Chilekwa Moses Project

IMPROVEMENT OF KABUNDI COPPER CATHODE (KBC) RECOVERY
THE COPPERBELLT UNIVERSITY
SCHOOL OF MINES AND MINERAL SCIENCE
METALLURGY DEPARTMENT
IMPROVEMENT OF KABUNDI COPPER CATHODE RECOVERY BY

ESTABLISHING AND EXPLOITING THE RELATIONSHIP BETWEEN
TANKLOADING PRACTICE, REJECTION FACTORS AND REJECTION RATES
AT KCM TAILINGS LEACH PLANT TANK HOUSE NCHANGA INTEGRATED
BUSINESS UNIT (NIBU)
NAME: CHILEKWA MOSES.K.
COMPUTER NUMBER: 06058176
SUPERVISOR: DR F.CHILESHE
DECEMBER 2010
THIS DISSERTATION IS SUBMITTED IN PARTIAL FULFILMENT AS A

REQUIREMENT FOR THE AWARD OF THE BACHELORS DEGREE (BEng) IN
METALLURGICAL ENGINEERING TO THE COPPERBELT UNIVERSITY
By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 0

DECLARATION
I CHILEKWA MOSES being the student in the faculty of school of mines and mineral
science of the Copper Belt University do affirmatively declare that, the work which has
been done in this dissertation has been solely mine. The other pieces of information that
has been consulted during the preparation of this report have been recognized and duly
acknowledged. As matter of fact I do stand here by asserting that, the information given in
this book has never been the product of any one’s submission at this institution or any
other institution for the same reasons as I do.
Author’s signature..............................................................Date........................................
Internal Supervisor’s signature..............................................Date.....................................
External supervisor’s signature.............................................Date.....................................

LETTER OF COMMITTAL
The Copper Belt University
P.O Box 21692
Kitwe
The Projects coordinator
Mining department
Copper Belt University
Kitwe
Dear Sir,
RE: LETTER OF TRANSMITTAL
I am here by presenting my final year project in partial fulfilment for the award of the
bachelor of Engineering in Metallurgical Engineering.
The project is a survey on the Improvement of the recovery of copper cathodes at tailings
leach plant Tank houses of the Konkola Copper Mines(KCM) Nchanga Integrated
Business Unit (NIBU).The projects has recommendations on how the Rejections can be
reduced and it further has information on the rejection rates at the tank houses in Chingola
It is indeed my earnest prayer that this dissertation is going to satisfy your requirements as
I have fewer words to express my gratitude.
Author’s Signature..........................................Date..........................................................
Supervisor’s Signature....................................Date..........................................................

DEDICATION
I dedicate this report to my parents, my mother MRS AGNESS MAMBWE and my late
father( may his soul rest in peace),MR LUCKSON CHILEKWA, for the care and
financial support which they gave me all along my school life. To you MUM and DAD I
say no word will have a meaning to express my gratitude for all you did. To the rest of my
family members, thank you for being there for me. To Lydia Banda, my dearest, thank
you for your attention and concern in times of difficulties that I have encountered in my
school life. Last but not the least to my aunt MRS RUTH MAMBWE I say thank you for
what you have done for me, my uncle MR. PEARSON KALEBWE thank you very much
for the Financial support you gave me in order for me to reach this height in my
education. The Most high God has made it possible for me to reach this level all because
he has immeasurable love for me, therefore I say thank you to the creator of the universe.
To my class mates,Muziya Kency Musonda, Bernard, Aongola Mukisi , Mukandawire

Darius, Musonda Edward, Chilufya Geofrey , Kampamba Laban , Mwamba Precious,
Chipili Chitalu, Chabatamfya Osward ,Kabondo Leornard, Mwila Lewis, Mwenshi
Sungani, Phiri Mabvuto, Nyirenda Muleza, Nyirenda Kondwani Gilbert, Ng’ambi
Banarbas Chandawe Andala, Mulenga Osebio, Zimba Kapepula, Mwanza Wiseman,
Musonda Ezekiah and Solochi Clifford to you friends, I salute you for your co-operation.
To my room mates, Kabunda Nash Hamwenzu ,Mwangata Ng`onga Henry Mushiba Abel
Thanks for being there for me. Also my former room mate Mr. Patrik Kombe, thank you
for your good interaction. I can not just leave this page without saying thanks to John
Mwisa and Jonathan Mwaba; to you friends may god continue showering his blessings
on you.

ABSTRACT
Nchanga Electro-winning Plant in the Tailings Leach Plant (TLP) has two Tank houses:
the Old Tank house, which was commissioned in 1930, and the New Tank house,
commissioned in 1974. The electrowinning Plant has in the recent financial years, 2006/7
to 2008/9, embarked on a quality improvement programme. Investment in infrastructure,
equipment upgrades, extensive human resource training and formulation and
implementation of effective plant operating philosophies have been undertaken with a
vision to becoming one of the best world class copper producers.
This paper discusses the search to assure and enlist the customer confidence by improving
the quality of Kabundi Copper (KBC) cathode to LME Grade A specifications.
The Nchanga EW Tank house has been continually producing 100% LME Grade A quality
cathodes for more than 8 months. These and many other benefits have resulted in
continued acceleration of the company’s bid to accrediting KBC to LME Grade A.
Keywords: Quality, Electro winning, TQM, LME Grade A cathodes
Konkola Copper Mines PLC (KCM) operates TLP at its Chingola mining complex in
Zambia. It is an integrated plant whose final product is electro-won cathode copper
produced at the tank house. Nchanga TLP accounts for 36% of KCM’s annual cathode
copper production.
After the 2006/07 financial year, a decision was taken to improve the quality of cathode
copper produced at the Electrowinning plant. It was aimed at cutting the cost of
reprocessing non- exportable cathode copper, which is smelted and electro refined at its
Kitwe copper smelting plant. Prior to the 2006/07 financial year, plans to enlist KBC as
LME Grade A were formulated and embarked on. It became apparent that Nchanga TLP
needed to produce quality cathode as this was crucial in exceeding the ever-changing
expectations of our customers.
To assure customer confidence, the following needed to be worked on:

 Reduce Impurity levels in KBC to within the London Metal Exchange LME
prescribed limits.
 Increase metal recovery to export to over 96 %.
 Ensure visual quality of KBC was upheld in order to register it as LME Grade A in
line with our quality objectives.
The study recommends that in order to reduce the rejection of cathodes to extremely low
levels the tank loading practice should be done properly. The shorts correction which is the
tank loading practice is very critical to crop of cathodes to be pulled next time. Therefore
the anomalies in the loaded cells should be rectified immediately without fail. Ensure that
all the twisted anode hanger bars are straightened. Straighten all the bent cathodes. The
correct use of jackets during pulling helps to reduce lead flakes. Shift controllers should
closely supervise the tank loading crew (shorts correction and wet flapping exercise) as it
is most crucial to the production of quality cathodes. The washing of cell contacts reduces
the open contacts because of sulphate crystals. For this reason washing of the contacts
should be done using steam under pressure. On the part of the PVC balls should be
supplied to all the cells so that acid mists are suppressed to enhance the working
environment. Improper alignment of cathodes in case of the old tank house will
contaminate the cathode with lead. If the recommendations are strongly adhered to, the
rejections would be reduced and the quality of copper cathodes would be enhanced.

ACKNOWLEDGEMENT
To start with, I would say am expressing my heart felt gratitude to the almighty God , for
having granted me the time and guidance, during my three months time of my industrial
attachment at Nchanga (KCM) in Chingola. All the lecturers at mining department for
their efforts in making it possible for us to go on Industrial attachment. I further thank my
internal supervisor DR. F CHILESHE for having been so kind and his tireless concern
during the periods of my consultations, sir, I say, I have no better word to express my
gratitude towards you. Further more, I thank my supervisors from KCM Miss Kutemba
Kapanji metallurgical projects and Mr. Chisulo Metallurgical accounting, the Manager
operations Mr Zimba and the assistance manager operations Mr Zambika for their
kindness and tireless diligence in guiding us during our experience at tailings leach plant,
(TLP) tank houses. Lastly but not the least I would like to thank Mr Kalasa the training
officer (TLP) for his cordial and warm welcoming of hospitality when we just reached
tailings leach plant.

TABLE OF CONTENTS
DECLARATION....................................................................................................................................i
LETTER OF COMMITTAL....................................................................................................................ii
DEDICATION.....................................................................................................................................iii
ABSTRACT.........................................................................................................................................iv
ACKNOWLEDGEMENT......................................................................................................................vi
LIST OF FIGURE..................................................................................................................................x
LIST OF TABLES.................................................................................................................................xi
NOMENCLATURE.............................................................................................................................xii
CHAPTER ONE INTRODUCTION.........................................................................................................0
1.0 Introduction............................................................................................................................1
1.1 The TLP Tank house vision.......................................................................................................1
1.1.1 Background..........................................................................................................................1
1.1.2 Quality Initiatives.................................................................................................................2
1.1.3 Overall Goal of the study.....................................................................................................3
1.1.4 Distinctive goal of the thesis................................................................................................3
1.1.5 Range of project (scope)......................................................................................................3
1.2.0 Plant Description..................................................................................................................3
1.2.1 The New Tank House............................................................................................................4
1.2.2 The New Tank House Lay Out .........................................................................................6
1.3.0 Process operation................................................................................................................9
1.3.1 Rectifier and load control.....................................................................................................9
1.3.2 Advance electrolyte flow.....................................................................................................9
1.3.4 Tank loading.......................................................................................................................10
1.3.5 Cathode production...........................................................................................................11
1.3.6 The starting sheet preparation...........................................................................................11

1.3.7 The starting sheet dimensions...........................................................................................12
1.3.8 Starting sheet inspection...................................................................................................12
1.3.10 Cathode pulling................................................................................................................13
1.3.12 Cathode handling and despatch.......................................................................................15
CHAPTER TWO LITERATURE SURVEY...............................................................................................17
2.0 Literature survey...................................................................................................................18
2.1 Electro winning.....................................................................................................................18
2.2 The cathode quality..............................................................................................................19
2.3 Removal of organic and suspended solids.............................................................................19
2.4 Anode corrosion....................................................................................................................20
2.5 Properties of lead- Ca-tin alloy anodes.................................................................................21
2.6 Effects of oxygen evolution...................................................................................................22
2.7 Effects of material oxidation in solution..........................................................................22
2.8 Electro-winning cell condition.........................................................................................22
2.8.1 Electrolyte circulation........................................................................................................23
2.8.2 Temperature of the electrolyte..........................................................................................24
2.8.3 Reagent addition................................................................................................................24
2.9.2 Capping boards or insulator blocks....................................................................................28
2.9.3 Power loss:.........................................................................................................................28
2.9.4 Other electrowinning operating parameters include:........................................................29
CHAPTER THREE..............................................................................................................................30
EXPERIMENTAL PROCEDURE...........................................................................................................30
3.0 Experimental procedure.......................................................................................................31
3.1 Primary data.........................................................................................................................31
3.2 Secondary data.....................................................................................................................31
3.3 Cathode rejection recording.................................................................................................31
3.3.1 Equipment..........................................................................................................................31
3.3.2 Observations......................................................................................................................32

3.4 Shorts correction...................................................................................................................32
3.4.1 Equipment..........................................................................................................................32
3.5 Spot-check............................................................................................................................33
3.5.1 Equipment..........................................................................................................................33
CHAPTER FOUR RESULTS AND DISCUSSION....................................................................................34
4.0 Results and discussions.........................................................................................................35
4.1 Primary and secondary data analysis....................................................................................35
4.2 Cathode rejections analysis during the period when rejection was more than four percent
(4%).............................................................................................................................................39
4.4 Shorts correction analysis.....................................................................................................43
4.4.1 Tank loading practice: Shorts correction. Date; 2 nd March, 2010.......................................43
4.4.2 Tank loading practice: Shorts correction. Date; 9 Th March, 2010.......................................45
4.4.3 Tank loading practice: Shorts correction. Date; 16 Th March, 2010......................................47
4.4.4 Tank loading practice: Shorts correction. Date; 26 Th March, 2010......................................49
4.5 Calculation............................................................................................................................51
4.6 Rejection rate during the period when rejection was less than the target four percent (4%)
....................................................................................................................................................53
4.7 Bar chart rejection rate during the period when rejection was less than the target four
percent (4%)...............................................................................................................................54
4.8 Rejection rate during the period when rejection was more than the target four percent (4%)
....................................................................................................................................................54
4.9 Rejection rate during the period when rejection was more than the target four percent (4%)
....................................................................................................................................................56
CHAPTER FIVE CONCLUSIONS AND RECOMENDATIONS.................................................................58
5.0 Conclusion and recommendation.........................................................................................59
5.1 Conclusion............................................................................................................................59
5.2 Recommendations................................................................................................................59
REFERENCES................................................................................................................................60
Appendices.................................................................................................................................61

Appendix 1..................................................................................................................................61
Appendix 2..................................................................................................................................67
Appendix 3..................................................................................................................................71
LIST OF FIGURE
Figure 1.1: Tank house layout..................................................................6
Figure 1.2: Tailings leach plant flow sheet...............................................7
Figure 1.3: New tank house and old tank house flow sheet....................8
Figure 1.4: Plastic caps on shoulders of anodes during pulling...........14
Figure 1.5: Cathode copper on a crane bailer during washing............15
Figure 4.1: Rejection less than target 4%..............................................36
Figure 4.2: Rejection less than target 4%..............................................38
Figure 4.3: Rejection more than target 4%...........................................40
Figure 4.4: Rejection more than target 4%...........................................42
Figure 4.5: Anomalies in the loaded cells...............................................44
Figure 4.9: Rejection rate against rejection factor................................54
Figure 4.9.1: Rejection rate against rejection factor.............................56
Figure 4.9.2: Overall rejection.................................................................57

LIST OF TABLES
Table1.1: starter sheet composition...........................................................12
Table1.2: starter sheet screening factors................................................. 13
Table1.3: Copper cathode screening factors.............................................16
Table2.1: Reagent addition parameters....................................................26
Table 4.1: Cathode analysis for July 2009 – March 2010........................35
Table 4.2: Cathode analysis for July 2009 – March 2010....................... 37
Table 4.3: Cathode analysis for April 2007 –November 2007.................39
Table 4.4: Cathode analysis for April 2007 –November 2007.................41
Table 4.5: Shorts correction analysis.........................................................43
Table 4.9: Percentage rejection rate..........................................................53
Table 4.9.1: Percentage rejection rate.......................................................55

NOMENCLATURE
KCM.....................................................konkola copper mines
TLP ......................................................Tailings Leach Plant
NIBU.....................................................Nchanga Integrated Business unit
LME......................................................London Metal Exchange
TQM.....................................................Total Quality Management
KBC......................................................Kabundi Copper Cathodes
SX..........................................................Solvent Extraction
HDPE...................................................High Density polyethylene
PVC......................................................Polyvinyl Chloride
DC ........................................................Direct Current
EW........................................................Electrowinning
SOPs......................................................Standard Operating and Maintenance
Procedures

CHAPTER ONE INTRODUCTION

1.0 Introduction
Konkola copper mine Nchanga integrated Business Unit (NIBU) is found on the copper
belt province of Zambia. IT is particularly found in Chingola. The Konkola copper Mine
(KCM), Nchanga Integrated Business Unit (NIBU), is partially owned by Vedanta plc
which controls a major part of the shares. Konkola Copper Mine Plc operates a Tailings
Leach Plant at its Chingola Mining Complex. The final product of this plant is electro-won
copper cathodes produced at the tank house. The Nchanga Tailings Leach plant, (TLP),
deals with the old and current tails. The tails are converted to copper cathode by electro-
winning through a series of Hydrometallurgical operations. The Nchanga TLP accounts for
36 % of the KCM’s annual cathode copper production.
The feed to TLP is current tailings from Nchanga concentrator and the reclaimed tailings
from old dump sites. The plant has one of the largest leaching facilities with several
counter current decantation units, 26 Horizontal Belt Filters, Solvent Extraction and 260
tonnes deposition capacity electro-winning plant per day.
1.1 The TLP Tank house vision: To be a world class copper cathode producer.
Mission statement: To cost effectively produce 100% LME Grade ‘A’ copper in safer
manner at more than 96 % recovery, to export within the dictates of the ISO 14001
Environmental standards and total quality management(TQM) ideals.
The TLP Tank houses produces cathode copper which is 99.99 % from advance electrolyte
with copper content of about 40 to 60gpl.
Evolution of cathode quality at Konkola Copper Mines plc
1.1.1 Background
KCM’s Nchanga tailings’ Leach plant has through coordinated quality improvements
efforts achieved recoveries of 96 %.The other efforts to improve quality of kabundi
copper(KBC) cathodes are:
 Introduction of team to maintain cell furniture to improve contacts in the cell

house.

 To improve metal recovery by establishing and exploiting the relationship between

tank loading practice and rejection factors and rejection rates.
After the 2006/2007 financial year, the company decided to improve the quality of cathode
copper at electro-winning plant. This was done to cut off the cost of processing non
exported cathode copper. This non exportable copper is smelted and electro-refined in
Kitwe smelting plant. Before the 2006-2007 financial year plans to register KBC as LME
Grade A metal were made and embarked on.
Because of the competition in the base metal business, it was apparent that there was need
to produce the quality cathode in pursuit to assure and enlist customers’ confidence.
In order to assure the customer’s confidence the following was required to be done:
 To reduce the impurity levels in the KBC to within LME prescribed limits.
 To increase metal recovery both at leaching and electro-winning from 63 to ±75% to
66 to ±96% respectively.
 To ensure the visual quality of KBC is upheld in order to rebrand KBC.
 Redefine and reshape attitudes Technicians and operators in the above respect
encompassing all levels of involvement within KCM.
 Employees and stake holders were and eventually convinced to join in the campaign
for quality. There was willingness across the employee levels to join quality campaign
there by inputting into the Nchanga’s campaign for quality.
1.1.2 Quality Initiatives
Several major investments were done. The centre of these was equipment and human
resource. These were:
 Rectifiers; silicon Rectifiers were decommissioned and replaced with thyrister rectifiers
beginning at the new tank house.
 Cast and rolled Sb-Pb Anodes; A campaign to replace all the Ca-Sn-Pb anodes with the
more energy effective and better performing rolled Sb-Pb anodes was embarked on. This
was meant to increase current efficiencies from 45 %to greater than 90%.
 Polymer concrete cells; replacement of the lead lining concrete cell with the polymer
concrete cells. This is to eliminate electrolyte leaks, curb current leaks to the ground in
order to improve current efficiency and power utilization.

 Old tank house decommissioning; aimed at eliminating both electrolyte and current
leaks in the Tank Houses. This increases deposition capacity.
 Operator training/re-training; Plant personnel were as well as exposed to technical
training to the theory of electro-winning. This continued through another phase of
training were this theory was linked to standard operating and maintenance procedures.
Strict compliance of SOPs was also introduced and monitored daily.
 TQM and quality circles; KCM PLC implemented total Quality Management. This was
an important step in redefining quality. Quality circles were formed by those
employees who subsequent to TQM convicted them selves to partner with the
management in the cause for quality KBC.
 Process improvements; Enhancements have provided for improved cathode quality.
This has reduced processing costs incurred in the refining of off Grade cathode copper.
1.1.3 Overall Goal of the study
The overall purpose of this Thesis was:

To improve the recovery of Kabundi Copper Cathodes.
1.1.4 Distinctive goal of the thesis
To establish the rejection factors. To establish the rejection rates and to exploit
relationship between tank loading practices, rejection factors and rejection rate.
1.1.5 Range of project (scope)
The range includes the rectifying Shorts in the just loaded cells called shorts correction,
monitoring the rejections of cathodes, collection of samples such as electrolyte to be taken
to the analytical for chemical analysis, monitoring of the loaded cells for anomalies in the
electrode or any other anomaly in the cell called spot-check and monitoring the anomalies
on the loaded starting sheets.
1.2.0 Plant Description
There are two tank houses at KCM’s Nchanga integrated business unit. These are New
Tank House and Old Tank House. Of the two Tank Houses the New Tank House is bigger
because part of the old Tank House has been decommissioned, for this reason much of the
attention was given to the new tank house during the collection of information.

1.2.1 The New Tank House
It is divided into three units, called units 1, 2 and 3.Units 1 and 3 have 80 cells each while
unit 2 has 160 cells. Each of these units has 8.98m3 cells loaded with 62 copper starting
sheets and 63 anodes. The new tank house involves the following; rectifier load control,
electrolyte flow to and from the tank house and through the cells, pumps and pipes, level
control of solutions in storage tanks, addition of reagents to the electrolyte and, sampling
and titration. It is designed to treat advance from SX plant. The flow rate of electrolyte
varies between 400-800m/hr in each unit cell.
Advance comes with 40-60gpl cu while spent leaves the tank house with 34-35gpl cu.
from SX Plant, advance is pumped to new tank house in the ‘’D1’’ tank and it is pumped to
unit one. After recirculation through unit one, the over flow is collected into the dearation
tank via the manifold. From there, it is pumped to unit two via ‘’D2’’ tank. After
recirculation through unit two, the electrolyte goes again to the dearation tank from where
it is pumped to unit three which is pumped to SX plant as the final spent electrolyte. The D
tank levels should be maintained between 45-95% full. This is very important because;
(1) Poor level control affect levels at SX plant.
(2) When the level drops below 40%, there is a risk of sucking air into the pump which
could have a very adverse effect on the equipment.
(3) Overflow occurs when pumps trip during very high levels.
(4) If the tanks are kept too low, organic might be sucked and pumped to the cells which
would result in explosion or defective cathodes. The 62 copper starting sheets are loaded
into the cells as cathodes and 63 Antimony-lead as anodes. The starting sheets used as
cathodes are high purity copper (i.e. 99.99 % Cu) from Nkana Refinery. The Antimony-
Lead Anodes are from the old Tank House casting plant and the anode contain 5 -7 %
Antimony. The advance electrolyte is received in D1 tank (247m3) before its fed to the
electro wining cells using re-circulation pumps, in the cells a current of up to 36KA is
passed with a potential difference of about 2.5v between the cells. The load (current) from
the rectifier to be used is normally dependent on the copper tenors in both advance and
spent electrolytes. The current is passed from bus bars to the electrolyte via the anodes
through to the cathode and out. The figure below shows the simplified new tank house lay
out.


Walk way
20 20 20 20
U3
cells cells cells cells
Cathode off loading and inspection area
40 40 40 40
U2
Cathode off loading and inspection area

Plan not to scale
Cell = 1.3m from

20 20 20 20 bus bar to bus bar
U1 Wal
k
Walk
wa
way
Walk way y
1.2.2 The New Tank House Lay Out
1.2.3 The Tailings Leach Plant Flow Sheet
Figure 1.1 Tank house lay out

Figure 1.1 new tank house lay out
Figure 1.2 Tailings Leach Plant Flow Sheet

500-
1500m
3
/hr,
≥35gpl
Cu
NEW TANKHOUSE
SPENT ELECTROLYTE
UNIT 1 - 80 CELLS UNIT 2 - 160 CELLS CELLS COPPER FOR Deareation
EXPORT
SPENT ELECTROLYTE SOLVENT
UNIT 3 - 80
(≥35gpl EXTRACTION
CuADVANCE
and D1
Deareation
D2
D3
ADVANCE
ELECTROLYTE
90-250m 3
/hr)
62/63 Cathodes/Anodes/Cell 62/63 Cathodes/Anodes/Cell 62/63 Cathodes/Anodes/Cell Tank
Tank
Figure
(1PLANT 1.4 showing
(500 -1500m TANK
3
/hr.
cthodes hanging on a
40 – 60gpl Cu
1.3.0 Process operation
SPENT TANK
90-250m3/hr 90-250m3/hr 90 -250m3/hr
OTH PROCESS SUMP
UNIT 2 - 144 CELLS UNIT 3 - 144 CELLS

40/41 Cathodes/Anodes/Cell 40/41 Cathodes/Anodes/Cell
OLD TANKHOUSE
UNIT 1 - 144 CELLS
40/41 Cathodes/Anodes/Cell
Figure 1.3 new tank house and old tank house flow sheet

Electro-winning is used to produce the copper cathodes using positive and negative
charges to win copper from solution form. The inputs to this process are, the copper
solution called the advance electrolyte, the positive electrode called the anode, the negative
electrode called the cathode and electric current. The other inputs are the reagent which
helps in the overall deposition of the copper. During electro-winning the anodes might
produce an impurity to the copper cathode as they are made of lead and antimony. Some
times the electrode might not be well loaded into the cell and this will cause the
disturbances to the deposition and produce substandard cathode which are rejected from
the export copper.
1.3.1 Rectifier and load control
Each unit has a rectifier substation. Each substation has a transformer and a rectifier
section. The rectifier section has different combination of rectifier units. Unit 1 has one
rectifier unit, unit 2 has two and unit 3 has two. The control panel for all the three rectifiers
serving the Tank house are grouped together in the tank house control room. Hourly
readings of the voltages and amperage are taken and are entered into the log sheet. The
maximum amperage is 36 000 amperes (36 kA).The rectifier station has two parts; a
regulated transformer and a rectifier. The transformer receives an 11 KV AC supply and
out put between200 to 400 v. The out put is fed to the rectifier to change the current from
alternating to direct current.
1.3.2 Advance electrolyte flow
A mixture of stainless steel and HDPE pipes take advance solution from solvent extraction
to the tank house with the copper concentration of about 40 to 60 g/l as permissible limits.
The final spent solution is pumped back to the solvent extraction plant with copper
concentration of 35 g/l. The actual temperature of electrolyte is 35⁰C.The feed flow rates
are unit 1, between 500 to 1500m3/hr. Unit 2, between 800 to 2400m 3/hr. Unit 3 between
500 to 1500m3/hr. On each of the units there are pumps that circulate the electrolyte
between the unit cells and the storage tanks (“D tanks”).from the dearation tank the
electrolyte is pumped to the next unit. It is the responsibility of the circulation operator to
check the adequate flow rates are maintained in the cells. This is done by checking the
colour of the solution and if it is overflowing into the overflow pipe. This is very important
as it is going to affect the quality of cathodes. Not carrying these checks may lead to the

cell becoming stripped. This results in the loose and less consolidated copper deposition.
In an extreme case copper powder may be produced. Depositing copper at very low copper
tenor will cause evolution of hydrogen gas in the cell. The gas might cause and mislabel
mixture and easily be ignited into an explosion
1.3.3 Advance solution Storage tanks level control
There are three tanks, one tank per unit the capacity for each tank is 247m3.These tanks
are known as D 1, D 2, D 3, for unit 1,2 and 3 respectively. The advance solution comes
from solvent extraction plant enters D 1 first. After circulating through unit one, the
solution is pumped by transfer pumps to unit 2 through D 2 tank and then to unit 3 through
D 3 tank. From dearation tank in unit 3 the solution is pumped back to solvent extraction
as spent electrolyte. The D tank levels are to be maintained between 40 to 90 % at all
times. The frequency of reading the D tank levels is once per hour .the levels are kept
within these limits for many reasons:
 Poor level control will affect the tank levels in solvent extraction section, i.e. they will
be full.
 If the levels drop below 40 % there is risk of sucking air into the pumps and this will
damage equipment.
 If transfer pumps trips the levels of the storage tank of that level will rise considerably.
 If tanks are kept too low organic will be pumped into the cells resulting in fires and
contamination of cathodes.
1.3.4 Tank loading
This is the process of loading the starting sheets into the cells, pulling of deposited copper
from the cells. It includes the following:
 Pulling of cathodes from cells.
 Primary inspection of cathodes.
 Final inspection of starting sheets before loading into the cells.
 Inspection of the electrodes after loading into the cells to ensure that current is flowing
through them.
Tank loading is one of the most critical activities at the tank house operations. The cathode
pulled on any particular day represents that day’s production. The sheet loaded represents
production for the next cycle. How this loading is done and how the cells are prepared
directly affects the tonnage and the quality of copper cathodes to be pulled next time.
Therefore tank loading is very important operation of the tank house and it needs great
attention. The loading of the starting sheets is done by the over head crane. When the crane
has off loaded its crop of cathode it goes to a rack and picks up a lift of starting sheets. The

starting sheets to be loaded must be dipped in water which is contained in dip tanks. This
is so because organic floating on top of the electrolyte might stick to the sheets if they are
not dipped in water. This might affect the quality of cathodes. Each of the three units has
two dip tanks, one in each bay located to the inspection area.
1.3.5 Cathode production
Anode preparation and inspection
The anodes are prepared within the vicinity of the old tank house at the plant called lead
casting plant. The anode used is the cast antimony-lead (Pb–Sb).These is about 6 %
antimony and the rest of the composition is lead. The other type of anode used is the rolled
lead-calcium-tin alloy. These are 0.08 % calcium, 1 % tin and the rest of the composition
is lead. The anodes are sand blasted. The anodes are prepared with the plastic insulation
fitted on them. This is done to provide insulation against the cathodes once loaded into the
cells. The anodes are inspected at the lead casting plant in the primary inspection. Anodes
with defects are rejected and are taken back for re-casting. The secondary inspection of the
anodes is at the tank house anodes with minor anomalies are rectified before they are
loaded into the cells for electro-winning process.
1.3.6 The starting sheet preparation
The chemical composition of the starting sheets should be within the chemical
specification .The starting sheets are from Nkana refinery and are assembled within the
premises of the tank house by the machine called wennmec starting sheet preparation
machine. While the team leader of the tank loading crew is doing the pre-shift checks, the
operator of the cathode inspection crew must check all the starting sheets in stock. The
major screening factor of starting sheet is done at the assembling machine by the operator
before the starting sheets racks are transported to the pulling bays or storage areas. The
inspection is done again before tank loading for two reasons. The first reason is that, some
of the starting sheets are damaged during transportation. For example, loops may fail
sheets may get burnt etc. The other reason is, to screen any substandard sheets.
1.3.7 The starting sheet dimensions

The starting sheets are square in shape with dimensions 95 ± 1 cm by 95 ± 1cm and 1mm
in thickness.
The starting sheets chemical composition is shown in the table below.
Table 1.1 Starter sheet compositions
element Co Ag Te Se As Sb Cr Bi Cd S
PPM < 0.1 10.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1
element Mn Si P Al Ni Fe Pb Sn Zn % Cu
PPM 0.7 1.8 0.4 0.7 0.6 1.5 < 0.1 < 0.1 < 0.1 99.998
1.3.8 Starting sheet inspection
The operator of the cathode inspection crew checks all the starting sheets in stock. The
main screening factors of starting sheets is done at the starting sheet assembling machine
called Weinberg machine. The operator at starting sheet preparation inspects the sheets
before transporting them to the pulling bays or storage areas. The starting sheets which are
not conforming to standards are removed from the racks their hanger bars are returned to
the assembling machine for re-assembling. The table below shows the screening factors
for starting sheets.
Table 1.2 Starting sheets screening factors
No. Defect Description
 1 Nodular Nodules on the surface and around the edges of the sheet.
 2 Torn edges Starting sheet with Edges which are torn,
 3 Holed Sheet with one hole or more any where on its surface area.
 4 Bent Sheet Sheet which has dents or is bent at the corners.
 5 Thick or thin No thick or thin
 6 Brittle No brittle sheets
1.3.9 Loading of starting sheets into cells

The loading of the starter sheets is done side by side with the Pulling copper cathode. The
loading of sheets is very important. Much attention is paid during the loading of starting
sheets. The starting sheets form the “seed” for the next crop of cathodes, care is taken
during loading. The crane is used to lift the starting sheets to be loaded into the cells.
When the crane has off loaded its crop of cathode it goes to a rack and picks up a lift of
starting sheets. The starting sheets to be loaded must be dipped in water which is contained
in dip tanks. This is so because organic floating on top of the electrolyte might stick to the
sheets if they are not dipped in water. This might affect the quality of cathodes. Each of the
three units has two dip tanks, one in each bay located to the inspection area.
1.3.10 Cathode pulling
After about 4 to 10 days the fully deposited cathode of about 40 to70 Kg are pulled from
the cells by using over head cranes. Before each lift is made the, the Tank loading
operators should place plastic caps on the “shoulders “of the anodes adjacent to the
cathode being pulled. The plastic caps were designed to prevent the lead anodes from
scraping off the cathode. The scrapping causes lead streaks on the cathode which can to
cathodes being rejected on lead account. The cathode bailer is attached to the hoist of the
crane. The cathode bailer has 21 hooks that are used for hanging the cathode hanger bar.
The crane crops twenty cathodes at a time. Each crop of cathode is called a lift. The
cathodes are dipped in water which was originally boiling at 100 0 c. This is done in order
to remove un- melted sulphur and organic at the surface of the cathodes. There three QIT
operators to do the pulling using one crane each. Both the loading and pulling are done by
one crane in each bay.

Figure 1.4 showing the plastic caps on "shoulders" of cathodes to be pulled
1.3.11 Cathode washing and Inspection
The crane will off load the cathode at the primary cathode inspection area. This area is
located in all crane bays between units. There is an inspection crew of four. The cathodes
are washed by a high pressure of air- cold water spray to clean them. The crane lowers its
lift to half a metre above the floor. While the cathodes are in this position the attendant
washes the cathodes with a “Y” shaped water gun that serves to combine the high pressure
air and water to create necessary pressure for washing. The spray is first targeted at the
loops to wash away the copper sulphate and any organic, the pray then further washes the
blade of the cathode. The secondary inspection is done at the guillotine machine The
tertiary is done while the cathodes are stacked in bundles in the north end of the loading
bay. Immediately after the spray washing, the cathodes are inspected and graded as either
first grade export copper K91 or K97. The basis for grading is the screening factors for
cathode shown in the table below.

Figure 1.5 showing the cathode copper hanging on the crane bailer during washing and
inspection
1.3.12 Cathode handling and despatch
The transportation of cathodes is done by the forklifts. The washing is within the premises
of the tank house where the cathodes thoroughly re-washed to remove any residual copper
sulphate solution and crystals. The copper bundles are made and they are taken for
weighing
Cathode guillotine
All the cathodes from the tank house are already graded. The potential export that has
contamination on the loops goes for guillotining at the guillotining machine. Rejected
cathodes are put aside while potential ones are guillotined. The standard KBC cathode K
91 only the loops are cut off. The K 97 to be cathodes are cut from the top and bottom to
remove contamination or physical defects.
Bailing
At the bailing the cathodes are inspected for cooper to be exported with loops. The loops
are folded such that they don’t protrude. The bails are loaded in two types of loading; local
loading go to KCM Nkana smelter and export copper loading destined to sea ports by
North rail and road transport

Table 1.3 showing copper cathodes screening factors
1 No organic contamination
2 No visible lead contamination, lead streaks and lead flakes
3 No nodular cathodes both on surface and edges.
4 No Direct shorts
5 No bad edges; very thin or thick edges.
6 No semi stripped or porous cathodes.
7 No stripped cathodes.
8 No badly pitted bottom edges
9 No torn edges.
10 No missing insulation strips.
11 No sludge contamination.
12 No adequate deposition on the loops.
13 No bad deposition
Screening factors for K 97 cathodes
Same as K91 but with top and bottom with the following.
1 Contamination with organic.
2 Contamination with lead anode flakes.
3 Badly pitted bottom edges.
4 Contamination with sludge.
5 Short looped cathode.

CHAPTER TWO LITERATURE

SURVEY

2.0 Literature survey

2.1 Electro winning
Electro-winning (EW) is the process of extracting a metal in aqueous form by using

electrolysis. The electro-wining process is the final stage in the cooper production. The
EW process follows the hydrometallurgy extraction of copper from the ores, then
purification and concentration by the solvent extraction (SX) process. The aim of the
electro-wining is to recover copper in form of high quality copper cathodes from rich
electrolyte. The spent electrolyte is returned to the SX at the required acid and copper
tenor. An EW tank house should produce high quality cathodes, with lowest operating and
maintenance costs. For this reason emphasis is given to achieve the objectives below.
 High quality of cathodes
 Minimal labour and energy requirements
 High reliability of operations
 Good working conditions in compliance with existing environmental

regulations.
The major process in puts into an electro- winning cell are the insoluble lead
anodes(positive electrode) and the copper cathode starting sheets (negative electrode).The
two electrodes are at an electrical potential. The two electrodes are immersed in acidified
copper sulphate solution in the cells. During the process of electro-winning, the following
reactions happen at the anode and cathode.
Anode reaction: An insoluble anode is used with oxygen evolution being the major
reaction.
− +
2 H 2 O−4 e →O2 +4 H
………………………………………………………………………............. (1.1)
Cathode reaction: This reaction involves the deposition of the metal from the soluble
electro active species.
Cu2+ +2 e− → Cu 0 …………………………………………………………….. (2.2)

The overall cell reaction will be as shown below:
1
CuSO 4 +2 e− + H 2 o→ Cu 0 + H 2 SO4 + O2
2 …………………….. (2.3)
What happens during the electrochemical reaction of electro-winning is the heterogeneous

chemical processes that involves the transfer of charge to or from an electrode. The
transfer may be at the cathode where stable species is reduced by transfer of an electron
from an electrode. At the anode, the stable is oxidized by the removal of electrons to the
electrode. The amount of reduction at the cathode and oxidation at the anode must be
equal. For electrolysis to occur
 Electrons must pass from the anode to the cathode through an external electrical circuit,
interconnecting the two electrodes.
 There must be a mechanism for charge transport between the electrodes within the cells.
2.2 The cathode quality
The development in the solvent extraction operation will have a marked impact on the EW
operations. This involves using the improved extraction reagents, use of the column
floatation cells and sand filters. It has become easy to remove the entrained organic from
rich electrolyte. The improvement of electro winning operation by optimization of the cell
condition for producing good cathodes enhanced by:
 The higher selectivity for copper over iron by the SX
 Lower sensitivity to temperature and acidity of the aqueous feed solutions.
To enhance cathode quality, attention should be paid to the following design features:
 Removal of entrained organic and suspended solids from the advance electrolyte.
 Reducing the corrosion rates of the lead alloy anodes
 Optimizing electro winning cell conditions.[1]
2.3 Removal of organic and suspended solids
There always some dissolved and mechanically entrained organic including solids in
suspension in advance electrolyte from solvent extraction the organic and suspended solids

normally silica enters the EW cells if preventive measures are not taken. The scouring
action of the oxygen released at the anodes, makes organic accumulates at the surface of
electrolyte. The organic will make the starting sheets during loading to be coated with an
organic film. This results in an even distribution of electric current and production of poor
quality cathodes. The cathodes themselves being coated with organic will be a basis for
rejection. Residual organic also makes a fire hazard. Organic will cause deposition of
spongy copper at the top of cathode. The spongy copper will entrain a lot of electrolyte
and impurities. Organic also reduces the effectiveness of guar gums as smoothening
agents. Less organic in the electrolyte ensures better performance of acid demisting
reagents. In the presence of organic, balls used to retain mist stick together and to stick to
cathodes. There are several systems that are used to prevent organic enter the electro-
winning. Some of these systems are listed below:
 The after settlers – which have increased residence time and allows for gravity
separation.
 The dual media pressure filters – the most widely used. These use garnet and anthracite
or activated carbon. These are very effective in removing organic from solutions.
 The use of floatation devices – this is the column vertical cell. The advance electrolyte
and air bubbles are introduced counter- currently. These do not require mechanical
agitation. They are best applied in granular with granular media filters.
 The advance scavenger electro-winning cells – these receive the advance electrolyte to
remove the remaining organic in the solution. They are equipped with an organic decant
system at the over flow.[1]
2.4 Anode corrosion
Lead-antimony anodes are commonly used in copper electro-winning. These types of
anodes have relatively low corrosion rates. The anode corrosion rate should be kept low.
The corrosion products may be occluded in the cathode deposit and cause lead
contamination to the cathodes. The tank house must have the design that allows for an
uninterrupted electrolysis. This is to reduce corrosion rate of the anode. Full grown
cathodes must be pulled in one-third of the cell loads. The pulled cathodes are replaced by

the starting sheets before another one-third load is pulled. The use of the shorting frame to
interrupt the current is important when cleaning or repairing the cell. Cobalt sulfate
(CoSO4.7H2O) should be added to the electrolyte to reduce anode corrosion. The cobalt
levels should be within 60 to 120 ppm. The cobalt decreases the anodic over potential and
therefore reduces power consumption. The sulfuric acid should be low ton reduce
corrosion but should be normal for effective copper stripping in the SX.
The anodes are lead alloy sheets which in the sulfate medium form the lead oxide coating.
The metal addition to the lead (e.g. silver) is to catalyze oxygen evolution and therefore
reduce over potential of the anode. The anode should always be larger than the cathode to
prevent deposition edge defect and hence obtain an even deposition.
2.5 Properties of lead- Ca-tin alloy anodes.
The chemical composition of the lead-calcium-tin anodes are 0.07 % Ca and 1.35 % tin.
This chemical composition provides maximum mechanical properties and stability. This
chemical composition resists corrosion and passivation. This type of anode has a
complete metallurgical bond at soldered joints therefore there is a low potential drop
between sheet and bus bar. The effect of calcium is that it increases the rate of anode
corrosion and mechanical properties but decreases anode potential. Tin imparts strength to
the lead alloy and reduces strength. Tin segregates it self into the sub grains forming
layers of tin rich material parallel to surface and therefore reduces corrosion. It improves
conductivity and reduces anode polarization.tin prevents conduction paths through
corrosion layer and prevents formation of tetragonal lead oxide.
The main reaction at the anode is generates oxygen. This oxygen has some affects in
electro-winning which are;
 Evolution of oxygen as a gas at the anode surface
 Oxidation of materials in solution
 Formation of peroxides
 Corrosion of the lead anodes

2.6 Effects of oxygen evolution
a) Creation of acid mist; the control methods for these are the plastic or bead covering,
foam and mist suppressant, mechanical shield ventilation.
b) Oxygen stir up Lead oxide (PbO2) flakes from cell bottom and this leads to lead
contamination of the cathodes.
c) Oxygen is transferred to cathode and oxidation of copper cathode happens.[5]
2.7 Effects of material oxidation in solution
This causes what is called chemical short-circuiting. At the anode iron (II) ions ( Fe 2+)
will oxidize to form iron (III) ions (Fe 3+).The ferric ions(Fe3+) diffuse to the cathode
where they again are reduced to Fe2+ ions. This means that one faraday has passed
through the solution without any metal deposition. The oxidation and reduction of iron
goes as a cycle and it reduces current efficiency. The two equations below show how
oxidation and reduction of divalent and trivalent ion happens at the anode and cathode
respectively.
Fe2 + →Fe 3+ +e− …………………………………… ((2.4) anode reaction
3+ − 2+
Fe + e → Fe …………………………………….. (2.5) athode reaction.
The ferric ions corrode the loops of the cathodes at the electrolyte level by the reaction;
Fe 3+ +Cu → Fe 2+ + Cu 2+ ……………………………. (2.6)
 Oxidation of Manganese; manganese dioxide (MnO2) reacts with corrosion products

(PbO2). Light PbO2-MnO2 layer may shed and can cause severe cathode
contamination. The effects of formation of peroxides and permanganate damage
the pipes, tank liners and cathode edge.[2][4][7]
2.8 Electro-winning cell condition

 It is very important to pay much attention to the design features of the cell for the
production of high quality cathodes. Conditions in all cells should be identical. To
produce dense and nodule free cathodes, copper tenor should be 34 grams per litre (gpl)
as minimum. The sulfuric acid tenor of should be 175gpl and electrolyte temperature of
44 ⁰C as minimum. The temperature can be increased without the current being lowered
provided iron has been removed from the electrolyte.
 Short-circuiting between cathodes and anodes can be reduced by using straightened

copper starting sheets and vertical hanging anodes.
 With electrodes free from short circuits less electrolyte heating will take place.
 The inter-electrode gaps are supposed to be as small as possible; this helps to reduce
the oxygen over potential at the anode.
2.8.1 Electrolyte circulation
The electrolyte flow rate and circulation should be given attention as they are very
important to the physical quality of the cathodes. The cells whose manifold pipes are
broken should have manifold pipes repaired. The electrolyte should be flowing slowly
through the cells; there will be no attempt to introduce convection since this can lead to
contamination of the cathode deposit by solids which form in the cell. Air sparging on the
cathode surface (i.e. passing air through the series of nozzles below the cathode) can
increase the current density by a factor of 5 to 10.[3]
At Nchanga (KCM) the electrolyte is circulated at the rate of 500 to 1500m 3/hr (12m3/hr
per cell).It is the responsibility of the circulation operator to check the flow rates in all the
cells. This is done by checking the colour of the solution and checking if the solution is
flowing into the overflow pipe. The cells are fed from the bottom using a perforated
manifold pipe that goes round the cell. The circulation is checked three times per shift.
Not carrying out these checks may lead to the cell becoming stripped. A stripped cell may
lead to a loose and less consolidated deposit. The other consequence of depositing at very
low tenor is the evolution of hydrogen gas. In the new tank house there are flow meters
embedded at the valves which measure the flow rate. At the old tank house the flow rate

can be measured by using the bucket and the stop watch. If the time that is taken to fill the
bucket is known, the flow rate can be calculated by using the formula:
V
Q=
t ; Where Q is the flow rate,
V is the volume of electrolyte in the bucket and (t) is the time taken to fill the bucket.
Care must be taken so that the electrolyte entering the cell through small holes in the
manifold does not scour the cathode where the electrolyte flow impinges
2.8.2 Temperature of the electrolyte
Temperature above ambient is used for its beneficial effects on kinetics of all steps in the
electrode processes. The diffusion coefficient, the exchange current density and the rates
of chemical reaction are increased. The temperature at KCM Nchanga New Tank House is
maintained between 35 ⁰C to 40 ⁰C. The temperature should be kept around this scope.
Keeping the temperature in this range has the following advantages; It increases the
diffusion and enhances mass transport. The temperature decreases the viscosity of the
electrolyte and this enhances the flow which will be evenly distributed. The electrolyte
conductivity increases help to decrease power consumption. The anode passivation is
reduced. Anode passivation reduces current density. Very high temperature may cause
evaporation of the electrolyte and increases acid mist. The acid mist disturbs the working
environment. If the temperature falls below 35 ⁰C the viscosity starts to increase. High
viscosity electrolyte makes the particulate matter flaking off anodes to be carried instead
of settling to the bottom of the cell as sludge.[3]
2.8.3 Reagent addition
Reagents are added to the electrolyte to improve the quality of copper produced. The
reagent affects the physical properties of the cathodes in a positive way. The reagent will
enhance the smoothness and hardness of the deposited copper.
At (KCM) Nchanga New tank house it is the responsibility of the circulating crew to add
the correct amount and to record to record the log sheets. The amount of reagent pr shift
is decided by the senior metallurgist Tank house or his nominee. The addition is
communicated to the operator through the reagent addition instruction book. The reagents

added to the solution are FC 1100 depressant, cobalt (CO 2+) in electrolyte, Guar, sodium
chloride and iron. The reagents are added to the electrolyte for the reasons outlined
below:
 Cobalt – to minimize anode flaking thus lessening lead contamination to the cathodes.
 Guar (Flocculants) – for smooth deposition of copper and to a lesser extent for
controlling the effect of suspended solids on cathodes by settling them to the bottom of
the cell.
 Sodium Chloride (NaCl) – salt is added to the electrolyte for smooth deposition of
copper and better lustre during deposition. Some chloride usually 20 ± 5 ppm is
beneficial in terms of cathode quality. Excess chloride will lead to chlorine gas formation
which pits cathodes and corrodes tank house building. Too little chloride can result in
copper crystal formation on the surface of the cathode resulting in a rough cathode.
Chloride can only enter the tank house in a number of ways. Entrainment of PLS in the
loaded organic or by the crud transfer from extraction to strip if the PLS has the chloride.
Accidental contamination can occur from water addition and acid addition to the tank
house. Any new source of make up water to electrolyte should be analysed for chloride
ion and nitrate ion.
 FC 1100 Depressant – for depressing the acid mists from the cells.
Iron – this is to prevent manganese oxidation. This because the high oxidation states of
manganese can affect the anode life and cathode quality. If manganese is oxidized to
MnO4 this powerful oxidizing agent will rapidly degrade the circuit organic.
Chloride ion above 30 to 40 ppm can be a major problem depending on the electromotive
force of the electrolyte. Chloride is very difficult to remove from the electrolyte. Every
effort should be made to minimize chloride transfer from extraction circuit to strip. The
main methods of preventing this transfer are:
 Use of appropriately phase continuity in E 1 usually aqueous continuous.
 Maintenance of adequate organic depth in E 1 settler.
 Picket fences and coalescers in E 1 settler.
 De-entrainment and coalescing devices in the loaded organic surge tank.
 Use of non modified extractants.

 Control of crud at proper level in E 1.
If all the above methods fail it may be necessary to install a scrub stage on the loaded
organic. The scrub can be very efficient. According to Cognis one plant which uses non
Modified oxide extractant blend has 55 g/l chloride in the PLS. This plant manages to
maintain the chloride level below 30 to 40 ppm by using a scrub stage on the loaded
organic [9].
2.8.4 The reagent addition parameters for the Nchanga Tank houses
NO DESCRIPTION PERMISSIBLE LIMITS ACTUAL
1 Cobalt (Co 2+ ) 100 to 150 ppm 120 ppm
2 Guar (Flocculants) 0.5 kg/tone Cu deposited 0.5 kg/tone Cu deposited
3 Sodium Chloride 20 to 35 ppm 29 ppm
4 Iron 700 to 1000 ppm 650 ppm
5 FC 1100 Depressant 5 L/ Day 5 L/ Day
Table 2.1 Reagent addition parameters
2.9 The cause effects leading to low KBC recovery are explained below
2.9.1 The Tank loading practice and associated anomalies
Bad shape
Below are the tank loading practices that will lead to bad shape once they are not put in
order:

 Capping boards not properly aligned or won out capping boards
 Bent or sagging anodes.
 Bent hanger bars
 Bent or missing knife edge bus bar
 Non cleaning of hanger bars.
 Un washed cell contacts
 Insufficient PVC balls in the cells
 Dirty loops as a result of not washing
 Un aligned cathodes
All the above anomalies will lead to open contacts either between the anode or the
cathode.
Direct Shorts
Below is the tank loading practices that will lead to direct shorts if they are not rectified.
 Hitting of anode by the bailer of the crane while pulling.
 Bent anodes.
 Bent starter sheets while loading.
 Improper handling of starter sheets, Careless Tank loading.
 Protruding insulator screw from anodes.
Lead flakes
Below is the tank loading practices that will lead to lead flake if they are not rectified.
 Extended power outages.

 Load fluctuations.
 Anode scale warps.
 Over oxidized anode.
 Non replacing of the aged anodes.
 Non cleaning of anode while desludging.
 Uneven current distribution.
 Localized high current density.
 Over due cells for desludging
Lead Streaks
 Not using jackets during pulling.
 Not brushing the cathodes after pulling.
 Bent cathodes.
 Careless movement of crane during pulling.
 Improper inserting of jackets during pulling.
 Missing anode insulator strips.
 Poor sample handling.
Nodular Cathodes
 No facility to judge flow through each cell.
 Variable flow across each cell in a unit.
 Improper addition of reagent.

 Non alignment of cathodes causes high variation of current in the cells.
 No screen to restrict the PVC balls getting into the circulation line. This leads to
chocked feed lines which results in under feeding cells and in under feeding cells and
finally nodular cathodes.
 No flushing facility; all the debris reporting to the cell feed valve or ring in there.
Desludged
Prolonged use of shorting frame to the neighboring cells of the desludged cell This results
into the cathodes of cells whose the shorting frame have been applied on to be under
weights.[6]
2.9.2 Capping boards or insulator blocks
The capping boards positively locate the anode and cathode and maintain this spacing for
improved current efficiency. At Konkola Copper Mine, Nchanga Integrated Unit, the
capping boards used are the polymer composite material. Polymer concrete cappings used
at new tank house is better than the rubber capping boards used at the old tank house.
Polymer concrete capping board is rigid and maintains the shape and electrode spacing.
However the polymer concrete material is subject to breaking when they are hit by the
crane bailer. This is mostly the cause of broken or missing slots of the capping boards.
2.9.3 Power loss:
Intermittent power losses can always be expected at some mining operations. Short power
loss period is of no concern to the solvent extraction circuit. However, extended power
loss in the electro-winning plant can be a problem. When power is lost in the electro-
winning cells, the cells with their anodes and cathodes become a "battery" with current
reversal. When this happens copper will plate onto the anodes until plant power is restored,
and then the copper plated onto the anodes will re-dissolve into solution and subsequently
be re-deposited on the starter sheets or the cathodes. This battery action sharply reduces

the life of the anodes, and/or results in a lot of Pb particles flaking on to the cathodes. To
avoid this problem during extended power losses, either all of the cathodes should be
pulled from the cells, or the plants should be designed with an auxiliary DC (Direct
Current) generator with a "trickle" current to oppose and neutralize the battery effect in the
cells. Removal of cathodes should be done if the power in the tank house cells is expected
to be off for more than one hour. This removal of cathodes from the cells is the
responsibility of the tank loading crew. [8]
2.9.4 Other electrowinning operating parameters include:
1) Anode spacing (the distance between the centers of the anodes)
2) is usually 10.2 centimeters.
3) Often copper electrolytes are heated to help produce better quality cathodes. An ideal
electrolyte temperature is about 115 degrees F (46 degrees C).
4) The flow rate in each electrowinning cell should be controlled to obtain sufficient
circulation to avoid copper depletion at the aqueous - cathode interface during the
electrowinning process. Several electrowinning plants use a standard minimum cell flow
rate of about 0.12 m3 /hour/ m2 of plating area. It might be necessary to install a recycle
pump to achieve this internal flow rate if the flow of the SX electrolyte is too low.
5) Current density in the electrowinning process varies widely at different copper plants
around the world. However, the average is generally within the range of 190 to 240
amperes/m2. [8]

CHAPTER THREE
EXPERIMENTAL PROCEDURE

3.0 Experimental procedure
The experimental procedure contains the data that was actually collected during the period
of study of the problem at KCM as well as the data collected from the past records. These
will be termed as primary and secondary data. The data which was collected ranges from
the rejections and rejection factors, tank loading practice such as shorts correction and
spot-check which is a tank loading practice. Spot-check involves checking for anomalies
in the cells which have been loaded after the tank loading crew has done the shorts
corrections. This is done in order to confirm whether the tank loading crew are performing
their shorts correction effectively. The figures are reflected in the analysis of the graphs are
from July 2009 to March 2010 on the part of the rejections. Part of the data was from the
record sources of the rejections. A comparison had to be made with the actual collected
data and the final analysis was compiled.
3.1 Primary data
This is the data that was collected directly from the plant during the operations of the tank
house.
3.2 Secondary data
This is the data that was collected from the written records of the operations and the
products
3.3 Cathode rejection recording
3.3.1 Equipment
 A pen
 Book for recording
Method
When ever there was pulling at the tank House. The information about pulling was gotten
from the supervisor tank loading crew or any other superiors of the tank loading crew. The
information about pulling would also be obtained from the pulling schedule. Extra care
was taken as to notice the days of pulling as pulling was not done every day depending on
the time and the growth of the cathodes.

The recording involved reporting on the site of pulling (Tank house) particularly at the
cathode off-loading area. This area is located in all crane sections in all crane bays. Before
the confirmation of the rejection was made, comparison was made with the samples of the
standard rejection which were displayed. If the basis for rejection was doubted, the tank
loading crew who were the specialists in that area would help. If the rejection were
miscounted the log sheet in which the records were entered by the crew would be resorted
to.
3.3.2 Observations
This was done during the washing of the cathodes and during the cathode unloading of the
cathodes. During this observation, the cathodes were inspected and those which were not
conforming to the standards (i.e. those which matched with rejection factors) were put
aside and the records were entered into the book as primary data.
3.4 Shorts correction
3.4.1 Equipment
 Pen
 Book
 Copper hanger bar
The shorts corrections were done on the cells that were being pulled and then loaded
afterwards. This was done physically using the copper hanger bar. The copper hanger bar
is used to contact the anode and the cathode. If the sparks are produced, it means there is
no short circuit or open circuit between the anode and the cathode. In a case where there
was a short circuit or the open circuits there were no sparks produced once the hanger bar
is contacted at the anode and cathode at once. The inability to produce the sparks by the
electrodes by the hanger bar gave the crew that, there could be a direct short or an open
circuit. A direct short is where the cathode is in contact with the anode. An open circuit can
be produced by either an anode or the cathode not resting on the knife edge of the bus bar.
If such a situation was encountered the record of the number of anodes and cathodes
having such anomalies were recorded in every cell that is inspected for shorts. Amongst
the anomalies inspected during the tank loading practice of the shorts corrections are as
follows:

 Bulging loops
 Direct shorts
 Sagging cathodes
 Missing or broken capping boards
 Anode off knife edge
 Cathode off knife edge
 Twisted hanger bar
 PVC balls gaps
 Un aligned cathodes.
All these were recorded as primary data once spotted.
The cells to be inspected on the days chosen were grouped in batches of ten cells per
inspection.
Result
The observed anomalies were recorded in the book for analysis.
3.5 Spot-check
3.5.1 Equipment
 Pen
 Book
Method
Spot-check is a tank loading practice which involves inspection of the loaded cells for any
abnormalities. This was done by going round the plant inspecting the already loaded cells
and recording their anomalies.
Result
The observed anomalies were recorded in the book for analysis.

CHAPTER FOUR RESULTS AND

DISCUSSION
4.0 Results and discussions

4.1 Primary and secondary data analysis
Table 4.1 Analysis for July 2009- March 2010

Month Average Average Average
Bad shape Direct shorts lead flakes
July 2009 16.6 14.2 -
August 12.3 16.4 3
September 15.6 7.6 2
October 22.9 10.1 -
November 17.8 5.7 11.5
December 19.5 3.2 -
January 21.3 5.6 4.5
February 17.7 4.6 -
March 19.8 5.9 3

2010
Total 18.17 14.34 2.67
% Total 48.36 38.17 7.1

The table above shows the average rejections from the month of July 2009 to March 2010.
These are the first three rejection factors which are the Bad shape, direct shorts and Lead
flakes. This was the period when rejection was less than the target four percent (4%) The
values for the averages have their source in the appendix.

Object 10
Figure 4.1 Rejection less than target 4%
The graph above shows the variation of the rejection with time. During the period of July,
2009 to March, 2010, the rejections were less than the target which was four percent
(4%).This means that the recovery was good. From the graph it can be seen that of the
three rejection factors bad shape had the highest rate of rejection. This is supported by the
total from the table which is 48.36%.The second highest of the rejection factors is the
direct shorts which can be seen from the graph and had 38.17% as the rate of rejection.
The lowest was the Lead flakes which had 7.1% as the rate of rejection. It is seen that the
three types of rejection factors in the graph were the major for July 2009 to march 2010.

Month Average Average Average Average Average Average
Lead streak Torn edges Nodular Organic Pitted Semi

bottom striped
July - - - - - -
August - - - - - -
September - - - - - -
October 2 - - - - -
November 8 - - 6.5 - -
December 4 - - - - -
January 1 - - - - -
February - - - - - -
March - - - - - -
Total 1.67 - - 0.72 - -
% Total 4.44 1.92
Table 4.2 Analysis for July 09 -March 10
This table above shows the averages of another group of rejection factors. The rejection
factors are the Lead streaks, Torn edges, Nodular, organic, pitted bottom and semi stripped.
For the same period of time when the rejection was less than the target 4 %, the total
percentages of rejection were as follows:
 Lead streaks 4.44%
 Torn edges -
 Nodular -
 Organic 1.92 %

 Pitted Bottom -
 Semi stripped -
The graph below shows the period when rejection was less than four percent (4%).
Object 12
Figure 4.2 Rejection less than target 4 %
The graph above depicts information in the previous table. Of the six rejection factors the
highest was Lead streaks with 4.44%. This is followed by the Organic contamination as
the rejection factor with 1.92% as shown in the previous table. By studying the table for
the cathode analysis for the stated period of time it is seen that the rejection factor above
were minor rejections. Since the rejection was less than the target this was the good
recovery period.

Month Average Average Average
Bad shape Direct shorts lead flakes
4.2
April 07 95.4 76.5 31.7
May 104 14.4 -
June 80 13 4
July 72.2 35 -
August 34.5 10.5 -
September 52 2 -
October 25.7 23 -
November 07 44.7 7.3 2
Total 63.56 22.71 4.71
%Total 24.37 8.71 1.81
Cathode rejections analysis during the period when rejection was more than four
percent (4%)
Table 4.3 Analysis for April 2007 -Nov 2007

The table above shows the cathode rejection analysis when the rejection was more than
limit which is 4 %.The period was from April, 2007 to November, 2007.If the rejection is
more than the target it means it is high such that it might affect the recovery. With the first
three rejection factors, which are Bad shape, direct shorts and lead flakes. The highest was
the bad shape with a rate of ejection of 24.37% then Direct shorts with 8.71 % and lastly
Lead flakes with1.81 %.

Object 14
Figure 4.3 Rejection more than target 4%
The table below shows the results of the cathode rejection analysis for April, 2007 to
November, 2010.During this period the rejection were more than the target for this group
of rejection factors, the highest rejection was desludged. Desluged had a rejection rate of
46.88% followed by lead flakes with the rate of 8.71%.The Lead streaks took the Third
place with the rate of 6.66 % and then Organic contamination with5.81%and finally the
semi stripped with 5.75 %.

Table 4.4 Cathode analysis for April 2007 –Nov20 07
Month Average Average Average Lead

streaks
Desludged Organic Semi
striped
April - 66.3 80 -
May - 13.5 - -
June 220 - 40 10
July 252 - - 5
August 240 4 - 120
September - - - 4
October 266 35.5 - -
November 465.25 2 - -
Total 122.25 15.16 15 17.37
% Total 46.88 5.81 5.75 6.66

Graph for the period during which rejection was more than the target 4%
Object 16
Figure 4.4 Rejections more than the target 4%
The graph above shows the rate at which the copper cathodes were being rejected by the
rejection factors shown in the legend key of the graph. As depicted by the graph the
highest was the Desludged, followed by the lead flakes then organic and finally the semi
stripped. This information can be confirmed from table before the graph.

4.4 Shorts correction analysis
4.4.1 Tank loading practice: Shorts correction. Date; 2nd March, 2010
Table 4.5 Shorts correction Analysis

Anomaly % occurrence
Bulging loops.............1 17
Direct shorts..............2 6
Sagging cathodes.......3 1
Missing Capping
Boards......................4 -
Anode off knife 7.2
Edge.........................5
Cathode off knife 20.2
Edge............................6
Twisted anode hanger 10.6

bar................................6
PVC balls gaps.............8 32.6
Unaligned Cathodes......9 5.1
The table above shows the results of the analysis of the shorts correction that was done on
the second day of March (2nd March, 2010).The occurrences of anomalies in the cells were
expressed as the percentage. The details of this information are shown in the appendix.

Object 18
Figure 4.5 Showing Anomalies in the loaded cells
.The graph shows the shorts correction which is done in order to rectify the anomalies
which are done .the particular anomalies showing highest was the PVC balls gaps. These
are used to prevent the acid mist from rising to the environment of the tank house and
disturb the working environment of the people.

4.4.2 Tank loading practice: Shorts correction. Date; 9Th March, 2010
Table 4.6 Shorts correction analysis
Bulging loops .........1 14.3
Direct shorts..........2 7.5
Sagging cathodes.....3 7.8
Missing Capping 9.1
Boards.....................4
Anode off knife 6.2
Edge.......................5
Cathode off knife 11.4
Edge......................6
Twisted anode hanger 0.7

bar............6
PVC balls gaps........8 31.9
Unaligned Cathodes..9 11
the ninth day of March (9nd March, 2010).The occurrences of anomalies in the cells were
expressed as the percentage. The details of this information are shown in the appendix.

Object 21
Figure 4.6 Anomalies in loaded cells
Figure 4.6 showing anomalies in the loaded cells
The graph above shows the results of the analysis of the shorts correction that was done on
the ninth day of March (9nd March, 2010).The occurrences of anomalies in the cells were
expressed as the percentage. The details of this information are shown in the appendix

4.4.3 Tank loading practice: Shorts correction. Date; 16Th March, 2010
Table 4.7 Shorts correction Analysis
Sagging cathodes.....3 1.2
Missing Capping
Boards.....................4 15
Anode off knife
Edge.......................5 4.9
Cathode off knife
Edge......................6 11
Twisted anode hanger

bar............6
11.3
Unaligned Cathodes..9 1.6
the sixteenth day of March (16nd March, 2010).The occurrences of anomalies in the cells
were expressed as the percentage. The details of this information are shown in the
appendix.

Object 23











The Graph above shows the
results of the Sagging cathodes.....3 - analysis of the
shorts correction that
was done on the Missing Capping sixteenth day of
March (16nd Boards.....................4 14.1 March,
2010).The Anode off knife occurrences of
anomalies in the cells were
Edge.......................5 5.9
expressed as the percentage. The
details of this Cathode off knife information are
shown in the appendix.
Edge......................6 18.5
Twisted anode hanger

bar............6
-

4.4.4 Tank loading
practice: Shorts
correction. Date; 26Th
March, 2010 Unaligned Cathodes..9 17.3
Table 4.8 Shorts corrections analysis

the second day of March (26th March, 2010).The occurrences of anomalies in the cells
were expressed as the percentage.

Object 25
The anomalies in the loaded cells which have just been shown in all these graphs will
affect the electrical contacts. The loose loops as a result of bulged loops on the hanger bar.
The direct shorts are the contacts between the electrodes.
Spot-check
Even after the shorts corrections had been done on the cells that had just been loaded there
were still more anomalies on the old tank house. This was found out after doing the spot-
check on the old tank house. The anomalies which were found in the cells were recorded
in the sport-check tables shown in the appendix in tables 2a 2b 2c 2d and 2e.

4.5 Calculation
During the period when rejection was less than 4 %
Average Bad shape 18.17
Average Lead flakes 2.67
Average lead streak 1.67
Average organic 0.72
Total 37.57
% Calculation
18.17
1. Bad shape, 37.57 × 100 = 48.36
14.34
2. Direct Shorts, 37.57 ¿100 = 38 .17
2. 67
×100=7 .1
3. Lead Flakes, 37 .57
1.67
4. Lead Streak, 37.57 ¿100=4.44
0 .72
×100=1. 92
5. Organic, 37 .57
6. Torn Edges -
7. Nodular -
8. Pitted Bottom -
6. Semi Stripped -

During the period when rejection was more than 4 %
Calculation
1. Average desludged = 122.25
2. Average Bad shape = 63.25
3. Average Direct shorts =22.71
4. Average Lead streaks =17.37
5. Average Organic =15.16
6. Average Semi stripped=15
7. Average lead flakes = 4.71
Total = 260.76
% Calculation
122. 25
1 Desludged, 260 .76 ¿100=46 .88
63 .56
×100=24 .37
2. Bad Shape, 260 .76
22. 71
×100=8 .71
3. Direct Shorts, 260 .76
17 .37
×100=6 .66
4. Lead streak, 260 .76
15 .16
×100=5. 81
5. Organic, 260 .76
15
×100=5. 75
6. Semi Stripped, 260 .76
4 .71
×100=1. 81
7. Lead Flakes, 260 .76
4.6 Rejection rate during the period when rejection was less than the target four
percent (4%)

Table 4.9 percentage rejection rate
Rejection factor % Rejection
Bad shape 48.36
Direct Shorts 38.17
Lead Flakes 7.1
Lead Streaks 4.4
Torn Edges -
Nodular -
Organic contamination 1.92
Pitted Bottom --
Semi Stripped -
The table above shows the rate at which the cathodes were rejected during the period when
the rejection was less than the target that is from July 2009 to mar2010.Durng this period
the highest rejection was the Bad shape, followed by the Direct shorts,Lead flakes, lead
streaks, Torn edges ,Nodular and organic contamination.
4.7 Bar chart rejection rate during the period when rejection was less than the target
four percent (4%)

Rejection Rate Vs rejection factor

60
50 48.36
40 38.17
30
% Rejection
20
10 7.1
4.4
1.92
0
0 0e 0
pe rts es ks es d io n
o m pe
d
sh
a o al k re
a dg o t tt
Sh F t E ca
th
in
a o rip
d ct ad
S rn B St
Ba ire Le
a d o
ul
ar tam
ed i
D Le T
od c on Pitt S em
N ic
g an
r
O
Rejection Factor
Figure 4.9 showing the rejection rates against rejection factors
The graph above shows the rate at which the cathodes were rejected during the period
when the rejection was less than the target that is from July, 2009 to march, 2010. During
this period the highest rejection was the Bad shape, followed by the Direct shorts, Lead
flakes, lead streaks, Torn edges, Nodular and organic contamination.

4.8 Rejection rate during the period when rejection was more than the target four
percent (4%)
Table 4.9.1 Percentage rejection rate
Rejection Factor % Rejection
Desludged 46.88
Bad shape 24.34
Direct shorts 8.71
Lead flakes 1.8
Lead Streaks 6.66
Organic
contamination 5.81
Semi Stripped 5.75
The table above shows the rate at which the cathodes were rejected during the period when
the rejection was more than the target that is from June 2007 to November12007. During
this period the highest rejection was the Desludged cathodes followed by the Bad shape,
Direct shorts, Lead flakes, lead streaks, organic contamination and finally semi stripped.


4.9 Rejection rate during the period when rejection was more than the target four
percent (4%)
Rejection rate against rejection factors

50
46.88
45
40
35
30
25 24.34
20
% Rejection
15
10 8.71
6.66 5.81 5.75
5
1.8
0
ge
d
ap
e
or
ts kes ak
s
tio
n
pe
d
d sh sh fla tre a ip
lu d ct S in str
es Ba e ad ad tam i
D
D
ir Le Le n e m
co S
ic
gan
r Rejection
O
Rejection Factor
Figure 4.9.1 showing the rejection rate against the rejection factors
The graph above shows the rate at which the cathodes were rejected during the period
when the rejection was more than the target that is from June 2007 to November12007.
During this period the highest rejection was the Desludged cathodes followed by the Bad

shape, direct shorts, Lead flakes, lead streaks, organic contamination and finally semi
stripped
4.9.1 Overall rejection
Rejection rate against Rejection factor

60
50 47.62
40
30
23.44 23.44
% Rejection
20
10 5.53 4.45 3.87 2.87

0
0 0
ap
e rts ed ak
s es ni
c
pe
d
ge
s ar
h ho dg rt e lf ak a p d dul
s lu rg tri E
d ctS es S d O is rn N
o
Ba ri e D ea d
L ea m To
D L Se
Rejection Factor
Rejection rate
Figure.4.9.2 showing overall rejection rate

CHAPTER FIVE CONCLUSIONS AND

RECOMENDATIONS

5.0 Conclusion and recommendation

5.1 Conclusion
After having carried out the study of the problem in this dissertation, it was concluded that
the rejected factors which where responsible for the rejection of cathodes were:
 Bad shape which was rejected at the rate of 47.62 percent.

 Direct shorts was rejected at the rate of 23.44 percent
 Desludged was rejected at the rate of 23.44 percent.
 Lead streak was rejected at the rate of 5.53 percent.
 Lead flakes were rejected at the rate of 4.45 percent.
 Organic contamination was rejected at the rate of 3.87percent.
 Semi stripped was rejected at the rate of 2.87 percent.
The highest rejection factor was bad shape cathodes rejected at 47.62 percent and the
lowest was semi stripped cathodes rejected at 2.87 percent.
5.2 Recommendations
After carrying out the survey that was conducted at the tank houses, the conclusions were
made. Following this the recommendation which were made was that; the shorts correction
which is the tank loading practice, is very critical to crop of cathodes to be pulled next
time. Therefore the anomalies in the loaded cells should be rectified immediately without
fail. Ensure that all the twisted anode hanger bars are straightened. Straighten all the bent
cathodes. The correct use of jackets during pulling helps to reduce lead flakes. Shift
controllers should closely supervise the tank loading crew (shorts correction and wet
flapping exercise) as it is most crucial to the production of quality cathodes. The washing
of cell contacts reduces the open contacts because of sulphate crystals. For this reason
washing of the contacts should be done using steam under pressure. On the part of the
PVC balls, they should be supplied to all the cells so that acid mists are suppressed to
enhance the working environment. Improper alignment of cathodes in case of the old tank
house will contaminate the cathode with lead.
REFERENCES

1.0 W.C. Cooper, D.J. Kemp, G.E. Lagos and K.G. Tan, Hydrometallurgy and
Electrometallurgy of copper, volume III, pergamon press. 1995. Pp 425
2.0 Terkel Rosenqvist, Principals of Extractive metallurgy, Mc Graw-Hill Book

Company, 1974. pp 466-479.
3.0 Derek Pletcher and frank c. Wash, Industrial Electrochemestry, second Addition, 1982.
PP 45-49, 219-226.
4.0 R.H Parker, Introduction to chemical metallurgy, pergamon press, Oxford, England,
1978.pp 310-317,319-348.
5.0 KCM Process Manual, Tank house projects pp 12-15
6.0 KCM Operations Manual, Tank loading practice, Nchanga electrowinning tank
house.p 1
7.0 A.K. Biswas and W.G. Davenport, Extractive Metallurgy, third edition, Pergamon
press, London. 1974. pp401-411
8.0 Solvent Extraction Plant Operating Manual for small and medium size, Leach-solvent
Extraction-Electrowing copper Recovery operations. P20
9.0 Gary kordosky, Cognis copperation.gary kordosky at@ cognis-us.com.

Appendices
Appendix 1
Daily cathode rejection analysis for july-2009
Table.1
Average Direct
shorts 14.21
Average Torne
edges 1
Daily cathode rejection analysis for- August-2009
Table.2
Average bad shape 12.30
Average Direct
shorts 16.35
Average Lead
flakes 3
Daily cathode rejection analysis for September-2009
Table.3
Average Bad
shape 15.61
Average Direct
shorts 7.65
Average Lead
flakes 2

Daily cathode rejection analysis for October- 2009
Table.4
Average Bad
shape 22.91
Average Direct
shorts 10.12
Average Lead
streak 2
Average Nodular 2
Daily cathode rejections analysis for November-2009
Table.5
Average Bad
shape 17.81
Average Direct
shorts 5.66
Average Lead
streaks 8 Daily cathode rejection analysis for December-2009
Average Lead
flakes 11.5
Average Organic 6.5

Table.6

Average Bad
shape 19.52
Average Direct
shorts 3.18
Average Lead
streaks 4
Daily cathode rejection analysis for January- 2010
Table.7
Average Bad
shape 21.25
Average Direct
shots 5.625
Average lead
streaks 1
Average Lead
flakes 4.5
Daily cathode rejection analysis for February-2010
Table.8
Average Bad
shape 17.66
Average Direct
shorts 4.625
Daily cathode rejection analysis for March-2010
Table.10

Average Bad
shape 19.75
Average Direct
shorts 5.90
Average Lead
flakes 3
Daily cathode rejection analysis for April 2007
Table. 11
Average Bad
shape 95.42
Average Direct
shorts 76.5
Average Lead
streaks 31.67
Average Organic 66.25
Average pitted
bottom 2
Average semi
stripped 80
Daily cathode rejection analysis for May-2007
Table.11
Average bad
shape 104
Average Direct
shorts 14.4
Organic
contamination 13.5
Daily cathode rejection analysis for June-2007
Table.12
Average Bad shape 80
Average Direct Shorts 13
Average Lead flakes 10
Average Semi stripped 40
Average desludged 220

Daily cathode rejection analysis for July-2007
Table.13
average bad
shape 72.66
average Direct
shorts 35
average Lead
flakes 5
average
Daily cathode rejection Desluged 252 analysis for August-2007
Table.14
Average Bad
shape 34.5
Average Direct
shorts 10.5
Average Lead
flakes 120
Average Nodular 2
Average Organic
1 4
Average pitted
bottom 19
Average
desludged 240

Daily cathode rejection analysis for september-2007
Table.15
Average Bad
shape 52
Average Direct
shorts 2
average Lead
flakes 4
Daily cathode rejection analysis for October-2007

Table.16
Average Bad
shape 25.75
Average Direct
shorts 23
Average Organic 35.5
Average
Daily cathode rejection analysis for November-
Desluged 266
2007
Table.17
Average Bad
shape 44.67
Average Direct
shorts 7.33
Average lead
streaks 2
Cell No. 271 272 273 274 275 290 292 293 294 295 Total %
Average
Desluged 465.25
Descriptio average Organic 2

n

Bulging
loops 11 6 12 10 7 4 10 12 13 5 90 17
Direct
shorts
8 3 6 0 4 1 7 3 - - 32 6
Sagging
cathode 4 - - - - - 1 2 - - 7 1
Missing -
capping
- - - - - - - - - - -
Anode off
knife edge
7 4 2 0 8 3 5 - 8 1 38 7.2
Cathode
off knife
edge 20.
2
19 15 21 3 12 2 5 - 17 13 107
Twisted
Anode
hanger bar
14 2 5 1 3 4 9 9 2 7 56 10.
6
PVC balls
gaps
16 23 8 - 17 16 28 10 21 34 173 32.
6
Cathodes
not aligned

5 - - 3 1 3 - - - 15
Sum 530
=
Appendix 2
Tank loading practice rejection: Shorts Corrections: New Tank house
Date: 2nd March, 2010.
Table. 1a
Tank loading practice: Shorts corrections; New Tank house
Date: 9th March, 20010
Table.1b
Cell No. 10 110 111 112 113 114 115 116 117 118 Total %
9
Descriptio
n
Loose 14.3
loops
8 7 9 3 10 1 - 4 - 2 44
Direct 7.5
shorts
3 - - 1 1 1 2 6 9 - 23
Sagging

cathode
5 - - - 6 3 1 2 3 4
Missing 9.1
/broken
Capping
slot - - - - 2 3 5 5 7 6 28
Anode off 6.2

knife edge
- 8 4 2 - - 1 - 4 - 19
Cathode off
knife edge
9 3 4 - - 1 2 12 4 - 35 11.4
Twisted
Anode
hanger bar
- - - - - - 1 1 - - 2 0.7
PVC balls
gaps
19 23 26 24 - - - - 6 - 98 31.9
Cathodes
not aligned
6 7 8 9 4 - - - - - 34 11
Sum 307
=
Tank loading practice: Shorts correction; New tank house

Date: 16th March, 2010.
Table .1c
Cell No. 261 262 263 264 265 266 281 28 283 284 %
2
Descriptio
n
Bulging 13.
loops 4
2 2 2 3 4 6 3 6 3 2 33
Direct 4.9
shorts
- 3 4 2 2 - 1 - - - 12
Sagging 1.2
cathode 1 - - - - - - 2 - - 3
Missing 15
/broken
4 - - - 2 2 8 9 7 5 37
Capping
slot
Anode off 4.9

knife edge
2 - 2 1 3 - 1 2 1 - 12
Cathode
off knife
edge 3 6 - 4 - 1 5 1 7 - 27 11

Twisted
Anode 11.3
hanger bar
9 3 2 2 - 1 3 - 5 3 28
PVC balls
gaps
8 3 - - - 9 - 19 23 28 90 36.
6
Cathodes
not aligned
1 - - - - - - - 2 1 4 1.6
Su 246
m=
Tank loading practice: Shorts correction; New tank house,
Date26th March, 2010
Cell No. 33 34 35 13 14 12 11 55 54 55 TOTAL %
Description
Bulging 12 6 8 9 6 - - 21 8 3 73 15.4
loops
Direct 3 - - - 6 2 1 - 4 - 16 3.38
shorts
Sagging - - - - - - - - -
cathode
Missing 3 1 3 6 8 15 19 5 4 3 67 14.1
/broken
Capping

slot
Anode off 4 6 9 3 6 - - - - - 28 5.9

knife edge
Cathode off 13 9 5 3 0 16 7 12 23 - 88 18.5

knife edge
Twisted 6 3 - - - - - - 4 2 15 0.000
3
Anode
hanger bar
PVC balls 14 16 12 34 3 8 19 23 6 0 105 22.2

gaps
Cathodes 8 14 6 4 15 - - - 19 16 82 17.3
not aligned
SU 474
M=
Table. 1d
Appendix 3
Tank loading practice: Spot-check: Old tank house,
Date: 7th April 2010
Table. 1a

Cell No. Observation
72 A
 9 Anode hanger bars with CuSO4.
Crystallization.
 1Rubber capping board not properly aligned.
 6 bulging loops.
72 B
 PVC balls between loops.
 19 Cathodes with CuSO4 crystallization o loops.

72 C
 15 Anode hanger bars with CuSO4.
Crystallization.
 PVC ball between cathode and bus bar.
 4 Anode hanger bars off bus bar.
 8 bent anode hangers.
Tank loading practice: Spot-check: Old Tank House
Date: 9th April, 2010
Table.2b

280  9 anodes not resting on capping board.
 4 bent anode hanger bars.
 10 capping slots broken.
 11 gaps of PVC between electrodes.
279  7 bent anode hangers.
 5 gaps PVC balls at outlet of cell.
 9 capping board broken.
278  12 bent anode hanger bars.
 5 capping boards broken.
 9 hanger bars at the edge of the capping.
(Potential drop)
277  8 bent anode hangers.
 2 abode hangers with copper sulphate crystals.
 7 shorts (anode-cathode contact).
 15 PVC gaps (between) electrodes.
 6 capping board slots broken.
276  9bent anode hanger bars.
Observation.
275  6 bent anode hanger bars.

 14 loops bulged.
 7 shorts (anode – cathode loop contact)

Tank loading practice: Sport-Check: Old Tank House
Date: 10th April, 2010

Cell Observation
No.
50 A
Table.2b
 6 gaps of PVC balls.
 Bulging loops.
 3 Anode hanger bars with copper sulphate,

crystallization.
50 B  1 Anode hanger bar off bus bar.
 12 loops with copper sulphate.
50 C  6 bent anode hanger bars.
 4bulged loops.
 No PVC balls at the cell feed.
50 D  Gaps of PVC balls at cell feed.
 3Bulged loops.
 4bent anode hanger bars.
 8 bent anode hangers.
 9 gaps of PVC balls.
50 E  4 Gaps of PVC balls.
 5bent anode hanger bars.
55 A  3 Gaps of PVC balls.
 4 bulged loops.
 9 loops with Copper Sulphate crystallization.

Tank loading practice: Spot-check: Old Tank House
Date: 8th April 2010
Table 2d
Cell Observation
No.
54 A
 9 Cathodes contacts with Copper Sulphate
Crystallization.
 Capping Board not properly aligned.
 5 Bent anode hanger bars.
 7 Bulging loops.
 1 anode not resting on the knife edge.
 6 PVC balls gaps (Anode –Anode)

54 B
 14 PVC balls gaps (Anode –Anode).
 Capping board not properly aligned.
 10 anode hanger bars resting on bus bars

Both side
 Out lived anodes dated 2004.
54 C
 17 Anode contacts with crystallization of
Copper Sulphate.
 3 Anodes resting on bus bars both sides.
 3 Bent anode hanger bars.
 29 anodes with Copper Sulphate crystallization.

Tank loading practice: Spot-check: Old Tank House.
Date; 20th April, 2010

56 E  6 Anode contacts with copper sulphate crystallization.
 2 Anodes not resting on the bus bar.

Table .2e
 9 Bent anodes hangers.
 5 PVC balls gaps.
56 F  Capping board not properly aligned.
 2 anodes resting on both sides.
 4 Anode contacts with Copper Sulphate crystallization.
 1 Anode drop(neither resting on the capping board
Nor bus bar).
 Outlet pipe leaking.
60 B  13 Bent anode hanger bars.
 12 Anodes with Copper sulphate crystallization.
 29 loops with Copper Sulphate crystallization.
6o c  4 gaps of PVC balls (anode-Anode).
 4 Anodes with copper sulphate crystallizations.
 9 loops with Copper Sulphate crystals.
51 A  6 Bent anode hanger bars.
 5 Gaps of PVC balls (Anode –Anode).


Chilekwa Moses Project

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Chilekwa Moses Project

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IMPROVEMENT OF KABUNDI COPPER CATHODE (KBC) RECOVERY

THE COPPERBELLT UNIVERSITY

SCHOOL OF MINES AND MINERAL SCIENCE

IMPROVEMENT OF KABUNDI COPPER CATHODE RECOVERY BY

NAME: CHILEKWA MOSES.K.

COMPUTER NUMBER: 06058176

THIS DISSERTATION IS SUBMITTED IN PARTIAL FULFILMENT AS A

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 0

other institution for the same reasons as I do.

Internal Supervisor’s signature..............................................Date.....................................

External supervisor’s signature.............................................Date.....................................

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 1

The Copper Belt University

P.O Box 21692

The Projects coordinator

Copper Belt University

RE: LETTER OF TRANSMITTAL

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 2

To my class mates,Muziya Kency Musonda, Bernard, Aongola Mukisi , Mukandawire

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 3

to 2008/9, embarked on a quality improvement programme. Investment in infrastructure,

equipment upgrades, extensive human resource training and formulation and

implementation of effective plant operating philosophies have been undertaken with a

vision to becoming one of the best world class copper producers.

Keywords: Quality, Electro winning, TQM, LME Grade A cathodes

To assure customer confidence, the following needed to be worked on:

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 4

 Increase metal recovery to export to over 96 %.

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 5

their efforts in making it possible for us to go on Industrial attachment. I further thank my

tailings leach plant.

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 6

CHAPTER ONE INTRODUCTION.........................................................................................................0

1.1 The TLP Tank house vision.......................................................................................................1

1.1.2 Quality Initiatives.................................................................................................................2

1.1.3 Overall Goal of the study.....................................................................................................3

1.1.4 Distinctive goal of the thesis................................................................................................3

1.1.5 Range of project (scope)......................................................................................................3

1.2.0 Plant Description..................................................................................................................3

1.2.1 The New Tank House............................................................................................................4

1.2.2 The New Tank House Lay Out .........................................................................................6

1.3.0 Process operation................................................................................................................9

1.3.1 Rectifier and load control.....................................................................................................9

1.3.2 Advance electrolyte flow.....................................................................................................9

1.3.4 Tank loading.......................................................................................................................10

1.3.5 Cathode production...........................................................................................................11

1.3.6 The starting sheet preparation...........................................................................................11

By Moses.K. Chilekwa, BEng MET @ 2010 C .B. U Page 7

1.3.7 The starting sheet dimensions...........................................................................................12

1.3.8 Starting sheet inspection...................................................................................................12

1.3.10 Cathode pulling................................................................................................................13

1.3.12 Cathode handling and despatch.......................................................................................15

CHAPTER TWO LITERATURE SURVEY...............................................................................................17

2.0 Literature survey...................................................................................................................18

2.1 Electro winning.....................................................................................................................18

2.2 The cathode quality..............................................................................................................19

2.3 Removal of organic and suspended solids.............................................................................19

2.4 Anode corrosion....................................................................................................................20

2.5 Properties of lead- Ca-tin alloy anodes.................................................................................21

2.6 Effects of oxygen evolution...................................................................................................22

2.7 Effects of material oxidation in solution..........................................................................22

2.8 Electro-winning cell condition.........................................................................................22

2.8.1 Electrolyte circulation........................................................................................................23