Copper Manufacturing

Process
General Flowsheet of Process
Concentrate
Roasting
Smelting

SO2
Slag
SO2
Slag

Converting
Anode shaft
furnace
Anode casting
Copper anodes
Electrolyte
Electrolysis

NiSO4
Electrolyte
purification

Cu solids
CuSO4

Copper cathodes
Anode slime
treatment
Melting and
casting

Precious
metals

Anode scraps

Copper
V00664/01 (10.2000) Copyright Sulzer Pumps Finland Oy 8

Copper Manufacturing Process

Pumps in Copper Electrolyse Process
Starting sheets

Anodes

Electrolyte from
purification

+ Cells

+ Cells

+ Cells

Anode scraps
Copper cathodes to
melting and casting
3.WSP/T or WKP/T

Electrorefining
Electrolyte to
purification
1.APP/T Circulating liquor tank
Liquid

2.APP/T

Filtration
4.WPP/T
Anode slime
to treating

V00664/02 (10.2000) Copyright Sulzer Pumps Finland Oy 9

Copper Manufacturing Process

Pumps in Copper Electrolyse Process
pH

Solids

1 Electrolyte

<1

Sb, Bi
10 mg/l

60-70/
140-158

1230/
77

20/
66

APP/T

Open1

Doubl. mech.2 A890 3A

(MR22) or
Dyn. (DS02)

Electrolyte
circulate

<1

Sb, Bi
10 mg/l

60-70/
140-158

1230/
77

30/
98

APP/T

Open1

Doubl. mech.2 A890 3A

(MR22) or
Dyn. (DS02)

Purification
feeder

<1

Cu, Ni,
precious metals

60/
140

1500/
94

35/
115

WSP/T Open
/WKP/
T

60/
140

1500/
94

35/
115

WPP/T Open

H2SO4 140...180 g/l

2 Electrolyte
H2SO4 140...180 g/l

3 Anode slime
H2SO4 140...180 g/l

4 Anode slime
H2SO4 140...180 g/l

<1

Cu, Ni,
precious metals

Temp. Density Typical Pump Impeller

(oC, oF) (kg/m3, head
type
type
3
lb/ft
m, ft

Seal type

Material3

Liquid

Single
mechanical
(ME03)5

654SMO4

Duty

Anode Slime
from Electrolyse
Cells

Doubl. mech.2
4
Filter feeder to
(MR22) or 654SMO precious metals
Dyn. (DS02)

1) Crystallization
2) Check always the entraining air through the static seal. The air harms the
process
3) Material recommendation is only for specified application
4) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has
granted Sulzer Pumps Finland Oy licence to produce this material
5) The shaft seal is not needed with WKP/T
6) The floating installation of the pumps in Electrolyse process

V00664/03 (10.2000) Copyright Sulzer Pumps Finland Oy 10

Copper Manufacturing Process

Pumps in CuSO4 Crystallization Process
Crystallization

Electrolyte from
electrolysis
1.APP/T

Steam

2.APP/T

3.APP/T

Mother liquor

Mother liquor separation

(centrifuge)
Water
CuSO4 sedimentation

To Cu removal
(electrolysis)
4.APP/T

CuSO4 -crystals
V00664/04 (10.2000) Copyright Sulzer Pumps Finland Oy 11

Copper Manufacturing Process

Pumps in CuSO4 Crystallization Process
Liquid

pH

Solids

Temp. Density Typical

o
o
3
( C, F) (kg/m , head
3
lb/ft ) m, ft

Pump
type

Impeller
type

1 Electrolyte
H2SO4 140...180 g/l

<1

Sb, Bi
10 mg/l

60/
140

1230/
77

18/59

APP/T

Open1

2 Cu-solution
H2SO4 140...180 g/l

<1

Cu, Ni

50/
122

1340/
84

17/56

APP/T

Open

3 CuSO4-solution
H2SO4 140...180 g/l

<1

Cu, Ni

50/
122

1560/
97

20/66

APP/T

Open

4 Cu-solution
H2SO4 250 g/l

<1

Cu, Ni

50/
122

1340/
84

20/66

APP/T

Open

Seal type

Doubl. mech.2
(MR22) or
Dyn. (DS02)

Material

Duty

A890 3A

Crystallizer feeder

Double mech.
(MR22)

A890 3A

Circulation

Double mech.
(MR22)

A890 3A

Crystallizer
discharger

Doubl. mech.2
(MR22) or
Dyn. (DS02)

A890 3A

Cu removal
feeder

1) Crystallization
2) Check always the entraining air through the static seal. The air harms the
process
3) Material recommendation is only for specified application

V00664/05 (10.2000) Copyright Sulzer Pumps Finland Oy 12

Copper Manufacturing Process

Pumps in Cu Removal by Electrolyse Process
Electrolyte from
CuSO4-crystallization

1.APP/T

+ I Cells

Cu-solids

+ II Cells

+ III Cells

Cu-solids

Cu-solids

Storage
2.APP/T

3.APP/T
Electrolyte to
evaporation
4.APP/T
V00664/06 (10.2000) Copyright Sulzer Pumps Finland Oy 13

Copper Manufacturing Process

Pumps in Cu Removal By Electrolyse Process
Liquid

pH

Solids

Temp. Density
o
o
3
( C, F) (kg/m ,
3
lb/ft )

Typical Pump Impeller

head
type
type
m, ft

1 Cu solution
H2SO4 250 g/l

<1

Cu, Ni

50-60/ 1230-1340/
122-140 77-84

15/
49

APP/T

Open

2 Cu-solution
H2SO4 250 g/l

<1

Cu, Ni

50-60/ 1230-1340/
122-140 77-84

15/
49

APP/T

Open1

3 Cu-solution
H2SO4 250 g/l

<1

Ni, Cu

50-60/ 1230-1340/
122-140 77-84

15/
49

APP/T

Open

4 Cu free solution
H2SO4 250 g/l

<1

Cu ~ 2 g/l

50-60/ 1230-1340/
122-140 77-84

15/
49

APP/T

Open1

Seal type

Doubl. mech.2
(MR22) or
Dyn. (DS02)
Doubl. mech.2
(MR22) or
Dyn. (DS02)
Doubl. mech.2
(MR22) or
Dyn. (DS02)
Doubl. mech.2
(MR22) or
Dyn. (DS02)

Material

Duty

A890 3A

1st stage cells

pumping tank feeder

A890 3A

2nd stage cells

pumping tank

A890 3A

3rd stage cells

pumping tank

A890 1B

Evaporator feed

1) Crystallization
2) Check always the entraining air through the static seal. The air harms the
process
3) Material recommendation is only for specified application

V00664/07 (10.2000) Copyright Sulzer Pumps Finland Oy 14

Copper Manufacturing Process

Pumps in Electrolyte Evaporation Process
2.APP/T
Electrolyte from Cu removal
(electrowinning)

Condensate
Droplet
separator
Evaporator
Steam
1.APP/T
Heater

Condensate

3.

4.APP/T
Condensate
5.

Filtration

NiSO4

Filtrate
tank
6.
Sulphuric acid
to process
V00664/08 (10.2000) Copyright Sulzer Pumps Finland Oy 15

Copper Manufacturing Process

Pumps in Electrolyte Evaporation Process
Liquid

pH

Solids

1 Cu free
H2SO4 250 g/l

<1

2 Condensate
H2SO4 60 g/l

Seal type

Material 1

Temp.
(oC, oF)

Density
(kg/m3,
3
lb/ft )

Typical
head
m, ft

Pump
type

Impeller
type

Ni
1 mg/l

60/
140

1230/
77

20/
66

APP/T

Closed

<1

50/
122

1000/
62

15/
49

APP/T

Closed

3 Ni-solution
H2SO4 300 g/l

<1

Ni
5 mg/l

120/
248

1500/
94

3.5/
11,5

Si-iron

4 H2O

90/
194

1000/
62

30/98

APP/T

Closed

Dynamic seal
(DS01)

A890 3A

Condensate

5 NiSO4
H2SO4 300 g/l

<1

Ni
5 mg/l

70/
158

1500/
94

20/
66

Filter feeder

6 H2SO4 300 g/l

<1

60/
140

1600/
100

25/82

NiSO4 filtrate

Doubl. mech.2
(MR22) or
Dyn. (DS02)

Duty

654SMO Feeder

Dynamic seal A890 3A

(DS01)

Condensate

Circulation

1) Material recommendation is only for specified application

2) Check always the entraining air through the static seal. The air harms the
process
3) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has
granted Sulzer Pumps Finland Oy licence to produce this material

V00664/09 (10.2000) Copyright Sulzer Pumps Finland Oy 16

Copper Manufacturing Process

Pumps in Anode Slime Treatment Process
Anode
slime from
electrolyse

Autoclave
Filtration

Precipitation

Filtration

1.WPP/T
Se solids

2.WPP/T
Roasting
furnace

3.APP/T
Liquid

Electrolysis
+

Converting
and casting

Te solids

Leaching

Cementation

Precipitation

Ag solids
4.
Au solids

Rh solids
5.

6.

Solution

Precipitation

7.
Au solids

Pt solids
Filtration

Filtration
8.

Waste
solution

V00664/10 (10.2000) Copyright Sulzer Pumps Finland Oy 17

Copper Manufacturing Process

Pumps in Anode Slime Treatment Process
Liquid

pH

Solids

Temp. Density
(oC, oF) (kg/m3,
lb/ft3)

Typical Pump
head
type
m, ft

Impeller
type

Seal type

Material

Duty

1 Anode slime
H2SO4 ~200 g/l

<1 Se,Te,BaSO4, 80/

176
PbSO4

1500/
94

20/66

WPP/T

Closed

Double mech. 654SMO2

(MR22)

Treatment feeder

2 Te-solution
H2SO4 ~200 g/l

<1

Se, Ag, Te

80/
176

1400/
88

20/66

WPP/T

Closed

Double mech. 654SMO2

(MR22)

Te filter

3 Te free
H2SO4 ~200 g/l

<1

80/
176

1400/
88

30/99

APP/T

Closed

2
Dynamic seal 654SMO
(DS01)

Electrolyte
purification

4 Ag free
H2SO4 ~1300 g/l

<1

Ag

70/
158

1700/
106

20/66

Precipitation

5 Rh free
H2SO4 ~1300 g/l

<1

50/
122

1300/
81

30/99

Process circulation

6 Ag free
HCl ~200 g/l

<1

70/
158

1500/
94

15/49

Feed 2nd stage

Au separation

7 Au free
HCl ~200 g/l

<1

60/
140

1700/
106

20/66

Pt filter

8 Noble metal free

HCl ~200 g/l

<1

50/
122

1000/
62

20/66

9 H2SO4 and Se
solids mixture

<1

1-2 %

80/
176

1400/
87

36/118 APP/T

Closed

Double mech. Hastelloy

E8
(MR22)

Waste solution
Se roasting fuurnace
liquid

1) Material recommendation is only for specified application

2) Avesta 654SMO is a trade mark owned by Avesta Sheffield which has granted Sulzer Pumps Finland Oy licence to produce this material
V00664/11 (10.2000) Copyright Sulzer Pumps Finland Oy

Application
Report

1(1)

AHLSTAR APP for Electrolyte Pumping

Anodes

Starting sheets

Electrolyte from
purification
+ Cells

+ Cells

Anode scraps
Copper cathodes to
melting and casting

+ Cells

Filtration

Electrolyte to
purification

APP22-80

AHLSTAR APP in Copper Electrolysis Process.

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor..........................
Speed.......................
Material.....................
Sealing......................

APP22-80
Special open impeller
APP Process pump
15 kW (20 hp)
1740 rpm
ASTM890 Grade3A
Double mechanical seal

Anode slime to treatment

An APP31-125 pump was installed to pump
electrolyte from the filtration of anode slime to
back to electrorefining. The pump is equipped
with a seal which prevents access of air into
the pumped liquid.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

33.3 l/s (528 USGPM)

15 m (49 ft)
Electrolyte
1
60 oC (140 oF)
13 %
1400 kg/m3 (88 lb/ft3)

N03845 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Application
Report

1(1)

AHLSTAR APP for Electrolyte Pumping

Anodes

Electrolyte from
purification

Starting sheets

Cells

Cells

Copper
cathodes to
Anode
scraps
melting and casting

Electrolyte to
purification
APP31-125

AHLSTAR APP in Copper Electrolysis Process.

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP 31-125
Open
APP Process pump
22 kW (16.4 hp)
1460 rpm
ASTM 743 CF-8M
Double mechanical seal

Filtration

Anode slime to treatment

An APP31-125 pump was installed to pump

electrolyte from a circulating liquor tank back to
electrorefining. The pump has been running in
this position for 14 years without bigger problems. The pump is equipped with a seal which
prevents acces of air into the pumped liquid.

Process Data
Q................................
H................................
Liquid.........................
pH..............................
Temperature..............
H2SO4 content ..........
Density......................

42 l/s (667 USGPM)

20 m (66 ft)
Electrolyte
1
70 oC (158 oF)
14.5 %
1230 kg/m3 (77 lb/ft3)

N03846 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Application
Report

1(1)

AHLSTAR APP for Electrolyte Pumping

Anodes

Electrolyte from
purification

Starting sheets

Cells

Cells

Anode scraps
Copper cathodes to
melting and casting

APP11-32

Electrolyte to
purification

Filtration

AHLSTAR APP in Copper Electrolysis Process.

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP11-32
Closed impeller
APP Process pump
4 kW (3 hp)
2905 rpm
ASTM 890 Grade 3A
Double mechanical seal

Anode slime to treatment

An APP11-32 pump was installed to pump electrolyte from a circulating liquor tank to purification. The application is quite corrosive and contains many kind of impurities. Duplex stainless
steel was chosen to manage the corrosion.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

1 l/s (16 USGPM)

30 m (98 ft)
Electrolyte
1
60 oC (140 oF)
14.6 %
1230 kg/l (77 lb/ft3)

N03847 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Electrolyte Pumping

Crystallization

Electrolyte from
electrolysis

APP22-32

Steam

Mother liquor

CuSO4
Sedimentation
Mother liquor separation (centrifuge)

Water

To Cu removal
(electrolysis)

AHLSTAR APP in CuSO4 Crystallization Process.

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.........................
Material.....................
Sealing......................

APP22-32
Open impeller
APP Process pump
3 kW (2.2 hp)
1500 rpm
ASTM 890 Grade 3A
Double mechanical seal

CuSO4 crystals
An APP11-32 pump was installed to pump electrolyte to crystallization. The application is quite
corrosive and contains many kinds of impurities. Duplex stainless steel was chosen to manage the corrosion and solids in the pumped liquid.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

2.8 l/s (44 USGPM)

18 m (59 ft)
Electrolyte
1
60 oC (140 oF)
14.6 %
1230 kg/m3 (77 lb/ft3)

N03848 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Application
Report

1(1)

AHLSTAR APP for Cu Solution Pumping

Crystallization

Electrolyte from
electrolysis

Steam

Mother liquor

APP31-100

CuSO4
Sedimentation
Mother liquor separation (centrifuge)

Water

To Cu removal
(electrolysis)

AHLSTAR APP in CuSO4 Crystallization Process.

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP31-100
Open impeller
APP Process pump
22 kW (16.4 hp)
1470 rpm
ASTM 890 Grade 3A
Double mechanical seal

CuSO4 crystals
An APP31-100 pump was installed to circulate
Cu solution in a crystallizer. The pumped liquid
contains crystallizable solids which can crystallize inside the pump. This means that the shaft
seal should be selected very carefully. Readyfitted non-flowing double mechanical seal was
selected because of a higher operating temperature in the seal faces on the product side.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

42 l/s (667 USGPM)

17 m (56 ft)
Cu solution with solids
1
50 oC (122 oF)
14.6 %
1340 kg/m3 (84 lb/ft3)

N03849 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Application
Report

1(1)

AHLSTAR APP for CuSO4 Solution Pumping

Crystallization

Electrolyte from
electrolysis

Steam

Mother liquor
APP22-32

CuSO4
Sedimentation
Mother liquor separation (centrifuge)

Water

To Cu removal
(electrolysis)

AHLSTAR APP in CuSO4 Crystallization Process.

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP22-32
Open impeller
APP Process pump
3 kw (2.2 hp)
1430 rpm
ASTM 890 Grade 3A
Double mechanical seal

CuSO4 crystals
An APP22-32 pump pumps crystallized CuSO4
to sedimentation. The solids content is about
16 % and crystallization is still going on inside
the pump. The shaft seal has to be selected
very carefully. Ready-fitted non-flowing double
mechanical seal was selected because of a
higher operating temperature in the seal faces
on the product side.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

0.5 l/s (8 USGPM)

20 m (66 ft)
CuSO4 solution with solids
1
50 oC (122 oF)
14.4 %
1560 kg/m3 (97 lb/ft3)

N03850 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Application
Report

1(1)

AHLSTAR APP for Cu Solution Pumping

Crystallization

Electrolyte from
electrolysis

Steam

Mother liquor

CuSO4
Sedimentation
Mother liquor separation (centrifuge)

Water

APP22-32

AHLSTAR APP in CuSO4 Crystallization Process.

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP22-32
Open impeller
APP Process pump
3 kW (2.2 hp)
1430 r/min
ASTM 890 Grade 3A
Double mechanical seal

To Cu removal
(electrolysis)

CuSO4 crystals
An APP22-32 pump pumps Cu solution back to
sedimentation. The sulphuric acid concentration
is quite high in this application, about 19 %. If
the temperature rises about 15 to 20 oC, then
super duplex stainless steel should be selected. APP22-32 from normal duplex stainless
steel has been working for about six years without having to replace the volute casing.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

1.4 l/s (22 USGPM)

15 m (49 ft)
Cu solution
1
50 oC (122 oF)
19 %
1340 kg/m3 (84 lb/ft3)

N03851 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Cu Solution Pumping

Electrolyte from CuSO4 crystallization

I Cells
+

Cu solids

II Cells

III Cells

Cu solids

Cu solids

Storage
APP11-32

Electrolyte to
evaporation
AHLSTAR APP in Cu Removal by Electrolysis

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor........................
Speed.......................
Material.....................
Sealing......................

APP11-32
Closed impeller
APP Process pump
7.5 kW (5.6 hp)
2950 r/min
ASTM 890 Grade 3A
Double mechanical seal

An APP11-32 pump pumps Cu solution to electrolysis cells to crystallize Cu to solids. The

pump has been running for 12 years now. The
volute casing of the pump was replaced after 8
years of operation. Air is not permitted in the
electrolysis process step. This is why a readyfitted non-flowing double mechanical seal was
selected.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

1.4 l/s (22 USGPM)

50 m (164 ft)
Cu solution
1
60 oC (140 oF)
19 %
1340 kg/m3 (84 lb/ft3)

N03852 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Cu Solution Pumping

Electrolyte from CuSO4 crystallization

I Cells
+

Cu solids

II Cells
+

Cu solids

III Cells
+

Cu solids

Storage
APP22-40

Electrolyte to
evaporation
AHLSTAR APP in Cu Removal by Electrolysis

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP22-40
Closed impeller
APP Process pump
3 kW (2.2 hp)
1440 rpm
ASTM 890 Grade 3A
Double mechanical seal

An APP11-32 pump pumps Cu solution to electrolysis cells to crystallize Cu to solids. Air is

not permitted in the electrolysis process step.
This is why a ready-fitted non-flowing double
mechanical seal was selected.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

6 l/s (95 USGPM)

15 m (49 ft)
Cu solution
1
60 oC (140 oF)
19 %
1340 kg/m3 (84 lb/ft3)

N03853 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Application
Report

1(1)

AHLSTAR WKP Cantilever for Floor Water Pumping

Electrolyte from CuSO4 crystallization

I Cells
+

Cu solids

II Cells

III Cells

Cu solids

Cu solids

Storage
To water
treatment
WKP23-250

Electrolyte to
evaporation

AHLSTAR WKP in Cu Removal by Electrolysis

Pump Data
Pump......................... WKP23-50
Impeller..................... Open impeller
Type.......................... WKP Wear resistant
cantilever pump
Motor........................ 11 kW (15 hp)
Speed....................... 1450 r/min
Material..................... ASTM 890 Grade 3A

A WKP wear resistant cantilever pump was installed to pump floor water in Cu removal by
electrolysis. The pump has been running for 4
years now. The volute casing of the pump is the
same after 4 years operation. The pump doesnt
need shaft seal or support bearings at the bottom side.

Process Data
Q............................... 5.5 l/s (87 USGPM)
H............................... 28 m (92 ft)
Liquid........................ Floor water
pH............................. 7
Temperature.............. 20 oC (68 oF)
Solids content .......... 1 - 5 %
Density...................... 1050 kg/m3 (66 lb/ft3)

N15393 / Metal, Copper en (12.2003), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products.
Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Cu-Free Solution Pumping

Droplet
separator

Electrolyte from Cu removal

(electrowinning)

Condensate
Steam
APP22-32

Heater
Evaporator
Condensate

Filtration

NiSO4

Filtrate tank
Sulphuric acid to process
AHLSTAR APP in Electrolyte Evaporation

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP22-32
Open impeller
APP Process pump
3 kW (2.2 hp)
1430 rpm
ASTM 890 Grade 3A
Double mechanical seal

An APP22-32 pump pumps Cu-free solution to

electrolyte evaporation. The pump has been running for about 6 years without having to change
the volute casing.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

1.4 l/s (22 USGPM)

20 m (66 ft)
Cu-free solution
1
60 oC (140 oF)
19 %
1230 kg/m3 (77 lb/ft3)

N03854 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Condensate Pumping

Droplet
separator

Electrolyte from Cu removal

(electrowinning)

Condensate
Steam
Heater
Evaporator
Condensate
APP11-32
Filtration

NiSO4

Filtrate tank
AHLSTAR APP in Electrolyte Evaporation

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP11-32
Open impeller
APP Process pump
4 kW (3 hp)
2880 rpm
ASTM 890 Grade3A
Double mechanical seal

Sulphuric acid to process

An APP11-32 pump pumps condensate from
electrolyte evaporation step in a Cu manufacturing process. Duplex stainless steel and double mechanical seal were selected. The pump
has been running for 6 years without bigger problems.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
Solids content ..........
Density......................

0.8 l/s (13 USGPM)

30 m (99 ft)
Condensate
7
90 oC (194 oF)
0%
1000 kg/m3 (62 lb/ft3)

N03855 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Condensate Pumping

Droplet
separator

Electrolyte from Cu removal

(electrowinning)

APP11-32

Condensate
Steam
Heater

Evaporator

Condensate
Filtration

NiSO4

Filtrate tank
Sulphuric acid to process
AHLSTAR APP in Electrolyte Evaporation

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP11-32
Open impeller
APP Process pump
2.20 kW (1.6 hp)
1425 rpm
ASTM 890 Grade 3A
Single mechanical seal

An APP11-32 pump pumps condensate from

electrolyte evaporation step in a Cu manufacturing process. The pumped liquid contains 6 %
of sulphuric acid. Duplex stainless steel and single mechanical seal were selected. The pump
has been running for 6 years without bigger problems.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

0.13 l/s (2 USGPM)

15 m (49 ft)
Condensate
1
50 oC (122 oF)
6%
1100 kg/m3 (68 lb/ft3)

N03856 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Te Solution Pumping

Autoclave
Anode slime from
electrolysis

Filter Precipitation

Se solids
Roasting
furnace

Filter

Liquid
APP11-40
+

Converting
and casting

Rh solids
Ag solids
Au solids

AHLSTAR APP in Anode Slime Treatmement Process

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor.........................
Speed.......................
Material.....................
Sealing......................

APP11-40
Open impeller
APP Process pump
15 kW (11 hp)
2920 rpm
ASTM 890 Grade 3A
Double mechanical seal

An APP11-40 pump pumps Te solution to Te

solids filtration. The pumped liquid contains 14%
of sulphuric acid and Te solids, also Cu and Ni
solids. Duplex stainless steel and double mechanical seal were selected. The pump has
been running for 5 years.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

5.5 l/s (87 USGPM)

50 m (164 ft)
Te solution with solids
1
90 oC (198 oF)
14 %
1400 kg/m3 (88 lb/ft3)

N03857 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

Application
Report

1(1)

AHLSTAR APT for Anode Slime Pumping

Anode slime from
electrolysis

Autoclave
Filter Precipitation

Filter

APT55-12

Se solids
Roasting
furnace

Liquid
+

Converting
and casting

Rh solids
Ag solids
Au solids

AHLSTAR APT in Anode Slime Treatmement Process

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor..........................
Speed.......................
Material.....................
Sealing......................

APT55-12
Open impeller
APT Process pump
400 hp (298 kW)
1180 rpm
ASTM 890 Grade 3A
Double mechanical seal

An APT pump pumps anode slime slurry to filtration. The pumped liquid contains 14% of sulphuric acid and different kinds of solids, about
30%. Duplex stainless steel and double mechanical seal were selected. The pump has been running for 10 years.

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

7700 USGPM (485 l/s)

150 ft (46 m)
Anode slime
1
120 oF (49 oC)
13 %
94 lb/ft3 (1500 kg/m3)

N03858 / Metal, Copper en (12.2001), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

1(1)

Application
Report

AHLSTAR APP for Anode Slime Pumping

Anode
slime from
electrolyse

Autoclave
Filtration

Precipitation

Filtration

Gas

Ejector

Te solids
Se solids
Roasting
furnace

Liquid
Electrolysis
+
+

APP32-80
Converting
and casting

Leaching

Cementation

Precipitation

Ag solids

Se Filter
Au solids

Rh solids
Solution
Precipitation

Au solids

Pt solids
Filtration

AHLSTAR APP in Anode Slime Treatment Process

Pump Data
Pump.........................
Impeller.....................
Type..........................
Motor..........................
Speed.......................
Material.....................
Sealing......................

APP32-80
Open impeller
APP Process pump
2230 kW (30 hp)
1460 rpm
Hastelloy E8
Double mechanical seal

Process Data
Q...............................
H...............................
Liquid........................
pH.............................
Temperature..............
H2SO4 content ..........
Density......................

Filtration

Waste
solution

Gas from Selenium roasting furnace mixed with

sulphuric acid and water was pumped with AHLSTARTM APP process pump. The first material
selection was Hastelloy B type material which
was lost in couple of months. Hastelloy B material was tested first because of good experience
in other process equipments. Hastelloy B was
changed to Hastelloy E8 type of material which
is nickel alloyed material also. The pump is
equipped with double mechanical seal. APP
pump from Hastelloy E8 material has been running three years without problems. The pump is
still running.

17 l/s (269 USGPM)

36 m (118 ft)
Sulphuric acid
1
80 oC ( 176 oF)
25 - 30 %
1400 kg/m3 (87 lb/ft3)

N03882 / Metal, Copper en (11.2002), Copyright Sulzer Pumps Finland Oy. This report is a general product presentation. It does not
provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

copper.xls

03/08/00 13:26

Sulzer Pumps Finland Oy

Pump Lifetime Costs Profile
Industry

Copper

Segment

2744

No. of pumps

25 (150)

Pump types

APP, WPP

ELECTROLYSE

Pump average lifetime (yr)

Volute Casing

Impeller

Casing Cover

Seal

9 yr.

5,3 yr.

5,3 yr.

2 yr.

Average Liftime Number of pumps

9 yr.

11,8

Remarks
Because of low voltage level in electrolyse, avoid
electrical corrosion

Cu REMOVAL by

11,5 yr.

8,8 yr.

8,8 yr.

2 yr.

11,5 yr.

Copper sulfate is reason for wearing

13,8 yr.

12,4 yr.

12,4 yr.

3,2 yr.

13,8 yr.

Some applications are very wearing because of high

16 yr.

13 yr.

13 yr.

2,3 yr.

16 yr.

8,7 yr.

5,7 yr.

5,7 yr.

2 yr.

8,7 yr.

ELECTROLYSE
ELECTROLYTE
EVAPORATION
CuSO4

acid and temperature values.

CRYSTALLIZATION
ANODE SLIME

applications

TREATMENT
ADDITIONAL INFO

Crystallized particles makes wearing in some

Low pH, high temperature and solid particles make
some wearing

Solid particles (Antimony, Bismuth and Arsenic) are cathered to the inside of pipelines and at least once a year the solid matter has to be removed off by
high pressure washing.
The motor and baseplate have to be protected by cover to avoid external corrosion in case if pumped liquid has got outside.