Shituru, Likasi 2010 CNMC, Muliashi 2011 ENRC Chambishi 2011 Tenke Fungurume 1-2

1994 Sterlite Silvassa 1996 Swil Gujarat, India 1997 Indo Gujarat, India 1998 Olympic Dam x2 2001 El Teben Egypt 2003 Tuticorin, Sterlite 2005 Sepon Copper (Taco) 2010 Tuticorin Sterlite 2-3

Machines in bold text include robots

Outotec Cathode

Outotec Cathode - More out of Cathodes

Over 350 000 permanent stainless steel cathodes manufactured for more
than 25 different plants.

Part of Outotec Tankhouse Solutions High mechanical strength Permanent protection against corrosion

Permanent protection against mechanical wear and tear

High current efficiency and consistent electrical properties New edge strip technology Individual identification code for tracking

Global presence worldwide service network

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Outotec Cathode

General problems with stainless steel cathodes

Galvanic corrosion of the hangerbar and corrosion of the plate to bar welding Uneven electrical conductivity Bending hangerbar structure and failing plate to bar welding Edge strip problems Stripping problems especially in wax less process

These generally known problems with the permanent cathodes inspirited Outotec in the 90s to start developing its own cathode technology with significant improvements.

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Outotec Cathode
Cathodes can be delivered either for separate (SPLIT) or envelope (TACO) cathode sheet technology
SEPARATE
CATHODES

SHEETS

ENVELOPE CATHODES
(TACO)

SHEETS

(SPLIT)

In the SPLIT cathode process the copper sheets are separated at the V-groove edge. Accurately and correctly manufactured cathode V-groove enables optimum separation of the copper sheets for separate cathodes when using split cathode technology.

In the TACO cathode process the copper sheets are partly grown together at the bottom edge with patented V-groove technology. This assures the copper sheets stay together after stripping in trimmed form. This enables reliable and trouble free handling of the copper sheets in future process stages.

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Outotec Cathode

Only bus bar contact areas are exposed

All stainless steel structure with laser welded joints

Patented hanger bar technology Integrated Outotec Edge Strips V-groove

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Outotec Cathode

Continuous laser welding

Only stainless steel to stainless steel laser welding No dissimilar metal welds which eliminates problems with galvanic corrosion No welding inclusion (Excellent corrosion resistance)

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Outotec Cathode - Hangerbar

Hanger bar construction Stainless steel tube with copper core Sound metallurgical bond Permanent protection against corrosion Excellent long term electrical conductivity Strong mechanical structure designed for heavy duty mechanized stripping

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Outotec Cathode - Manufacturing

Manufacturing Outotecs cathodes are manufactured at its own workshop with automated production lines. Fully automatic production lines for cathode manufacturing and quality control. Outotec Cathode delivery comply with ISO and OHSAS quality assurance systems for:
Research and Development ISO 9001:2000
Environmental System ISO 14001 Health and Safety OSHA 18001 Project Implementation ISO 9001:2000 Manufacturing ISO 9001:2008

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Outotec Cathode - 2nd generation Edge Strips

Edge strip manufacturing Outotecs edge strips are integrated to the vertical sides of the steel plate with patented high pressure molding technology. Permanently fixed edge strips are designed for high mechanical stresses and impacts caused by mechanized stripping. Since 2009 Outotec has been using in-house developed second generation upgraded manufacturing process. This high pressure manufacturing process guarantees identical edge strip quality through production and maintenance. Outotec has upgraded material from HD-PE (black) to new higher perfomance special grade of PP (white).

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Outotec Cathode Quality Control

Cathode quality is guaranteed by continuos follow up of material, manufacturing and operation qualities in our own research facilities.

Plate straightness and dimension

Laser welding quality Cathode conductivity check Random plate surface quality Edge strip quality

V-groove dimension

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Outotec Cathode - References

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Outotec Cathode - Service

Cathode service options:

I Minimum service
Hand held maintenances tools and racks

II On-site cathode service shop

Edge strip detachment machine Cathode sheet straightening unit Edge strip replacement machine (ESRM)

III Outotec cathode service center

Automated edge strip detachment machine Cathode sheet straightening unit Automatic edge strip replacement machine V-grooving machine

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Edge Strip Replacement Machine (ESRM)

Dimensions Weight Capacity, Single table Double table Operators required 5000x2200x2500 mm 8000 kg 6-10 cathodes/h 10-14 cathodes/h 1 with lifting equipment OR 2 without lifting equipment

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Outotec Cathode - Service

References List / Equipment deliveries Plant / Operation
Novgorod Metallurgy Plant, Russia Kyshtym Copper Plant Expansion, Russia Xiangguang Copper Plant, China

Equipment
Semi automatic edge strip replacement machine (ESRM) with cathode maintenance equipment. Semi automatic edge strip replacement machine, Hand held edge strip repairing tools Semi automatic edge strip replacement machine withcathode maintenance equipment, Hand held edge strip repairing tools Semi automatic edge strip replacement machine Hand held edge strip repairing tools Semi automatic edge strip replacement machine with cathode maintenance equipment 2nd Generation automatic edge strip replacement machine with cathode maintenance equipment Hand held edge strip repairing tools Hand held edge strip repairing tools 2nd Generation automatic edge strip replacement machine with bottom edge strip tooling for Ti-motherblanks.

Year
2002 2006 2007

Lane Xang Minerals Sepon Copper, Laos Montanwerke Brixlegg AG, Austria Cobre Las Cruces, Spain Ta Mara, Peru Assarel Medet JSC, Bulgaria CNMC Luanshya Copper Mines PLC, Zambia Paranapanema S.A. , Brazil

2008 2008 2008 2010 2010 2011 2012

References List / Maintenance Services Plant / Operation

NewBoliden Harjavalta Copper, Finland Montanwerke Brixlegg AG, Austria Novgorod Metallurgy Plant, Russia 2nd

Equipment
Generation automatic edge strip replacement machine. Full Service cathode maintenance at Outotec Turula Workshop / Finland 2nd Generation automatic edge strip replacement machine. Full Service cathode maitenance at Outotec Turula Workshop / Finland 2nd Generation automatic edge strip replacement machine. Upgrade of edge strip quality from original 2002 delivered 1st generation extrusion machine. On-site service visit with mobile ESRM unit.

Year
2009 present day 2010 present day 06/2012 09/2012 (one time overhaul)

Anglo Rustenburg Mines Limited, South Africa

2nd Generation automatic edge strip replacement machine. Upgrade of edge strip quality from original 2007 delivered 1st generation extrusion machine with bottom edge strips. On-site service visit with mobile ESRM unit.

04/2013

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RCC Novgorod Metallurgy plant (Russia)

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Anglo Platinum Rustenburg (RSA)

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Anglo Platinum Rustenburg (RSA)

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Job Done Happy Customer

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