hk4d6623

TMS 2017, 27th February 2017, San Diego
METTOP-BRX Technology
Eliminating Concerns and Highlighting Potentials of the Concept of
Tankhouse Optimization
Mettop Group
Organigram and Subdivisions
Dr. Andreas Filzwieser

Dr. Iris Filzwieser
DI Stefan Wallner
SA
Mettop at a Glance
Meet Customers Problems – Tailor-made process optimization
Tankhouse Engineering Furnace Integrity Cooling Technology
METTOP-BRX Technology Cooling Solutions

Process Modelling
Basic Engineering ILTEC Technology
CFD Simulation
Detail Engineering Feasibility Studies
Gas Purging Systems
Feasibility Studies
3D Refractory Engineering
Consulting decreasing OPEX
Consulting increasing Current Efficiency
METTOP-BRX Technology
Concerns and Possibilities of the Technology
Why rethinking tankhouse design?
Aims and achievable benefits
Targets for tankhouse optimization:

• High current efficiency
• High chemical cathode quality
• Low operating cost
• Lower footprint
• Low bound capital
METTOP-BRX Technology enables higher current

densities and will result in higher productivity.
Basis
Different Flow Mechanisms and Improvement by METTOP-BRX Technology
Conventional Cell
Natural Convection
Basis
Conventional Cell
Forced Convection
What is different?
Improved Forced Convection
• Enhanced flow of electrolyte in between the electrodes

• More homogeneous distribution of all inhibitors directly in front of
the active cathode surface
• More homogeneous temperature distribution
What is different?
Natural Convection
Anode
Cathode
What is different?
Anode Cathode Anode Cathode
Nozzles
• Increase in electrolyte velocity in front of anode/cathode

• Decrease in diffusion boundary layer
• Higher relative movement (velocities) realized by implementing a
parallel electrolyte flow between the electrodes
• BUT NO change in flow profile
• No change of anode slime flow pattern
What is different?
Different Flow Mechanisms – How not to do
uforced convection
Gasblasenrührung
Increased
Ablösung der
hydrodynamischen
hydrodynamic and
Grenzschicht
diffusion boundary
layer
natural
unat. Konvektion
convection
(y)
y
x
What is different?
Enhanced Natural Convection Forced Convection
+
• Higher electrolyte flow rate and flow directly in front of the cathode leads to a decreased diffusion
boundary layer.
• Direct introduction of the inhibitors near the active cathode surface lead to a more homogeneous
distribution
• Current density distributions is more homogenous
• Direct electrolyte introduction leads to a more homogenous electrolyte temperature distribution
Using the METTOP-BRX Technology a current density of up to 450 A/m²

at a current efficiency of above 98 % can be achieved.
Can METTOP-BRX Technology be
realized in existing tankhouses?
Brownfield Approach - Parallel Flow Device (PFD) for upgrading existing tankhouses
• Special positioning devices – cathode spacers for accurate electrode positioning

• PFDs are customer-tailored to guarantee optimum results for each specific
tankhouse.
Parallel Flow Device Hanging Device
Hardware
Cathode Spacers
Openings for cleaning

Nozzles
How can METTOP-BRX Technology be
realized in new tankhouses?
Greenfield Approach – Parallel Flow Plate for optimized tankhouse performance
• Parallel Flow Plate (PFP) is a combination of PFD and the cell itself
• the METTOP-BRX Technology can be integrated in the polymer concrete cells
Parallel Flow Plate (PFP)
Polymer Concrete Cell Design for PFP
Is METTOP-BRX a proven Technology?
Montanwerke Brixlegg AG, Austria – Upscaling an Existing Tankhouse in 2007
• Higher current density and increased production

• Additive adjustments for current efficiency increase
• Better cathode quality due to more homogeneous additive distribution
• Shorter down times when filling the groups due to higher flow and faster filling
• Higher flow for faster heating-up of the anodes
• Fewer shorts occur due to accurate cathode positioning/guiding system.
Is METTOP-BRX a proven Technology?
Xiangguang Copper, China – Installation of a new Tankhouse in 2011
• Pumps for direct pumping (i.e., no overhead tanks) for approximately 100 l/min per cell
• New design of electrical system for 420 A/m² (2 electric circuits) and new design of heat exchangers
• Continuous addition of inhibitors
• Increase in productivity from 200 000 t/year (conventional cell) to 300 000 t/year (METTOP-BRX)
Xiangguang Copper reports current efficiency of > 99 % at 420 A/m²

Can every tankhouse be easily equipped?
Requirements for optimum performance of the METTOP-BRX Technology – Greenfield Approach
• Adequate tankhouse design including equipment (comprising electrical and electrolyte

system, as well as the mechanical components)
• Electrolyte system for high flow: Adequate piping diameters, as well as direct pumping
instead of overhead tanks
• Electrical system for high current density: Suitable rectifier, transformer, and bus bars
• A good electrode quality/geometry is essential for exact positioning
• Crane positioning system to guarantee exact electrode positioning
• Stainless cathodes or smooth copper mother sheets
Conventional flow pattern New electrolyte circulation system

Requirements for optimum performance of the METTOP-BRX Technology – Brownfield Approach
Due to increased flow and circulation rate, the capacity of the piping and
pumping systems will be the limiting factors.
Different approaches for solving:
• Creating internal loops for two third of the electrolyte flow and using
the existing piping for one third
• Increasing the current density by taking out anodes and cathodes

and creating the higher flow using pumps installed into the cells
• Replacing partly the existing pipes and change to

a direct pumping system
Requirements for optimum performance of the METTOP-BRX Technology – Brownfield Approach
Internal Loop – schematic flow pattern Internal Loop (red lines) – flow pattern
What does an installation mean
economically?
Either brownfield application as well as greenfield application
For a new tankhouse following CAPEX decrease can be achieved using 420 A/m²:
• Lower overall tankhouse footprint (~ 20 %)
• Less cells (~ 25 %)
• Less cathode plates (~ 25 %)
• Less electrolyte and edge strips
• Less anodes in the tankhouse (40-55 Mio US$ bound capital reduction)!!
The costs for machines (anode preparation machine, stripping machine, etc.) and electrical
installation (generator, rectifier, bus bar, etc.) will remain the same
For the OPEX calculation of importance:

• Interest savings due to a much lower CAPEX costs
• Increase in power consumption due to a higher current density
economically?
Figures given by Xiangguang Copper
Permanent
Item Unit METTOP-BRX Starting sheets
cathodes
Current density A/m² 420 280 250
Current efficiency % 99.37 96.68 94.00
Steam
t/t Cu 0 0.49 0.8
consumption
AC unit
kWh/t Cu 490 397 450
consumption
Integrated energy
Kgce/t Cu 60.22 93.06 130.98
consumption
economically?
Figures given by Mr. Zhou; Xiangguang Copper
 High efficiency and large capacity. The average value of current density reaches up
to 420 A/m². Max value is up to 500 A/m². The capacity has been increased at least
exceeding 50 % of the existing regular electrolysis capacity.
 Low integrated energy consumption. Production can proceed without steam, the
integrated energy consumption is 25 % lower than the advanced value of the
national standard GB21248-2014.
 Shorter production cycle and less funds tied-up. The production time is 30 %
shorter than within conventional electrolysis. Funds turnover is faster and funs
tied-up is less. The inventory costs are reduced as well. These mean funds tied-up
can reduce 500 million RMB per year for a copper smelting plant with capacity of
400,000 tons per year. Profit maximization is possible to be achieved.
Summary
Today’s most advanced tankhouse technology – the METTOP-BRX Technology –

allows:
• Increasing the current density and productivity by up to 50 % compared to

conventional copper electrorefining tankhouses.
• Can either be installed in existing facilities – in order to increase production – or
considered in new plants – in order to reduce the footprint of the entire
tankhouse.
• Right now the benchmark for a copper refinery is Xiangguang Copper, China,
running their tankhouse no. 2 at 420 A/m² at a current efficiency > 99 % using
the METTOP-BRX Technology.
Thank you!
uforced convection
Gasblasenrührung
Increased
Ablösung der
hydrodynamischen
hydrodynamic and
Grenzschicht
diffusion boundary
layer
natural
unat. Konvektion
convection
(y)
y
x
Spacing Device
Increase of current efficiency by 1 – 2 %

Spacing Device
Spacing Device

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TMS 2017, 27th February 2017, San Diego

Dr. Andreas Filzwieser

Tankhouse Engineering Furnace Integrity Cooling Technology

METTOP-BRX Technology Cooling Solutions

Targets for tankhouse optimization:

METTOP-BRX Technology enables higher current

Improved Forced Convection

• Enhanced flow of electrolyte in between the electrodes

Anode Cathode Anode Cathode

• Increase in electrolyte velocity in front of anode/cathode

Enhanced Natural Convection Forced Convection

Using the METTOP-BRX Technology a current density of up to 450 A/m²

• Special positioning devices – cathode spacers for accurate electrode positioning

Openings for cleaning

• Higher current density and increased production

Xiangguang Copper reports current efficiency of > 99 % at 420 A/m²

• Adequate tankhouse design including equipment (comprising electrical and electrolyte

Conventional flow pattern New electrolyte circulation system

• Increasing the current density by taking out anodes and cathodes

• Replacing partly the existing pipes and change to

For the OPEX calculation of importance:

Today’s most advanced tankhouse technology – the METTOP-BRX Technology –

• Increasing the current density and productivity by up to 50 % compared to

Increase of current efficiency by 1 – 2 %

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