BROCHOT LIMPACT June 2009 1
WHO IS BROCHOT LIMPACT 2
BROCHOT GROUP • BROCHOT – Designer/Supplier of custom process/handling equipment for Non Ferrous Metals Industry. – 35 years experience. • Annual Sales 50 MM Euros • Brochot Group - 470 employees. • Head Office – Paris • Work Shop – France, Canada • Sales/Service Companies in Middle East, China and Russia • ISO 9001Qualification. • CE regulations compliant. 3
Krasnoyarsk Engineering Co (KEC) S.E.E.E. 4 KGHM Copper Project – May 2009
Brochot – Limpact Synergy for Non Ferrous Metals Refining • Limpact – 37 years of supplying cathodes to non- ferrous metal refineries world-wide. • Brochot – 50 years world leader in custom engineering & fabrication of process materials handling equipment. • Combined Synergy – Offer a complete package • Integrated systems solution provider to Copper & Zinc refineries. • Cathodes, Equipment & Automation 5
BROCHOT WORKSHOP WINGLES FRANCE Brochot Equipment workshop is located in Wingles, northern France: • 10,000 m2 fabrication, assembly and test facility. – Fully equipped machining center. – Crane capacity up to 40 Tons. • 8 meters clearance under the hook. • 22,000 m2 total plant area. – (10,000 m2 covered and 12,000 m2 open.) Fully equipped in-house facility allows Brochot to meet very tight delivery schedules. 6
LIMPACT – Cathode Fabrication Facility in Canada • 3500 m2. Cathode fabrication and assembly facility. • Automated Cathode Welding. • ISO 9001-2000 Certified 7
TECHNOLOGY 8
Process of Explosion Bonding 9
Unique, Value-added Cathode Technologies Provide Competitive Advantage • Explosion Bonding Technology creates a “solid state” bond between dissimilar metals – Stainless steel blade and copper hanger bar • Edge Strips are mechanically pinned and adhesive to ensure edge strip stays in place. • Inherent cathode straightness is assured. 10
Limpact – Explosion Bonded Cathodes • Metallurgical bond is created between two dissimilar metals – electron sharing across the bond surface • Two dissimilar metals unite by thrusting both metals together by the detonation of a covering explosive. • Excellent Corrosion Resistance – No dissimilar welds therefore NO galvanic corrosion – No deterioration of electroplated copper hanger bar system 11
Electrical Efficiency • With our ability to obtain a metallurgical bond between the two dissimilar metals, there is virtually no electrical resistance at the interface. • In testing done at the independent Ontario Research Foundation, there was no contact resistance found across the bond interface under test conditions with a sensitivity to detect 0.02 micro-ohms/sq.in. Therefore there is less heating of the contact and increased electrical efficiency 12
Stainless Steel Cathode Performance • Cathode Design - Explosion Bonded Tube over Solid Copper Hanger Bar • Customer measured voltage drop after 24 hrs plating: – Test cathode 0 hrs plating: 19 mv loss, 281 a/m2 – Test cathode 24 hrs plating: 22.6 mv loss, 307 a/m2 13
Bond Strength • Impact bonding provides a shear strength across the dissimilar metal bond approximately equal to the shear strength of the metal itself. • Tests show that the shear strength of the LIMPACT contact is 11,000 p.s.i. (773 kg/sq.cm.) to allow shear loading of about 28,000 lbs (12,700 kg) across the bond face between the two metals. 14
PERMANENT STAINLESS STEEL COPPER CATHODES 15
Limpact addresses Your Cathode Quality Issues Limpact Cathode Issues Solution ¤ Electrical Efficiency ¤ Efficient Copper Contact ¤ Corrosion Damage ¤ Lower Electrical Resistance ¤ Maintenance Cost ¤ Longer Cathode Life ¤ Cathode Copper Quality ¤ Mechanical Strength 16
Limpact Delivers Benefits : � Energy Savings � Increase Cathode Life Time � Decrease Maintenance Cost � Outstanding Copper Quality 17
Stainless Steel Tube • Explosion bonded Stainless Steel tube fitted over solid copper bar • Seal tube ends with a Polyurethane sealant • Stainless Steel to Stainless Steel welds 18
Stainless Steel Tube - Tube-end can have different designs 19
Explosion-Bonded Copper to Stainless Steel Limpact headbar with stainless steel tube cut and pealed back to show explosion-bonded surface Bonded surface is uniform and stronger than the yield strength of the Copper 20
Hanger Bar Life > 15 + years 21
Stainless Steel Cathode 22
Stainless Steel Cathode Components 23
CATHODE COMPARISON - COMPETITORS 24
Cathodes Comparison – Competitor 1 LIMPACT Explosion-Bonded Cathode Competitor Cathode with hollow Solid copper bar and stainless to stainless Stainless Steel hanger bar encapsulated Welds yield electrical efficiency and long life with an electroplated copper coating – copper coating corrodes over time 25
Cathodes Comparison – Competitor 2 LIMPACT Explosion-Bonded Cathode Competitor Cathode with dissimilar Weld material Stainless steel to stainless weld obliterated through galvanic corrosion 26
Cathodes Comparison Performance Refurbishment of Performance hanger bar system Performance Competitor 1 without Electroplated hanger bar system refurbishment Electroplated copper corrodes overtime. Deterioration of hanger bar system occurs – operator must plan for refurbishment. Year’s Competitor 2 Sudden failure Performance Refurbishment Solid copper bar system Galvanic corrosion due to dissimilar welds (even when weld is encapsulated in Stainless Steel sheathing) failure unpredictable Year’s Performance Limpact No corrosion repair reported for over 15 years. Superior performance over Constant Superior Performance time 27 Year’s
CATHODE STRIPPING MACHINE 28
Cathode Stripping Machines LOW CAPACITY SYSTEMS •Semi-Automatic 60 Cathodes per Hour •Various options to reduce cost •In Line Layout or « U » shaped layout to best fit plant layout HIGH CAPACITY SYSTEMS •Fully Automatic 600 Cathodes per Hour •Options – corrugation; sampling; SCADA; cathode tracking etc •Robotic or traditonal « U » shaped designs available 29
Low Capacity Cathode Stripping Machine Semi-Automatic 60 Cathodes per hour: • Cathode Infeed Conveyor • Cathode Washing System • Cathode Transfer System • Semi-Automatic Stripping Station • Copper Sheet Stacking Station • Blank Outfeed Conveyor • Hydraulics Equipment and Electrical Controls 30
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Semi-Automatic Cathode Stripping Station Key Features •Hammer and Flex to strip copper cathodes •Hammer – break initial bond between copper and blank at solution line level. •Flex– adjustable to suit copper plating conditions. •Spring mounted stripping knife •Knife position adjustable – no contact with stainless steel blank •Operator visibility and access. Ease of access to strip « sticky » cathodes. •Copper Discharge •1- By gravity (base configuration) •2- By belt conveyor (optional) 33
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High Capacity Cathode Stripping Equipment Automatic 600 Cathodes per hour: • Cathode Handling system • Cathode Wash System • Automatic Stripping Machine (Robotic) • Copper Sheet System (Sampling, corrugating, stacking) • Blank Outfeed System • Copper Bundle System (weighing, labelling, strapping One (1) operator plus one (1) forklift driver « TACO » Cathode 37
Typical Layout - Linear Typical Layout - Linear 38
Typical Layout - Robotic Typical Layout - Linear 39
Cathode Transfer System Transfer Car SST Transfer racks Wash Booth Infeed Conveyor 40
Wash Booth - Typical 41
Cathode Stripping system - Robotic • The high capacity cathode stripping system consists of one (1) machine with two (2) stripping stations • The stripping machines have the following functions: – Lock head bar of cathode - no stress applied to the weld of the blank during flexing – Flexing – Hammering - combined with flexing operation (can be turned off) – Articulating hooks - separation of copper – Knives - separation of copper from SST blank (as required) – Copper sheet discharge (bottom door + motorised rollers + chute to conveyor) 42
Robotic Cathode Stripping System 43
Cathode Stripping System - Robotic • One robot picks up cathodes from the infeed conveyor and loads them into the alternative stripping machines. • A second robot picks up blanks from the stripping machines and places them onto outfeed conveyor. • Robot can also perform the following operations automatically (on operator’s request): – Rejection of damaged blanks – Insertion of new cathodes • Copper sheets are guided via a chute to the receiving conveyor. 44
Advantages of Robot • Layout flexibility : no need for pits • Reliability : average MTBF = 60,000 hours • Ease of use/programming : no need of training for operators – 2/3 weeks for maintenance staff • Maintenance : Two (2) hours per week • Services readily available • Additional flexibility: blank rejection, new blank introduction, copper rejection, etc… • Adopted by the industry 45
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