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COPPER CATHODE PROCESSING

The journey of Copper from electrolyte to a marketable product culminates in the crucial post-electrowinning phase at the Copper cathode plant. Once the electrowinning cycle was complete, the cells yielded crude Copper cathodes – substantial Copper sheets adhering to reusable stainless steel blanks. The initial, highly mechanized step involved the precise removal of these Copper sheets. Automated stripping machines were employed, designed to efficiently peel the deposited Copper from the inert cathode blanks without damaging either the valuable Copper or the blanks, which were immediately returned to the electrolytic cells for reuse.

After separation, these raw Copper sheets, often referred to as full plates, underwent further refinement. They were then conveyed to a trimming station where hydraulic shears or guillotines cut them to precise, standardized dimensions. This sizing ensured uniformity for subsequent handling, packaging, and adherence to customer specifications. While the electrowinning process itself yielded high-purity Copper, a final surface preparation, usually a thorough rinse with demineralized water, was performed to remove any residual electrolyte, dust, or minor surface impurities. This step ensured the pristine quality and appearance of the final product.

Finally, the prepared Copper cathodes were systematically stacked. They were typically stacked horizontally, often on pallets, in precise numbers – commonly 20 to 50 sheets per stack, depending on the cathode thickness and desired bundle weight. These stacks were then bound with steel strapping, ready for weighing, quality inspection, and dispatch to various industries worldwide.

To transform these cathodes into various Copper products, they were subjected to further processing at facilities exterior to the mine. This usually involved melting the cathodes in a shaft furnace, followed by continuous casting and rolling. The molten Copper was cast into a suitable form, often a thick slab or strip, which was then passed through a series of rolling mills. This mechanical working reduced the thickness of the Copper, enhances its grain structure, and improved its mechanical properties; ultimately producing high-quality Copper sheets of the desired gauge and finish, maintaining the exceptional 99.99% purity.

Original photos courtesy of Salvador Rivera (Author: silvia)