Bus Bar

Our bus bar current density normally 1A/mm² to 1.25A/mm² , 99.99% purity red copper.

Also flexible bus bar, support, insulator and shorting frame etc. all available for you.

Layout 3D drawing for you.

How Does PRS Ensure Copper Busbar Quality?

Watch our full testing and manufacturing process.

High-Conductivity Copper Busbar System for SX-EW & Copper Refineries

In copper electrorefining (ER) and electrowinning (EW) tankhouses, the direct current (DC) distribution network operates under low voltage and high amperage (typically ranging from 10 kA to over 48 kA). Under these aggressive operational conditions, any localized resistance within the copper refinery busbar layout results in continuous voltage drop, elevated temperatures, and direct power loss.

PRS provides full-scope tankhouse busbar engineering, supplying customized copper bus bars manufactured from high-purity copper (T2 / ASTM C11000 / ISO Cu-ETP). We integrate a complete electrical layout covering cathode busbars, anode busbars, inter-cell connectors, and main DC busbar routes from the rectifier to the cells.

Whether for a turnkey new SX-EW project or the upgrade of an existing refinery tankhouse, our rigid and flexible copper busbars provide reliable electrical performance, minimal resistance, and an extended service life in high-acid, high-temperature environments.

Typical Busbar Layout Components:

Main DC busbars (rectifier to cell bank)
Anode & cathode cell busbars
Inter-cell connectors & jumpers
Multi-layer flexible busbars (soft connections)

Production Process & Quality Control

Our manufacturing and inspection protocols are strictly structured to ensure dimensional repeatability and ultra-clean electrical contact surfaces.

1. Copper Raw Material Selection & Extrusion

We utilize premium-grade high-purity T2 copper billets. Through advanced continuous extrusion equipment, the copper’s grain structure is tightly aligned, optimizing its tensile strength and electrical conductivity.

2. Precision CNC Machining

All straight sections, main DC routes, and interlocking joints are finished via precise CNC cutting, bending, and drilling. Contact joints are milled flat to maximize the physical surface area in contact, preventing localized electrical hot spots.

3. Rigorous Dimensional & Quality Inspection

Every critical tolerance—including hole alignment, width, and thickness—is manually verified using calibrated vernier calipers. We conduct resistivity tests to guarantee maximum electrical performance before shipment.

4. Secure Packaging and Delivery

Finished copper segments are cleaned and wrapped in protective film to prevent surface oxidation, deep scratches, or dimensional distortion during sea freight.

Copper Bus Bar Technical Parameters

Item	Specification / Standard
Material Grade	High-Purity T2 Copper / ASTM C11000 / ISO Cu-ETP
Copper Purity	≥ 99.90%
Electrical Conductivity	≥ 97% IACS (International Annealed Copper Standard)
Resistivity Check	Micro-ohm meter verification per production batch
Supported Footprint	Turnkey layouts tailored for 3,000 TPA to 100,000+ TPA tankhouses, matching rectifier outputs up to 48 kA
Thickness / Width / Length	100% Customized based on plant engineering drawings
Surface Finish	Mill Finish / CNC Machined Flat Contact Joints
Busbar Types Available	Flat Rigid Busbar, Laminated Flexible Busbar, Special-Shaped Busbar
Primary Applications	Copper SX-EW Plants, Electrorefining (ER) Tankhouses, Smelting Workshops

Why Choose PRS Copper Busbars

Tailored Engineering: 100% custom manufacturing based strictly on your site layout and drawings.
Guaranteed Material Purity: We test and certify ≥ 99.90% copper purity and ≥ 97% IACS conductivity.
Advanced Solutions: One-stop supplier for rigid, flexible, and special-shaped (heteromorphic) inter-cell busbars.
Voltage Drop Minimization: Milled contact joints and optimized bolt patterns ensure minimal power loss.
Global Project Experience: Reliable power distribution systems proven in SX-EW and electrorefining tankhouses worldwide.

Packaging & Shipping

The components undergo a systematic packaging process tailored for international sea freight:

Each machined piece is cleaned to remove manufacturing oils and sealed in protective film.
Bars are isolated by structural wood or foam spacers to fully eliminate metal-on-metal friction.
The entire assembly is blocked securely inside heavy-duty wooden cases or reinforced steel frames, engineered safely for forklift handling.

Frequently Asked Questions

Q1: What is the main function of a copper busbar in a tankhouse?

A: A copper busbar forms the heavy direct current (DC) network, distributing electrical current efficiently between the rectifiers, electrolysis cells, anodes, and cathodes with minimal voltage drop. This is the core of any electrowinning copper bus bar system.

Q2: How to ensure the stable output of 99.99% high-purity gold?

A: Every project package includes a detailed EW/ER busbar installation drawing. Each fabricated copper piece is marked with a unique, durable ID tag that corresponds directly to the engineering blueprint, allowing rapid assembly without on-site cutting or modifications.

Q3: What types of copper busbars do you supply, and are they suitable for SX-EW?

A: We supply flat rigid busbars, laminated flexible copper busbars, and special-shaped (heteromorphic) inter-cell busbars. All of them are specifically designed for the high-acid, high-temperature environments of copper SX-EW and electrorefining plants.

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