Copper Electrowinning Pilot, 10–50 kg/day: Reference Configuration

A reference configuration for a copper electrowinning pilot producing 10–50 kg of cathode per day from PLS or strip liquor.

Sizing logic

Daily production fixes the current: 1 kA for 24 hours deposits about 26 kg of copper at 100% current efficiency. So a 20 kg/day pilot needs roughly 1 kA at 85% CE. That single number sets the rectifier, the busbar and the cathode area.

Item	Specification	Notes
Rectifier	1–2 kA, 6–12 V, thyristor or switch-mode	Constant current mode; ripple < 5%
Cells	2–4 cells, PP or FRP	Cell voltage 1.8–2.2 V
Anodes	Pb-Sn-Ca or MMO on Ti	Pb requires mist control and handling care
Cathodes	316L stainless, 0.5–1 m² each	Edge strips to prevent shorts
Circulation	10–30 L/min per cell	Uniform flow across cathodes
Mist control	Floating balls or hood + scrubber	Mandatory for operator exposure
Heating	Immersion or heat exchanger, 35–45 °C	CE falls below ~30 °C

Busbar and layout

At 1 kA, busbar sizing and contact resistance matter. A loose contact becomes a hot spot and a voltage drop that looks like poor CE. Use tinned copper, torque to specification, and check thermal images after the first week.

Impurity sensitivity at pilot scale

A pilot has a small electrolyte volume, so impurities concentrate quickly. Plan a bleed from day one, and monitor iron, chloride and organics. Organics carried over from SX are a common cause of rough, nodular deposits.

Output for qualification

Cathode samples at 99.99% Cu are usually needed for offtake discussions. Keep a sample log with cell conditions — buyers ask how the sample was made.

Send your target daily output, feed tenor and impurity profile, and we will size the rectifier and cell count.