In copper electrowinning operations, the cathode stripping machine (Manipulador de Catodos) is essential for removing deposited copper from stainless steel cathode plates. A well-designed stripping line can significantly improve production efficiency, product consistency, and operational safety.
This article provides a detailed step-by-step breakdown of the full cathode stripping process based on PRS’s modular system. A demonstration video is included below for reference.
Step-by-Step Breakdown of the Cathode Stripping Process
1. Cathode Receiving and Washing
The process begins with the receiving and washing unit, which prepares the cathode for stripping.
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Cathodes are automatically centered by guiding components during unloading.
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The plate passes through three sequential rinse zones:
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Stage 1: Reused rinse water
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Stage 2: Moderately clean water
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Stage 3: High-purity rinse water
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This progressive cleaning ensures surface cleanliness and helps protect the stripping blades.
2. Rotating Transfer Arm
After washing, the rotating transfer arm moves the cathode to the stripping station.
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In the featured project, two servo-driven arms are used:
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One rotates 90°, positioned between the receiving conveyor and the stripping station.
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Another rotates 180°, between the blank discharge and reject conveyor.
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Compared to robots, these arms are cost-effective and energy-efficient, making them ideal for plants below 6,000 tons/year capacity.
3. Three-Stage Stripping Station
The stripping station is the heart of the system and uses PRS’s patented three-stage method:
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Stage 1: Pneumatic hammer tapping to loosen the copper sheet (95% success rate).
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Stage 2: Blade insertion with partial downward cut and outward peel (up to 99% success).
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Stage 3: Full-length vertical blade cut when previous steps fail (ensures 100% detachment).
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Sensor feedback controls whether the next stage is needed, ensuring low energy usage and extended equipment life.
4. Blank Cathode Discharge Conveyor
Once stripping is completed:
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The stainless steel cathode blank is discharged via a conveyor system.
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It is then routed back to the electrolysis process or moved to inspection.
5. Copper Sheet Buffer and Stacking
After stripping, the copper sheets slide into a buffer chute and are transferred to the stacking area.
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A shock-absorbing chute ensures gentle handling of copper sheets.
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The stacking unit aligns and stacks sheets automatically into uniform bundles.
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Future modules like weighing, bundling, sampling, and labeling can be integrated as needed.
Flexible and Scalable Design
PRS’s cathode stripping machine is built for modularity:
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A base configuration with six units is sufficient for 5,000–10,000 tons/year.
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Additional modules (e.g., reject conveyors, auto-sampling, or labeling systems) can be added without redesign.
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This design ensures future upgrades are seamless and cost-effective.
Real-World Benefits
Clients using PRS stripping systems report measurable improvements:
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Reduced manual labor and operating time
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Higher stripping precision and copper purity
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Lower equipment wear and power consumption
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Better layout adaptability and long-term cost savings
