BROCHOT LIMPACT June 2009 1 WHO IS BROCHOT LIMPACT 2 BROCHOT - - PDF document

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BROCHOT LIMPACT

June 2009

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WHO IS BROCHOT LIMPACT

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• BROCHOT – Designer/Supplier
• f 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.

BROCHOT GROUP

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KGHM Copper Project – May 2009 Krasnoyarsk Engineering Co (KEC)

S.E.E.E.

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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

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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.

BROCHOT WORKSHOP WINGLES FRANCE

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LIMPACT – Cathode Fabrication Facility in Canada

• 3500 m2. Cathode fabrication and assembly

facility.

• Automated Cathode Welding.
• ISO 9001-2000 Certified

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TECHNOLOGY

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Process of Explosion Bonding

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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.

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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

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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

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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

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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.

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PERMANENT STAINLESS STEEL COPPER CATHODES

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Cathode Issues Limpact addresses Your Cathode Quality Issues

¤ Electrical Efficiency ¤ Corrosion Damage ¤ Maintenance Cost ¤ Cathode Copper Quality

Limpact Solution

¤ Efficient Copper Contact ¤ Lower Electrical Resistance ¤ Longer Cathode Life ¤ Mechanical Strength

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Energy Savings Increase Cathode Life Time Decrease Maintenance Cost Outstanding Copper Quality

Limpact Delivers Benefits:

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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

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Stainless Steel Tube - Tube-end can have different designs

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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

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Hanger Bar Life > 15 + years

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Stainless Steel Cathode

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Stainless Steel Cathode Components

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CATHODE COMPARISON - COMPETITORS

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Cathodes Comparison – Competitor 1

Competitor Cathode with hollow Stainless Steel hanger bar encapsulated with an electroplated copper coating – copper coating corrodes over time LIMPACT Explosion-Bonded Cathode Solid copper bar and stainless to stainless Welds yield electrical efficiency and long life

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Cathodes Comparison – Competitor 2

Competitor Cathode with dissimilar Weld material

• bliterated through galvanic corrosion

LIMPACT Explosion-Bonded Cathode Stainless steel to stainless weld

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Cathodes Comparison Performance

Competitor 1 Electroplated hanger bar system Electroplated copper corrodes

• vertime. Deterioration of hanger

bar system occurs – operator must plan for refurbishment. Competitor 2 Solid copper bar system Galvanic corrosion due to dissimilar welds (even when weld is encapsulated in Stainless Steel sheathing) failure unpredictable Limpact No corrosion repair reported for over 15

• years. Superior performance over

time

Refurbishment of hanger bar system Performance without refurbishment Refurbishment Sudden failure Performance Year’s Year’s Year’s Performance Performance

Constant Superior Performance

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CATHODE STRIPPING MACHINE

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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

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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

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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)

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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

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Typical Layout - Linear

Typical Layout - Linear

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Typical Layout - Robotic

Typical Layout - Linear

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Cathode Transfer System

Infeed Conveyor Wash Booth SST Transfer racks Transfer Car

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Wash Booth - Typical

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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

• ff)

– Articulating hooks - separation of copper – Knives - separation of copper from SST blank (as required) – Copper sheet discharge (bottom door + motorised rollers + chute to conveyor)

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Robotic Cathode Stripping System

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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.

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Advantages of Robot

• Layout flexibility : no need for pits
• Reliability : average MTBF = 60,000 hours
• Ease of use/programming : no need of training for
• perators – 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

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Copper Sheet System

Receiving Conveyor Copper from stripping machines Transfer Carriage Sampling unit Corrugating Press Stacking Robot

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Copper Bundle System

Stacking robot Weighing, labelling, and strapping units

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Options

• Sampling Machine

– Random Punch - 96% of sheet area

• Corrugation of copper sheets
• Strapping options:

– 3rd perpendicular strap – Strip width : 19, 25 or 32 mm – Strip materials : steel and/or plastic

• Storage conveyor - storage positions
• Transfer System – Materials of construction

– SST or Carbon w. expoxy – Base : SST infeed ; Carbon outfeed

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AUTOMATION

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Discrete Controls

Controls and Automation technologists integrate all types

• f controllers such as:
• PLC’s
• Robots
• Drives
• Servos
• Vision Systems
• Safety Devices
• Actuators
• Custom Equipment

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Process Controls

Controls and Automation technologists integrate all types

• f controllers such as:
• PLC / DCS
• SCADA
• Metering
• Flow Control
• PID control
• Fuzzy Logic
• Instrumentation
• Custom Applications

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PLC Programming

We will provide expert assistance when it comes to your PLC and PLC programming needs. Selection of controllers Supply hardware System design System development Detailed logic control flow diagrams Documentation and training PLC programming Process simulation In-house testing Site start-up and commissioning Continual upgrades and modifications

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Electrical Design

We will provide fully engineered, designed drawings for your complete system, from general arrangement drawings to panel drawings ready for panel shop construction. Single line and control schematics Control system and LAN architecture PLC I/O drawings Logic flow diagrams Control panels

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Automation Options

Data collection, analysis and reports

SCADA Other options

Cathode tracking:

Cell performance Electrode performance - maintenance Cathode quality vision inspection system

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Modern Architecture

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D&D’s Copper Processing Experience

Chuquicamata, Chile Collahuasi, Chile Copper Range, US Cypress Miami Mines, Arizona El Abra, Chile Escondida (Oxide), Chile Kennecott, Utah LG/Nippon Metal, Korea Lomas Bayas, Chile Mantos Verde, Chile NICICO – National Iranian Copper Industries Company Noranda CCR, Quebec Phelps Dodge,Texas Radomiro Tomic, Chile Santa Barbara, Chile Tintaya, Peru Zaldivar, Chile

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OTHER SUPPLIES VIA “TEAM NETWORK”

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Cell Block

Electrolytic Cells – ICT or

CTI

SST Cathodes – Limpact Cell Top Furniture – Exma DC Busbars and Power

Supply – G Corner & Limpact

Accessories – Various

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Electrolytic Cells – ICT or CTI

Polymer Concrete Corrosion Resistant Electrical Isolation Integrated Supports Integrated Feed System Integrated Overflows Integrated Guides All dimensions needed by

the process

Fully transportable

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Cell Top Furniture - EXMA

Customized Designs Modular or Full Cell

Length

Accurate Positioning Premium Materials

High Mechanical Resistance High Electrical Resistance Corrosion Resistant

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DC Busbars – G CORNER

Complete Design Maximum output per cross

section

Minimum Electrical losses in

connections

Main Feeder Bus Bars from

T/R Unit

Riser & Apron Bus bars Intercell Bus Bars Shorting Switches &

Flexibles

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Transformer/Rectifiers - NEELTRAN

Single floor fabrication –

All in One Shop

Own Oil Filled

Transformers

Complete Auto-Cad and 3-

D Design

Full Shop Test CSA Certified UL Listed

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Acid Mist Capturing - SAME

Acid Mist Capture at

Source

Contaminants Recovery at

Wash Chamber

Full Compliance of

regulations, particualrly at Altitude and Sub-Zero applications

Fully Integrated with

mechanical handling

Friendly to Operators

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WHY BROCHOT – LIMPACT ?

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Why Brochot - Limpact ?

• BROCHOT LIMPACT “Team” offers a Total Solution:

– Cathodes, Equipment, Automation – Integration Engineering – Flexible approach - maximize value at lowest cost

• ATTRACTIVE PRICE

– Technology equal or better

• The LIMPACT Stainless Steel Cathode is the “PREMIUM” Cathode

– Proven installed base – Minimize Cathode voltage drop : Energy Savings – “Strongest cathode – Longest life + Lowest costs

• GUARANTEES
• FINANCING available

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BROCHOT LIMPACT TEAM

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BROCHOT has formed a “team” consisting of world experienced Project and Design talent and supply “partners” that previously completed the supply of over 35 electrode (cathode & anode) processing systems to over 15 copper and zinc producers. KEY TEAM MEMBERS: Clyde Wright – General & Project Management. Alex Lillo – Plant and Process Design. William Lee – Cathode Expert, President Limpact International. John Bosscher – Mechanical Design and Process Expert. Michel Pescheux – Mechanical Design D&D Automation - automation and system integrator.

BROCHOT TEAM

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BROCHOT TEAM REFERENCES and CUSTOMER TESTIMONIALS

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• Chuiquicamata, Chile
• Kennecott, Utah
• Noranda CCR, Quebec

Copper Cathode Stripping System – References

BROCHOT TEAM EXPERIENCE

Conversions

• Collahuasi, Chile
• Copper Range, US
• El Abra, Chile
• Escondida (Oxide), Chile
• LG Metal, Korea
• Lomas Bayas, Chile
• Mantos Verde, Chile
• Phelps Dodge,Texas
• Radomiro Tomic, Chile
• Santa Barbara, Chile
• Cypress Miami Mines, Arizona
• Zaldivar, Chile
• Tintaya, Peru

Greenfield

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STAINLESS STEEL CATHODE REFERENCES

Customer Name Country Customer since Kidd Creek Canada 1995 Minera Rayrock Peru 1998 White Pines USA 1995 MICCL Myanmar 2001 Padaeng Thailand 2002 INCO – Voisey Bay, Pilot Plant Canada 2004 Electrowinning Resources Ltd Zambia 2007 AURUBIS OLEN Belgium 2008

TRES VALLES Chile

2009

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CATHODE REFERENCES - ZINC

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Customer Testimonial

“Limpact stainless steel cathode blanks were first put into service in the fall of 1995. WPCR tank house operates with three types of cathode blanks, ISA,CMF, and Limpact. In 2003 overall tank house current efficiency was 94.5%, Limpact current efficiency averaged 96.25%. The last three week current efficiency average for Limpact cathodes was 97.3%.”

Dick Barlock, Operations Superintendent, White Pine Copper Refinery (WPCR)

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Customer Testimonial

Limpact cathodes installed at Kidd Creek Copper Refinery in Timmins, Canada – 23,000 cathodes or some 95% are Limpact,

• NOT Kidd Process in their own operating plant !

– Installed for 15 years – Operators prefer Limpact cathodes , “they look still today like brand new” over “own” Kidd (Cobra) Process cathodes ! – The new “superior” design, the explosion bonded hanger bar, yields electrical voltage drops equal to or superior to both Kidd and ISA cathode

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THANK YOU

FOR MORE INFORMATION www.limpact.com www.brochot.fr