References
Modernization of an electrolysis department and fully automated PGM sludge processing
MMC Norilsk Nickel intended to comprehensively modernize its electrolysis department at the copper plant and build a state-of-the-art plant for processing precious metal-containing anode slimes (PGM sludge). The aim was to achieve maximum efficiency and product purity at every stage of the process.
The new system was to enable fully automated, unmanned production in continuous 24/7 operation, guarantee seamless traceability and maximum process reliability when handling valuable precious metals and at the same time significantly increase occupational safety by minimizing manual intervention.
Commissioning: 2014
Project details
- Client: MMC Norilsk Nickel (AG Norilsk Nickel)
- Location: Norilsk, Russia
- Contract type/services: Basic and detailed engineering (according to Russian standards, project planning, supply of equipment & documentation, installation supervision, commissioning, training of operating personnel
Our solution
Engineering Dobersek delivered a turnkey concept with two identical lines operating in parallel, comprising the following main modules:
- Filtration: Two filter presses with peristaltic pump units
- Vacuum drying: Two vacuum-operated dryers (90-140 °C)
- Cooling & grinding: Two mills for regrinding the thickened sludge
- Automated filling: machine incl. loading hopper, precision scale, sealing module, dust extraction system, label printer and conveyor belt
- Supply infrastructure:
- Compressed air station for filter cloth cleaning and ventilation
- Reagent and auxiliary supply with corrosion-resistant piping
- Process and electrical engineering: Fully corrosion-resistant valves, pump station for process water with steam heating
- Automation: PLC control (Allen Bradley & Siemens), process visualization, data archiving and transfer via Ethernet TCP/IP
Thanks to the use of proven OEM components and a closed, digitally monitored system, the system guarantees maximum operational reliability, simple maintenance and seamless material traceability.
Customer benefits
Continuous production: 365 days/year with 24-hour operation thanks to fully automated lines
Maximum process security: closed monitoring prevents losses and unauthorized access
Outstanding product quality: residual moisture < 3 % and grain size < 1 mm guarantee optimum further processing
Occupational safety: Minimizing manual intervention significantly reduces potential hazards
High economic efficiency: throughput capacity of up to 415 t/year and optimized energy use reduce OPEX and CAPEX
Technical data
- Plant type: Two complete, parallel processing lines for precious metal-containing anode slimes (PGM sludge)
- Throughput:
- 10 m³ sludge / 2 h (solids content 8-10 %)
- Up to 415 tons of moist PGM sludge per year with 365 d × 24 h operation
- Residual moisture after vacuum drying (< 3 % at 90-140 °C)
- Particle size of the dried sludge < 1 mm
- Filling capacity 800-1 200 kg/8 h layer in 24.5 kg PVC bags (± 50 g, accuracy 0.1 g)
- Connected load: 374 kW; 237 electrical connections; 204 measuring stations
Project highlights
- Two fully automated lines for parallel operation and redundancy
- Integrated weighing and sampling systems for complete traceability
- Turnkey handover including staff training for immediate start of production
- Compliance with the strictest Russian standards in engineering and documentation
PGM sludge processing rethought
With this modernization, MMC Norilsk Nickel set new standards in PGM sludge processing: a highly efficient, safe and fully automated solution that combines the entire process from filtration to packaging in one integrated concept.
Success stories that count.
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The Mirny diamond mine operates in a permafrost area with frozen ground all year round. Phase 1 already showed that the annual sludge volumes exceeded the available landfill sites. The aim of both project phases was to drastically reduce the landfill area, increase the internal water cycle to over 95 % and keep residual moisture in the filter cake below 25% – all without interrupting ongoing operations.
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State-of-the-art environmental technology for sustainable energy: our flue gas desulphurization plant at the Šoštanj power plant ensures a significant reduction in sulphur emissions and meets the highest environmental standards.
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Efficient phosphate ore processing in Uzbekistan: Following the successful commissioning of the phosphate processing plant at the "Tashkura I" deposit, we increased production capacity by 52 t/h with the construction of the calcination plant at the "Tashkura II" deposit and set new standards in the use of resources and technological development.
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