Department of Materials Science and Metallurgical Engineering

Developments in copper electrowinning technology in recent decades have shown significant advantages of permanent cathode technology and the use of edge strips on cathode blanks. The aim of this research was to determine the viability of sustainably and cost-effectively converting an existing low current density starter-sheet copper electrowinning operation at Rustenburg Base Metals Refinery, which is labor-intensive and highly dependent on structural integrity and equipment reliability. An eighteen-harvest cycle permanent cathode pilot trial was conducted in the starter-sheet tankhouse under existing plant operating conditions, allowing for the assessment of the ability to consistently produce good quality copper. The results indicated that the implementation of permanent cathodes could optimize the operational excellence of the electrowinning process, presenting a potential pathway to enhance productivity and reduce labor dependency in the copper production sector. The research contributes to the body of knowledge on sustainable practices in metallurgical engineering and suggests further directions for technology adoption in the refining process.