brochot limpact

BROCHOT LIMPACT
June 2009
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WHO IS BROCHOT LIMPACT
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BROCHOT GROUP
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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.
Krasnoyarsk Engineering Co (KEC)
S.E.E.E.
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KGHM Copper Project – May 2009
Brochot – Limpact Synergy
for Non Ferrous Metals Refining
• Limpact – 37 years of supplying cathodes to nonferrous 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 WORKSHOP
WINGLES FRANCE
Brochot Equipment workshop is
located in Wingles, northern
France:
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10,000 m2 fabrication, assembly
and test facility.
– Fully equipped machining center.
– Crane capacity up to 40 Tons.
• 8 meters clearance under
the hook.
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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.
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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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Limpact addresses
Your Cathode Quality Issues
Cathode
Issues
¤ Electrical Efficiency
¤ Corrosion Damage
¤ Maintenance Cost
¤ Cathode Copper Quality
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Limpact
Solution
¤ Efficient Copper Contact
¤ Lower Electrical Resistance
¤ Longer Cathode Life
¤ Mechanical Strength
Limpact Delivers Benefits:
3 Energy Savings
3 Increase Cathode Life Time
3 Decrease Maintenance Cost
3 Outstanding Copper Quality
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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
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LIMPACT Explosion-Bonded Cathode
Solid copper bar and stainless to stainless
Welds yield electrical efficiency and long life
Cathodes Comparison – Competitor 2
Competitor Cathode with dissimilar Weld material
obliterated through galvanic corrosion
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LIMPACT Explosion-Bonded Cathode
Stainless steel to stainless weld
Cathodes Comparison
Performance
Refurbishment of
hanger bar system
Performance
Performance
without
refurbishment
Competitor 1
Electroplated hanger bar system
Electroplated copper corrodes
overtime. 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
Year’s
Performance
Sudden failure
Refurbishment
Year’s
Performance
Limpact
No corrosion repair reported for over 15
years. Superior performance over
Constant Superior Performance
time
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Year’s
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:
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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:
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Cathode Handling system
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Cathode Wash System
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Automatic Stripping Machine (Robotic)
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Copper Sheet System (Sampling, corrugating,
stacking)
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Blank Outfeed System
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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
Transfer Car
SST Transfer
racks
Wash
Booth
Infeed Conveyor
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Wash Booth - Typical
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Cathode Stripping system - Robotic
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The high capacity cathode stripping system consists of one (1)
machine with two (2) stripping stations
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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)
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
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
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Copper Sheet System
Copper from
stripping machines
Transfer
Carriage
Sampling unit
Corrugating Press
Receiving
Conveyor
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
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Controls and Automation
technologists integrate all types
of controllers such as:
PLC’s
Robots
Drives
Servos
Vision Systems
Safety Devices
Actuators
Custom Equipment
Process Controls
Controls and Automation
technologists integrate all types
of controllers such as:
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PLC / DCS
SCADA
Metering
Flow Control
PID control
Fuzzy Logic
Instrumentation
Custom Applications
PLC Programming
We will provide expert assistance when it comes
to your PLC and PLC programming needs.
ƒ Selection of controllers
ƒ Supply hardware
ƒ System design
ƒ System development
ƒ Detailed logic control flow diagrams
ƒ Documentation and training
ƒ PLC programming
ƒ Process simulation
ƒ In-house testing
ƒ Site start-up and commissioning
ƒ 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.
ƒ Single line and control schematics
ƒ Control system and LAN architecture
ƒ PLC I/O drawings
ƒ Logic flow diagrams
ƒ Control panels
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Automation Options
SCADA
ƒ Data collection, analysis and reports
Other options
ƒ Cathode tracking:
ƒ Cell performance
ƒ Electrode performance - maintenance
ƒ 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
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High Mechanical Resistance
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High Electrical Resistance
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Corrosion Resistant
DC Busbars – G CORNER
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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
Transformer/Rectifiers - NEELTRAN
„ Single floor fabrication –
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All in One Shop
Own Oil Filled
Transformers
Complete Auto-Cad and 3D Design
Full Shop Test
CSA Certified
UL Listed
Acid Mist Capturing - SAME
„ Acid Mist Capture at
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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
WHY BROCHOT – LIMPACT ?
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Why Brochot - Limpact ?
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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 TEAM
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.
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BROCHOT TEAM REFERENCES and
CUSTOMER TESTIMONIALS
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BROCHOT TEAM
EXPERIENCE
Copper Cathode Stripping System – References
Greenfield
Conversions
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Chuiquicamata, Chile
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Kennecott, Utah
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Noranda CCR, Quebec
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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
STAINLESS STEEL CATHODE REFERENCES
Customer Name
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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
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
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