precision technology
Copper Electrorefining Plant
Electrolytic Copper Refining Plant — From Cast Anode to LME Grade A (99.99%) Cathode
A Copper Electrorefining Plant(tankhouse) is the core refining workshop following the anode fire-refining process. Cast copper anodes (refined from scrap or blister copper in an anode furnace) are electrolytically refined in polymer concrete cells to yield high-purity LME Grade A copper cathodes (≥ 99.99% Cu).
Process Overview: Anode In, Cathode Out
The core cycle: cast anode → electrolytic cell → cathode deposition → stripping → LME Grade A cathode. Underneath, electrolyte heating/circulation, anode slime recovery, and staged purification keep the reaction stable cycle after cycle.
Technical Process Detail
The Main Cycle
Cranes load cast anodes alongside reusable stainless‑steel cathode plates. Over 10‑12 days, copper dissolves from the anode and redeposits onto the cathode. Anodes operate through a longer 20‑24‑day cycle, after which scrap returns to the anode furnace.
Electrolyte Heating & Reagents
Steam‑heated plate exchangers maintain electrolyte at 62–65 °C, and VFD pumps circulate it straight into the cells. Operators dose glue and thiourea to foster smooth, dendrite‑free cathode growth.
Anode Slime & Copper Recovery System
Slime-laden electrolyte is drained, decanted, and filter-pressed. Dry slime cake goes to gold/silver/PGM recovery; filtrate copper returns to circulation instead of being lost.
Multi-Stage Purification (De-Cu Bleed System)
A staged bleed keeps impurities from building up faster than the anode dissolves them in:
1st De-Cu recovers standard cathode copper;
2nd De-Cu co-deposits copper with As/Bi/Sb once impurities rise;
3rd De-Cu performs deep removal, sending sludge to the slime line; a Nickel Recovery Line diverts electrolyte once Ni passes ~15 g/L, recovering crude nickel sulfate.
One System, Not Separate Machines: Plate Handling & Automation
This is where most electrorefining projects lose efficiency — not in the chemistry, but in how plates move between stages. Handling capacity, stripping capacity, and conveying/stacking capacity all need to be sized to move together, not quoted as isolated machines:
- Plate handlingplanned alongside cell arrangement, not after it
- Cathode stripping— manual or automated — sized to daily cathode output
- Conveying and stacking, with robotic handling for higher-automation projects, connecting stripping straight to the finished-product area
Route: Anode Plate → Electrorefining → Plate Handling → Cathode Stripping → Conveying → Stacking → Finished Cathode.
See our related article: [From Anode Plate to Cathode Copper: Inside a Copper Electrolysis Plant]
Copper Electrolysis Equipment
A tankhouse this size runs on a handful of major systems, not a long parts list.
Here’s what actually makes up the line:
The design integrates electrolyte circulation & purification, power supply (rectifier/transformer), conveying‑and‑stacking, and safety systems (acid mist extraction, anode washing) around these four core units and sizes all auxiliary systems for matching capacity. Furthermore, PRS supplies all these auxiliary pieces of equipment for the electrolysis workshop.
Quality & Scalability
As an Electrolytic Copper Refining Plant for 99.99% high purity cathode, quality here means LME Grade A, ≥99.99% Cu, with As/Bi/Sb/Ni/Pb held within LME-registerable limits and batch-to-lot traceability. Capacity is built from repeatable cell groups — scaling from 3,000 t/a to 30,000+ t/a by adding power modules and cell blocks, with layout and rectifier sizing planned up front so expansion doesn’t disrupt production.
This is a test report for cathode copper recovered from copper scrap. Test results show that the copper purity of the product is 99.99%.
Why Work With PRS
- Full EPC Scope— design, equipment, civil coordination, installation, and commissioning under one contract
- On-Site Commissioning Support— engineers stay through trial operation until the plant runs stable
- Plate Handling Engineered In— not an afterthought bolted onto the cell layout
- Fast, Predictable Delivery— modular supply chain shortens lead time to first cathode