Implementation of digital automated control systems at electrolytic copper refining plants in Vietnam

The work aims to develop digital control and management systems of copper electrolytic refining processes when addressing energy efficiency issues. Thermal imaging scanners can be used to monitor the process state of an electrolytic cell. In this regard, the experience in the automation and control systems of OJSC Novgorod Metallurgical Plant was considered. Mathematical research methods and a stochastic model developed in the MatLab software were used. This model was applied at the Lao Cai copper-smelting plant (Vietnam). The proposed algorithm is based on the temperature variation in electrolyte depending on the heating of cathode and anode sections during short circuits due to dendritic growth, as well as process disturbance time. The algorithm was developed using the Visual BasicScript programming languages. The temperature rise in short circuit areas was recorded using a thermal imaging scanner immediately after the colour change of the cathode surface. It was shown that the duration of a short circuit depends on the amount of sludge deposited in an electrolytic cell. The sludge formed following the destruction of intergrown dendrites contains precious metals. The developed measures, along with those of digitisation, are necessary for effective management, taking into account the functional and kinetic characteristics of the copper refining process. The proposed solutions and control algorithms will allow remote access systems with augmented reality elements when creating a digital twin. This will reduce the specific power consumption by 20 –25% while decreasing the number of electrode short circuits. Controlling the composition and level of electrolyte and sludge will reduce material losses and maintain the concentration of noble metals in the electrolyte. To improve the control quality of automation during the electrolytic production of cathode copper, a number of technical measures were proposed that provide additional points of control to expand the process database. Furthermore, the proportion of manual periodic measurements of process parameters is reduced.

Autoclave treatment of cakes after pressure oxidation leaching of chalcopyrite concentrates

The existing technologies for copper-porphyry ores enrichment, located in deposits in the Urals of Russia, allow the production of chalcopyrite concentrates of the following composition, %: 21.5 Cu, 24.5 Fe, 26.5 S, 0.4 Pb, 17.6 SiO2, 1.8 CaO, 2–6 Au (ppm), 20– 40 Ag (ppm). A conventional technology for processing such concentrates includes autogenous smelting, matte desulfurization and blister copper refining. Pressure oxidation leaching (POX) is considered the most promising alternative technology for chalcopyrite concentrate processing. The POX of concentrates originated from Mikheevskii GOK allow the production a cake of the following chemical composition, %: 56–65 Fe2O3, 25–30 SiO2, 2.7 Ca, 0.3–1.0 Cu, 2–7 S, 0.6–0.8 Pb, 4–12 Au (ppm), 40–80 Ag (ppm); mass loss was 37–45 %. A standard method of cake cyaniding provides satisfactory indicators of precious metal extraction, but it requires a cumbersome area to be arranged for their processing and offers no solution for residue disposal. In this regard, this paper investigates the method of subsequent cake processing using autoclave treatment (AT) for iron removal. The study shows how the following parameters affect the results of this process: t = 110÷210 °C, H2SO4 = 15÷60 g/dm3, τ = 45÷ ÷120 min. A statistic description of the AT operation is developed. Recommended AT conditions (t = 110 °C, H2SO4 = 60 g/dm3, τ = 60÷100 min) allow to obtain the POX cake yield reduced to 30–35 % of the source material with the following composition, %: 28–33 Fe2O3, 47–53 SiO2, 2–5 Ca, 0.6–2.0 Cu, 0.8–1.5 Pb, 2–8 S. At the same time, the content of precious metals in the cake reaches 12–16 Au (ppm) and 80–120 Ag (ppm). Options for using AT products are proposed.

Characterization and process development for the selective removal of Sn, Sb, and As from anode slime obtained from electrolytic copper refining

The aim of this work was to develop a process for the removal of Sn, Sb and As from anode slime out of copper refinery to disburden a subsequent pyrometallurgical processing for precious metals refinement. For this reason, a detailed literature survey was conducted, followed by a characterization to find the present compounds/alloys and their morphology. A newly developed process concept for the separate extraction of the afore mentioned three target metals was developed and verified by leaching experiments, combined with thermodynamic calculations on their behavior under varying conditions. In this context, the influence of leaching temperature, alkalinity of leaching solution, and solid-liquid ration were evaluated on the extraction yields of Sn, As, and Sb, as well as how to exploit these findings to obtain separate streams enriched in the respective metals.