Copper Electrowinning Circuit Design: Optimised Costing as a Function of Cell Arrangement, Productivity, Rectiformer Size and Throughput

Sizing, designing and costing copper electrowinning circuits require a thorough understanding of fundamental parameters and practical needs to optimize capital costs and productivity. This study aims to establish relationships among cell house configurations, the number of cathodes per cell, and rectifier-transformer sizes throughout various production tonnages. A high-level selection guide is provided to assist in identifying cost-effective copper electrowinning circuit designs tailored for specific production rates. The methodology involves multi-variable analyses and mapping of critical parameters, including cell house layouts, crane and stripping machine productivity, alongside sensitivity analyses using data tables. The compiled model delineates an optimal operational bandwidth for productivity and capital costs, applicable for production throughputs ranging from 10 ktpa to 200 ktpa of cathode plated copper. The data culminate in a comprehensive overview validated against existing installations across the globe, revealing that effective designs typically do not exceed 84 cathodes per cell. This paper facilitates a deeper understanding of the operational limits while providing a framework for enhanced circuit design efficiency and cost management.