When providing EPC (Engineering, Procurement, and Construction) services for copper electrowinning plants, one crucial consideration is the impact of intense sunlight on the equipment. In regions with strong UV exposure, such as Australia and parts of Africa, UV damage can significantly impact the longevity and performance of electrowinning cells. To address this challenge, we have developed a comprehensive surface protection process to ensure the durability and effectiveness of these cells in sunlight-intensive climates.
The Challenge
Copper electrowinning cells are exposed to various environmental factors, including UV radiation, which can degrade materials over time. In climates with high levels of sunlight, it is essential to implement protective measures to prevent UV damage and ensure the cells remain operational over the long term.
Our Surface Protection Process
Preparing the Molds
The first step in manufacturing the electrowinning cells involves creating molds that give the cells their final shape. Proper mold preparation is crucial to ensuring that the resin materials form correctly.
- Mold Grinding: We ensure both the inner and outer molds are ground to a smooth surface, providing a high-quality finish.
- Applying Release Agent: A mold release agent is applied to prevent the resin from sticking to the mold, allowing for an easy and clean demolding process after the resin hardens.
Inner Surface Protection
Protecting the internal surface of the copper electrowinning cells is critical because, despite being shielded from direct sunlight, internal surfaces still need to maintain structural integrity. Our process ensures that these surfaces are UV-resistant.
- Coating Material: A non-colored vinyl resin, known for its excellent UV resistance, is applied to the inside of the mold. To reinforce the surface, we also add a layer of surface felt.
- Thickness: The coating is applied at a thickness of 1-2mm, ensuring a solid, durable layer.
- Rinsing: After the resin solidifies, the internal surface is carefully rinsed with clean water to remove any excess material or contaminants.
Outer Surface Protection
The external surface of the cells is where UV resistance is most critical, given the intense sunlight in Australia. We apply an additional protective layer to guard against potential degradation from long-term exposure.
- Coating Material: A grey or white vinyl resin is used to create a UV-resistant shield on the outer surface. We reinforce this with one layer of chopped strand mat, which adds strength and durability.
- Thickness: As with the internal surface, we apply this layer at a 1-2mm thickness.
- Rinsing: The external surface is rinsed after the resin hardens to ensure it is clean and ready for use.
Closing the Molds
Once the inner and outer surfaces have been prepared and coated, the molds are closed to finalize the structure. This step ensures that the resin fills the molds completely, forming the body of the copper electrowinning cells.
Casting the Resin Mortar
With the molds closed, we pour the resin mortar into them. This material will harden into the strong, UV-resistant structure of the electrowinning cells.
Demolding
After the resin has fully cured, we remove the molds, revealing the completed copper electrowinning cells. The demolding process is smooth thanks to the release agent applied earlier.
Quality Inspection
Every cell undergoes a thorough inspection to ensure it meets the strict standards required for long-term, reliable operation in a high UV environment. Any issues are resolved before the cells are prepared for shipment.
Packaging for Export
Given the heavy-duty nature of these cells and the long journey to the plant site, we package the cells in steel frames. This packaging provides additional protection during sea transportation, ensuring the cells arrive safely, undamaged, and ready for installation.
Conclusion
By implementing this customized UV-resistant surface protection process, we are ensuring that our client’s copper electrowinning cells will withstand the harsh sunlight. This careful attention to material selection and manufacturing methods guarantees that the plant will operate smoothly and efficiently for years to come, with minimal risk of UV-related damage. As part of PRS’s comprehensive EPC service, we are committed to delivering not only a fully functional plant but also long-lasting equipment designed for local environmental conditions.
