Mapua Institute of Technology School of Earth and Material Science and Engineering Intramuros, Manila

Mapua Institute of Technology School of Earth and Material Science and Engineering Intramuros, Manila Report on Mill Practice In the Outokumpu Research Center, Outokumpu Oy, Pori, Finland 01 April 2003 to 31 May 2003 In Partial Fulfillment Of the Requirements for the Summer Mine and Mill Practice (MTBL 406) Michael Francis G. Lagman Bachelor of Science in Metallurgical Engineering June, 2003

Abstract The training at Outokumpu Research started from 01 April 2003 to 31 May 2003. The duties there were a three weeks of measurement in which the temperature, cell voltage and flow rate were measured. Two commercial cells were measured daily, one in the morning and one in the afternoon. During and after the measurements, a report was done right after the measurement campaign, in which the report was regularly checked and being edited by the assigned tutors. Description of the job and the report was not mentioned because of the confidentiality paper that was signed. The electrolytic copper refining process, was known and that a good experience was obtained. Rather, a brief discussion was reported about the company. In this report some background of the Outokumpu Company were discussed and briefly explained. Pictures of the worldwide presence of the company were shown and some key figures of their plant were shown for added information. The company is present globally and locally, that is making a difference and bringing another meaning in the world of metals. Adding value to metals was one of their key objectives. 2

Table of Contents Chapter 1 1.1 Description of Facility 6 1.1.1 Outokumpu as a Group.6 1.1.2 Outokumpu Research Center 13 1.1.3 Outokumpu Harjavalta Metals Copper Refinery 17 1.2 Background 18 1.3 Location 20 1.4 Accessibility 21 1.5 History 22 Chapter 2 2.1 Division of Facilities 25 2.2 Flow Chart/Organizational Chart 25 2.3 Experimental Research Activities 28 2.4 Competence Areas 29 2.5 Mineral Technology 30 2.6 Hydrometallurgy 36 2.7 Pyrometallurgy.38 Chapter 3 3.1 Environment 42 3.2 Social Aspects 44 3

Chapter 4 4.1 Activities 45 4.2 Description of the Job 48 Chapter 5 5.1 Conclusion 52 5.2 Recommendations 52 6.0 References 53 Appendix A Average Statistics of Outokumpu Harjavalta Metals Copper Refinery 54 4

Acknowledgement The training at Outokumpu Research Center, was made possible by my father, Manuel M. Lagman and to his superior the president of Okphil, Inc., Mr. Mario Guillermo, for the training in Pori, Finland. A great deal of appreciation is also mentioned to my tutors in Pori, Finland. Sade Harle, Development Manager for the Outokumpu Research. Henri Virtanen, Hydrometallurgy Department manager. Petteri Pesonen, Plant Superintendent of Outokumpu Harjavalta Metals Copper Refinery for helping me in taking the measurements in the plant. Lastly, I would also like to thank my professors, friends, family and especially God on making this training possible and the writing of the report easier. 5

Chapter 1 1.1 Description of Facility 1.1.1 Outokumpu as a Group Outokumpu consist of companies that specialize in stainless steel, fabricated copper and zinc metal production and development and sales of related technology. The group operates worldwide, more than 90 percent of net sales are generated outside of Finland. It employs approximately 21,000 people in more than 40 countries. The company s vision is to be the leading metals and technology Group that creates real value added both to its customers and shareholders. Figure 1.1.1e shows the division of services of the group. Operational structure of the Outokumpu Group of companies is shown in figure 1.1.1. Research and development is given special attention by the company, which explains its leadership in the world of metal development and fabrication. Outokumpu is globally present, assuring the future of metal consumption and metal technology for the human race. Figure 1.1.1d shows the pictorial view of the company. 6

Figure 1.1.1. Operational Structure of the Outokumpu Group 29% 25% 5% 10% 16% 15% Others Building and Construction Welded Tubes Transportation Catering and Households Process Industry Figure 1.1.1a. Pie Chart showing the Stainless Steel Products at Outokumpu 7

1.1.1a Stainless Steel Production Durability, resistance to corrosion and easy cleaning make stainless steel the ideal choice for various demanding applications including cutlery, facing and razor blades and oil platforms. Figure 1.1.1a shows the stainless steel products of AvestaPolarit. Stainless steel operations are the responsibility of AvestaPolarit, which is partly own by Outokumpu, is one of the world s largest producer of stainless steel. The slab capacity will increase from 1.75 million tons to 2.75 million tons due to large investments by the end of 2004. The most important production units are located in Finland, Sweden, Britain and the US. The Group has a chromium mine in Kemi and a ferrochrome smelter in Tornio, both in Finland. Table 1.1.1a shows the key figures for the stainless steel. AvestaPolarit s market share in stainless steel coil market is 28 % in Europe and 8 % globally. Table 1.1.1a. Key Figures for the Stainless Steel Production, 2002 Net Sales (EUR million) 3,002 Personnel 9,147 8

Production (tons) Steel Slabs 1,594,000 Cold Rolled 807,000 White Hot Strips 385,000 Tubes and Tube Fittings 70,000 Quarto Plate 95,000 Long Products 180,000 Precision Strip 21,000 5% 10% 43% 14% 13% Others Industrial Machinery and Equipment Electrical Electronics and Communication Building and Construction Heat Transfer 15% Figure 1.1.1b. Pie Chart showing the Copper Products at Outokumpu 9

1.1.1b Copper Production Outokumpu makes use of superior properties of copper: heat transfer, electrical conductivity and signal transmission, which are needed increasingly to enhance communications, heat transfer, energy production and construction. Figure 1.1.1b shows the copper products of Outokumpu. Outokumpu is the second largest producer of fabricated copper products with a 10 % global market share. Outokumpu has production in 14 countries. The products include ACR tubes, radiator strips used in the automotive industry, copper tubes, strips and connectors used in the electronics and communication industries, sanitary tubes and roofing and architectural products used in the building and construction industries and welding electrodes. Production has also been shifted to higher value-added products, such as components for electrical and air-conditioning and heat exchanger appliance manufactures and superconducting wire. Table 1.1.1b shows the copper production for the year 2002. Outokumpu produces copper for copper products raw material at Harjavalta and Pori, both in Finland. 10

Table 1.1.1b. Key Figures for the Copper Production, 2002 Net sales (EUR million) 1,669 Personnel 7,564 Deliveries / Production (tons) Fabricated Copper Products 415,000 Blister Copper 161,000 Copper Cathode 115,000 7% 45% 23% Industrial Machinery and Equipment Computers and Electronics Transportation Building and Construction 25% Figure 1.1.1c. Pie Chart showing the Zinc Products at Outokumpu 11

1.1.1c Zinc Production Outokumpu produces high quality zinc at Kokkola, Finland and Odda, Norway. Main products are two-ton zinc ingots, which are used mainly for corrosion preventing coating of carbon steel (galvanization). The most important use of galvanized steel is in construction and transportation. Figure 1.1.1c shows the zinc production for 2002. Outokumpu s share of zinc production in Europe, the main market area, is 15 % and globally 5 %. Table 1.1.1c. Key Figures for the Zinc Production, 2002 Net Sales (EUR million) 418 Personnel 1,117 Production (tons) Zinc 380,000 Figure 1.1.1d. Pictorial View for the Whole Outokumpu Group 12

Figure 1.1.1e. Part of Outokumpu a leading metals and technology group 1.1.2 Outokumpu Research Center Outokumpu Research Oy is the research and development center of the Outokumpu Group. For 50 years the research center has helped develop new and innovative processes, which have enhanced the cost efficiency of metals production, and increased the competitiveness of its clients. As a part of Outokumpu Group, Outokumpu Research is well aware that its research work must lead to results, which can be turned, into practical benefits. Comprehensive problem solving capability requires the ability to fully prove that the problem has truly been solved, also from a financial point of view. 13

For the description of the facilities, Outokumpu Research Center has the widest range of laboratory equipment and test pilot plants in the world. Laboratory equipment has range from atomic adsorption spectrometer to scanning electron microscopes. The Center houses all laboratory equipments in one building. Outokumpu Research Center, with its facilities, can analyze specimen from the ore, with its compounds or elemental components, to metallographic specimens. Computers run almost all the facilities and equipment in the Center so data acquisition is versatile. Outokumpu Research Center, with its world class facilities and standards can develop new and improve technologies when it comes to mining, metallurgy and the like, making it the backbone of the Outokumpu Company. It is here where the famous Flash Smelter was developed. Outokumpu Research Center can carry out research and analytical services in chemistry, fluid dynamics, materials selection and modeling, and simulations. The state-of-theart laboratories are constantly being improved and developed to guarantee outstanding research quality and accuracy. The Center has its own library and a network of information retrieval in order to have more reference and material and access to international data banks. 14

5% 11% 40% 9% Development of Research Methods New Innovations (Explorative) Services Product Development (Strategic) Process Research (Incremental) 35% Figure 1.1.2. Pie Chart for the Portfolio of the Research Activities at Outokumpu 1.1.2a Portfolio of Research Activities Product development examples include: solvent extraction of copper, nickel, cobalt, zinc, molybdenum and precious metals, mineral processing and refining of platinum group metals (PGM) and a new copper metal production process-hydrocopper which offers copper producers a way to reduce their investments and operating costs by using minimum amount of chemicals and equipments. New innovations are also being carried out for membrane 15

technologies, ion exchange, new depolarizing, anode materials, and new metal joining techniques, future zinc process, and PGM refining techniques. Figure 1.1.2 shows the portfolio of research activities. 1.1.2b Portfolio of Research Center Outokumpu Research Center employs 197 people of which, 29 are post-graduate, and 56 graduated, 85 technicians and 27 operators. Research facilities include: 8 laboratories and 2-bench scale pilot plants, which are hydrometallurgical and pyrometallurgical, pilot plants. Table 1.1.2 shows the research and development of the Outokumpu Research Center. Table 1.1.2. Research and development Activities at Outokumpu Research Center Process Research Problem solutions in production Process improvements Expansion investments Technology sales and services Product Development Development of existing technologies 16

Development of new technologies Services Standardized research services as environmental measurements, chemical analysis New Innovations New business products or essential improvements in the existing technologies New initiative ideas not having any technology definition, yet Development of Research Methods Development of existing and new experimental research methods New tools to carry out research work 1.1.3 Outokumpu Harjavalta Metals Copper Refinery Electrolytic refining of copper in Outokumpu uses the basic principle of other refineries when it comes to recovering high purity copper. Copper anodes are being transported by train from Outokumpu Harjavalta Smelter, which is about 20 kilometers from the electrolysis plant. 17

The basic principle of electrolytic refining of copper is by passing a current and then dissolving the copper anodes into the electrolyte, which is a solution of CuSO4 H2SO4 H2O, by way of diffusion and convection. Then the copper ions and electrons that were dissolved are being electroplated to the copper cathodes thus giving a high purity copper. Figure 1.1.3 shows the crane operated loading of copper cathodes into electrolytic cells. Figure 1.1.3. Harvesting of Copper Cathodes at Outokumpu Copper Refinery. 1.2 Background The versatility of the intellectual and physical resources available enables Outokumpu Research s clients to save on investments in research facilities. It has helped 18

develop new and innovative ideas and processes, which enhanced the performance and the efficiency of metal productions, and their uses. Outokumpu Research is aware that its research work must lead to results that could lead to practical benefits. The problem solving aspect is comprehensive and it requires the ability to fully probe the problem, and must be in a practical or financial point of view. Outokumpu Research is well known for its flexibility are democratic approach to research. Their clients can somewhat participate in the operations and the conduction of the research. Most of the needed analysis of Outokumpu is being made in house because basically its facilities are located in just only one roof. The Outokumpu group brings about cost efficiency oriented, so that every detail and every aspect of the research would be of value, to its client. Services provided by Outokumpu Research Center cover a wider array of research doings, coming from process and equipment development to consultative research covering mineral technology, hydrometallurgy and pyrometallurgy. Many innovations were also developed in Outokumpu Research Center, in order to facilitate its growing hunger for intelligence and high quality of research and development. The quality of the research and development, and its works 19

are mainly certified by SFS EN ISO 9001 certificate. Outokumpu Research laboratory s emission measurements are accredited by FINAS (Finnish Accreditation Service), which is an accreditation body that checks for the safety of the wastes emitted by a facility and is controlled by the government of Finland. Table 1.2 shows the sales of the Center. Table 1.2. Outokumpu Research Sales Sales in 2002 Sales inside Outokumpu Group Stainless Steel Copper Zinc Technology Other Operations Outokumpu Technology Management EUR 10.8 million 92 % 1 % 24 % 9 % 35 % 1 % 22 % (Corporate) Sales outside Outokumpu Group 8 % 1.3 Location Outokumpu Research Center is situated for about 200 kilometers north of Helsinki. Outokumpu Research Center is 20

just within a compound of other facilities, like the Outokumpu Pori Copper, that produces copper products. The refinery for the copper cathodes is also situated inside the compound, which is practical for the whole company. Figure 1.3 shows the compound layout of the plant in Pori, Finland. Figure 1.3. Compound Layout of Outokumpu in Pori 1.4 Accessibility Accessibility to the Outokumpu Compound, specifically the Outokumpu Research Center, is about a four and a half to five hours bus trip from Helsinki to Pori, and about twenty minutes drive from Pori to the plant or compound. 21

There are two ways of means of transportation for the Outokumpu Plant in Pori. Airplane is also an option to travel there, and takes about 30 minutes to an hour to get to the airport in Pori. Accessibility of the plant is quite easy, because as you go along the way there is directions that are shown on how to get to the plant. Figure 1.4 shows the location of Outokumpu in Pori, Finland. Figure 1.4. Location of Outokumpu at Pori, Finland 1.5 History Basically the word Outokumpu was named after a place, which has a massive ore deposit discovered in Eastern Finland in 1910. Outokumpu means strange hill. In its 22

nine decades of operation, it has evolved from a completely Finnish company to a metals and technology group with global operations. The company started in 1910, thus expanding it globally and internationally as years pass by, the company holds a lot of shares and greatly affects the technology of metals on how we used and produce them today. The history of the Outokumpu Group brings about many innovations and discoveries on the value of metals. 1.1.5 Focus of Metallurgical Research of Outokumpu In 1970 s Flash Smelting of copper concentrates to blister copper was developed. The Flash Smelting furnace pilot runs for foreign customers in the production of copper lead and sulfur. Ferro-alloys and chromium salts was also developed. The 1980 s, lead flash smelting was introduced. Flash converting was also developed for copper production. Cobalt and Nickel chemicals and powders were studied and started up in 1984 for the cobalt and nickel production. Bioleaching was also developed, that use bacteria or organic materials in order to leached ores for copper production. In the 1990 s, PyroZinc and HydroZinc were introduced for the zinc production, which started in 1998 at Kokkola. 23

Finland. For the production and refining of nickel, the DON (direct oxidation of nickel) smelting was also introduced for nickel concentrates, which started up in 1995 in Harjavalta, Finland. Another innovation was also being developed during the 1990 s up to present for the treatment of copper (HydroCopper ) which is a new method of copper production. Figure 1.1.5 shows the operations of the company. The focus of metallurgical research of Outokumpu for the last 30 years developed new and improves innovations for the metal industry. Flash Smelting Technology is one of their prides and joys, that for now it is regarded as the most energy efficient and environmentally friendly smelter in the whole world. Figure 1.1.5. Competent operations of Outokumpu 24

Chapter 2 2.1 Division of Facilities The facilities of Outokumpu Research Center are highly accessible, because almost all of its laboratories are situated in one roof. The main laboratories for hydrometallurgy, pyrometallurgy and mineral technology are situated in the first floor of the building. The laboratories for ore analysis are basically in the first and second floor. Library facilities and other multimedia equipments are situated at the second floor of the building. The pilot scale plants are situated in the compound besides the refinery. A new pilot plant is now being set-up for the HydroCopper project of the company. 2.2 Flow Chart/Organizational Chart For the flowchart and organizational chart are given, so that a better understanding of the hierarchy on the staff is observed, and that some flow sheet and flowchart of some processes present in the compound are shown and explained briefly. Figure 2.2 shows the organizational Chart of Outokumpu Research Center. Mineral technology, hydrometallurgy and Pyrometallurgy operations and pictures were also discussed in order to know some of the operational expertise of the Outokumpu group of Companies. 25

Figure 2.2a. Organizational Chart of the Outokumpu Research Center Organizational Chart of the Outokumpu Research Center brings about many competent personnel that are actively involved to one another in order analyze and determine the best possible way to deal with metals. The center with almost all of its personnel is postgraduate and some have a doctor s degree. 26

Figure 2.2b. Typical Flowsheet for a Copper Refinery. Figure 2.2b shows a typical flowsheet for a copper refinery. Outokumpu harjavalta Metals Copper Refinery uses the basic flowsheet above, except for minor details or specifications of the plant that needs to be set in order to cope up with the environment in the area. Flowsheet for the Electrolytic Refining of Copper at Outokumpu is basically pattern in the above flowsheet. The flowsheet that was made simple in order to be understood easily for the reader. 27

2.3 Experimental Research Activities Figure 2.3. Pictorial View of the Experimental Research Activities The Experimental Research Activities for the Outokumpu Research Center has experimentations for the hydrometallurgy and pyrometallurgy department. From the diagram above, the two competent areas are the backbone of metallurgy. Technical support, method development and analytical services are offered both in the hydrometallurgy and pyrometallurgy department. Technical Support assists on the maintenance and construction of test equipments and materials management. Method Development brings about developing of research and analytical methods and then 28

research equipment investments. The Analytical Services gives support for chemical analysis and material characterization. Figure 2.3 shows the experimental activities of the Center. 2.4 Competence Areas Figure 2.4. Competence Areas of the Group From the diagram above, figure 2.4, it shows the special competence areas of the Research Center. Core competence areas include Mineral Technology, Extractive Metallurgy having the sub-headings of hydrometallurgy and pyrometallurgy, ferrotechnology and other special competence areas. Special competence areas includes 29

mineralogy, solvent extraction, material science, electrochemistry, reactor technique, fluid dynamics, structure analysis, analytical chemistry, process chemistry, process control and thermodynamics. Outokumpu Research Center has the one of the most sophisticated techniques in the processing and fabrication of metals. The center gives the full report for their customers to meet their growing needs for the metal industry. 2.5 Mineral Technology Mineral technology for the Outokumpu Group is one important aspect for the company. Figure 2.5f shows the involvement of the company in mineral technology. The Company is involved in the technology and operations of equipments as well as maintenance for the mineral processing industry. Figure 2.5a shows some grinding mills. Figure 2.5a. Outokumpu Grinding Mills for the Mineral Processing Industry 30

From the figure 2.5a, grinding mills are used in the mineral processing department in order to have a desirable size for the ores that were crushed so that the concentrations of the ores will be easier. Figure 2.5b. Ceramec Classifiers and Thickeners, respectively Classifiers and thickeners figure 2.5b, are also used in the mineral processing industry, in the department of flotation. Chemicals and equipment maintenance is also offered by the company. The concentration of minerals may vary for ages, but the principle is always the same. Some processes were old, but they are being used today. Outokumpu looks for ways and tries to improve the processes that were in the past in order to have a better value for the metals industry of today. The metals industry of today 31

brings about many technologies, but basically meets the same principle. Figure 2.5c. Flotation Cell and a computer generated diagram of the cell Outokumpu is fusing the high technology of computers today and the principles of mineral processing. Computer simulations for the mineral technology (figure 2.5c) The flow of the different liquids and chemicals are being monitored for the studies and profitability of operations of the processes. The laboratories for the mineral processing technology is aided by computers in order to observed and define problems of the processes. Computers are really a great help in the processing and fabrication 32

of metals. Mineral Technology is truly main factor in the Outokumpu Group. Figure 2.5e shows the mineral technology of the company. Figure 2.5d. Separators and Induction Chamber Research Work at high temperatures with different gas atmospheres. Figure 2.5d shows a separator and an induction chamber that can be used to higher temperatures. This equipment enables the Center to analyze samples to a level, which some laboratories are unable to perform. Separators, also product of the company brings the needed equipment and production in the mineral technology industry. Mineral technology is one of the main production and specialty of the Outokumpu Group. Outokumpu brings the needed equipment 33

and techniques that needs to be acquired by the mineral industry. Figure 2.5e. Outokumpu Mineral Technology Division 34

Figure 2.5f. Involvement of Outokumpu Research in Mineral Technology 35

2.6 Hydrometallurgy Figure 2.6a. Hydrometallurgical Equipments of Outokumpu Outokumpu has the widest range of equipment for the hydrometallurgical department. Flotation equipments for the industry are a rare breed because of their fusion with high technology computers that makes the needed analysis and other experimentation easier. Figure 2.6a shows some hydrometallurgical equipments of the company. 36

Figure 2.6b. Hydrometallurgical Reactions Process Involvement Hydrometallurgical reactions process involvement for the Outokumpu Group are sophisticated and proven. The Group brings many compilations of equipments and different strategies for the hydrometallurgy department. Figure 2.6c shows the involvement of Outokumpu in Hydrometallurgy. 37

Figure 2.6c. Involvement of Outokumpu Research in Hydrometallurgy 2.7 Pyrometallurgy Figure 2.7a. Outokumpu Anode Casting Wheel Anode Casting Wheels of the Outokumpu Company are high tech and that full automization of the process is used. 38

This makes the job easier. Figure 2.7a shows the Anode Casting Wheel Of Outokumpu. Figure 2.7b. Outokumpu Flash Smelting Furnace 39

Figure 2.7c. Shows a worker operating at high temperatures 40

Figure 2.7d. Involvement of Outokumpu Research in Pyrometallurgy The pyrometallurgy department of the Outokumpu Group is leading in the smelter industry. Outokumpu Flash Smelting was name as one of the best available techniques in recovering copper, nickel, etc. Figure 2.7b shows the famous flash smelter of the company. Figure 2.7d shows the involvement of Outokumpu research in pyrometallurgy. 41

Chapter 3 3.1 Environment The working environment at the Outokumpu Research Center was I think a very good one, because almost all of its employees have access to each other in order to have a synergy that could make a group cooperation, to make a productive projects or research that is being done. For the employees, they all work together and at the same time correlate what is being done, and what is being asked, in order to meet a client s demand or the companies demand. Career building or enrichment is one of its main objectives, in order to have an excellent working environment. As for the physical environment, the temperature ranges from 2 to about + 8 degrees Celsius. The country basically has a winter season, nut for these months it is common that it is spring. The environment was cold, and that it is snowing. The end of the month, which is April, or for the first week of May, the environment changes and springtime comes; the sprouting of the leaves, in the trees makes it beautiful. As much as possible the company strictly implements environmental safety in order to care for the environment. It is annually reporting the waste disposal and the analysis of its waste on nearby 42

river systems, and other ecosystems. Environmental hazards are also published annually in order to inform the surrounding community, as well as the government that the wastes are disposed correctly and responsibly. Figure 3.1 shows the involvement of the company in the world of metals. Figure 3.1. Life Cycle of Metals; Outokumpu is involved on the shaded parts. 43

3.2 Social Aspects The social aspects of the company are quite very good. The employees are much more willingly to help others, if you only ask. The people are helpful, and that they offer their assistance when you are in need and or in somewhat in trouble. Employees greatly affect the evolution of the company because it is the working force or the backbone of every business. The development of the company, I guess mainly the social aspects greatly brings about the efficiency of the business, and also the success of it. 44

Chapter 4 4.1 Activities For the duration of two months, I was assign to different areas, and facilities. In the first week of training I was thought to the different working equipments that are available at the office. Almost all of the employees have an access to a computer that is interconnected with a network in order to have group cooperation for its research or project works. The later weeks, I was assign to the electrolytic refining of copper in order to know the principles and actual operation of an electrolysis plant. Actual data were observed and obtained so that a true working environment in electrolytic refining of copper could be experienced. The people there also thought me on how to take measurements for temperature, cell voltage, flow rate, amount of shorts and how to determine a good quality of cathode copper. For the remaining few weeks, office assignment was given in order to make the report or research, to evaluate and correlate the data obtained in the training practice at the electrolysis plant. Everyday activities are basically, measurement of data from cell section to cell section, then interpretation and recording of data to be presented later. Figure 4.1b and 4.1c shows different test simulations 45

observed in the Center. Figure 4.1a shows a laboratory size flotation cell that was observed during the training. Figure 4.1a. Batch Type flotation Cells. Figure 4.1b. Simulations for Equipment Testing 46

Figure 4.1c. Gas Colored Simulations for Analysis. Figure 4.1d. Pictures of the plant in Outokumpu Copper Refinery at Pori, Finland 47

4.2 Description of the Job For the two months training, I was as assign to the Outokumpu Pori copper, in which I was to train in the electrolytic refining of copper. For the duration of or for about four to five weeks in the electrolysis area, in which I am suppose to measure the cell voltage, temperature, flow rate, amount of shorts and the quality of the cathodes of each cells. The job description as I was train to is the observation and the measurements of data needed to be analyzed in order to have a report or somewhat a correlation to the parameters that I have obtained. A research or a report was done for the remaining few weeks of stay in order to present this data to the tutors and managerial heads of the department. The measurements or the obtaining of data was not that difficult, but the only thing that was hard is the environment, in which, the smell of the sulfuric acid, this is by the way; the electrolyte used in the refinement of copper foul smells. The temperature inside the plant is also uncomfortable, because the electrolyte should have a temperature ranging form 65 70 degrees Celsius. Some data that were obtained are a little bit close to each other, because the Outokumpu Pori Copper was already using standard data in order to refined copper. Electrolytic refinement of Copper consists mainly 48

of electrochemically dissolving copper from impure anodes and selectively plating the dissolved copper in pure form to the copper cathodes. The anodes contain for about 99 99.8 % copper, which is some of the industrial range of anode composition. The impurities of the anode include from oxygen to gold. Traces of these elements will be reduced in order to obtain a high purity copper cathode, which may result to about 99.999+ % copper. The copper cathode are further melted or cast to form products such as wires or tubes and other desired final product in order for them to use other adaptive purposes. The electro-refined copper may contain less than twenty parts per million impurities, plus oxygen, which is controlled at about 0.025 %. Figure 4.2a. Pyrometallurgical process for copper sulfides 49

Figure 4.2b. Copper Products of Outokumpu in Pori, Finland. Figure 4.2c. Colled Rolled Copper Products. 50

Figure 4.2d. Cold Rolled Copper Products Figure 4.2e. Outokumpu Superconductors 51

Chapter 5 5.1 Conclusion For this report, the summer plant practice at Outokumpu Research Center is really a very good learning experience for soon to be graduates of metallurgical engineering. Sophisticated equipments and high technology facilities are observed and operated. The facilities at Outokumpu Research Center are state of the art and also the pilot plants are excellent in obtaining metallurgical data. The learning and working environment is highly concussive because of the applications of the theories and principles that are learn from school. 5.2 Recommendations Based from my experience, I highly recommend training in this facility because the learning and working experience is out of the ordinary. For the training, makes up for the opportunities that are waiting for us in our chosen field in the future. The working experience mainly boasts of the standards of other companies in the Philippines. The Outokumpu Research Center has great pride on its employees that are mainly of higher degree of education, including doctor s degree that could mould the trainee to its highest potential. 52

Reference: Baltazar, V. and Caissey, J. (1991) Electrorefining of Copper Anodes with Silver Levels, in copper 91/Cobre 91, Volume iii, Hydrometallurgy and Electrometallurgy of Copper, edited by Copper W. C., Kemp, D. J., Lagos, G. E. and Tan, K. G., Pergamon Press, New York, 329-340. Biswas, A. K. and Davenport, W. G. (1994) Electrolyte Properties in Copper Refining, in Extractive Metallurgy of Copper, Pergamon, Oxford, 324-357. Outokumpu Company Magazines, PO Box 60, FIN-28101 Pori, Finland. 53

Appendix A. Average Statistics of Outokumpu Harjavalta Metals Copper Refinery Type Cathode Production Rate, Capacity tons/year Production for 2001, tons/year Production for 2002, tons/year Electrolytic Cells Number of Commercial Number of Stripper Cells Construction Material Lining Material Dimensions, L x W x H, (inside) Anodes, cathodes per cell Anodes Type % Cu L x W x T, mm Weight, kg Center line spacing, mm Life, days % Scrap Year: 2001 Year: 2002 Anode slimes, per ton of cathode, kg Year: 2001 Year: 2002 Cathodes Type L x W x T, mm Plating time, days Weight of cathode, kg (average) Total impurities Year: 2001 Year: 2002 Electrolyte Conventional Anodes, Copper Starting Sheets 125000 115471 114906 692 (PRC) 68 (DC) Pre cast reinforced concrete plane elements (old) and T-elements (new) PP 3600 x 1100 x 1200 (old) 3580 x 1090 x (1240 1390) (new) 30, 31 Conventional 99,1 925 x 900 x 45 (commercial) 965 x 945 x 45 (stripper) 310 (commercial) 370 (stripper) 112 16 21,9 23,0 5,9 5,6 Removed after 16 days Copper Starting Sheets, starting sheet blank is stainless steel 960 x 960 x 0,7 8 120 < 16,7 < 18,07 54

Cu, g/l Year: 2001 Year: 2002 H 2 SO 4, g/l Year: 2001 Year: 2002 Addition Agents, g/ton of cathode Glue Year: 2001 Year: 2002 Thiourea Year: 2001 Year: 2002 Is the electrolyte filtered? Power and Energy Cathode current density, A/m 2 Year: 2001 Year: 2002 Cathode Current Efficiency, % (average) Year: 2001 Year: 2002 Cell Voltage, V Cell Current, ka Year: 2001 Year: 2002 kwh/ton of cathode, AC Year: 2001 Year: 2002 61 58 147 145 126 128 68 67 Electrolyte is not filtered Thiourea is regularly analyzed (polalography). 316-commercial, 230-stripper (effective) 318-commercial, 230-stripper (effective) 92,0 90,6 550 (average) 17,3 17,4 445 (average, PRC + DC) 453 (average, PRC + DC) 55