Copper electrolytic refining is a crucial link in the copper smelting industry chain, and its core objective
is to purify crude copper to high purity copper cathode of over 99.95% by electrolysis. As the global
demand for copper continues to grow, optimizing the design and configuration of electrolytic refineries
has become a core issue for increasing production capacity and reducing energy consumption. In this
paper, from the process principle, equipment selection, system layout of three dimensions, in-depth
analysis of modern copper electrolytic refinery construction points.
Process design: scientific process lays the foundation for high efficiency
1. Electrolysis system construction principles
Typical copper electrolysis refining system contains three functional modules: electrolytic cell group, circulating filtration
device and automatic stripping unit. The design needs to follow:
Maximize current efficiency: adopt bipolar method or parallel pole plate layout, keep the current density in the
reasonable range of 220-280A/m².
Electrolyte stability control: copper sulfate solution concentration is maintained at 160-200g/L, and the
temperature is precisely controlled at 55-65℃.
Impurity removal mechanism: Remove anode sludge through continuous filtration system, with dynamic
monitoring of arsenic, antimony and other elements.
2. Intelligent parameter regulation
Modern plants are generally equipped with DCS distributed control system to realize:
Real-time monitoring of tank voltage (fluctuation range ≤ 0.05V)
Automatic regulation of electrolyte circulation flow (flow rate 0.8-1.2L/min)
Dynamic compensation system for cathode and anode spacing (error ≤2mm)
Equipment Configuration: Accurate Selection Determines
Operational Efficiency
1. Core equipment specifications
Electrolysis tank set: made of polypropylene/glass fiber reinforced plastic composite material, single
tank capacity up to 5m³, design life over 15 years.
Cathode and anode processing system: fully automatic traveling crane realizes precise lifting of the
pole plate, with positioning accuracy of ±1mm.
Environmental protection filtration device: four-stage counter-current washing unit, anode sludge
recovery rate>99.8%.
2. Optimization of energy consumption
High-frequency switching power supply replaces traditional silicon rectifier, power conversion
efficiency is increased to 96%.
Waste heat recovery system converts electrolyte waste heat into heating energy for the plant.
Variable frequency drive technology enables auxiliary equipment to save power up to 30%.
Space Layout: Systematic Planning to Enhance
Production Efficiency
1. Functional partition design logic
Electrolysis main workshop: single-story steel structure plant, span ≥ 30m, equipped with 10-ton
double girder crane.
Circulation system area: underground piping network connecting electrolyte storage tanks, heat
exchangers and filtration units.
Finished product processing area: fully enclosed stripping-washing-packing line with cleanliness
up to ISO 8 standard.
2. Logistics flow optimization strategy
Raw material storage → electrolysis preparation → finished product discharge to form a
unidirectional linear flow.
Specialized AGV carts realize zero cross-transportation of pole plates.
Three-dimensional storage system saves 40% of space
Environmental protection and sustainable development design
1. Three wastes treatment technology
Waste gas treatment: negative pressure collection system + two-stage acid mist spray tower, the
emission index is better than GB25467 standard.
Wastewater reuse: MVR evaporation and crystallization device to realize zero discharge of wastewater.
Solid waste resourceization: anode sludge extracts gold, silver and other precious metals, and the
residue is made into raw materials for building materials.
2. Clean production innovation
Photovoltaic roof annual power generation can meet 15% of the plant's electricity demand
Intelligent water system reduces water consumption to 0.5m³ per ton of copper
Digital twin platform realizes equipment failure warning and energy consumption prediction
Industry Trends
The current copper electrolytic refining technology is breaking
through in two directions:
Process enhancement: pulse electrolysis technology increases current efficiency to 98%.
Intelligent upgrade: machine vision system realizes real-time detection of copper cathode defects.
Low-carbon transition: biomass reductant gradually replaces traditional fossil fuels.
Through the integration of scientific design and advanced technology, modern copper electrolysis
refineries are realizing industry breakthroughs in terms of a 12% reduction in overall cost per ton
of copper and a 25% increase in production capacity, providing key material support for the
global energy transition.