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

measured

rate

were

daily,

measured.

one

in

the

Two

commercial

morning

and

cells
one

in

were
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

difference

and

bringing another meaning in the world of metals. Adding

value to metals was one of their key objectives.

Table of Contents

Chapter 1
1.1

Description of Facility6

1.1.1

Outokumpu as a Group.6

1.1.2

Outokumpu Research Center13

1.1.3

Outokumpu Harjavalta Metals Copper Refinery17

1.2

Background18

1.3

Location20

1.4

Accessibility21

1.5

History22

Chapter 2
2.1 Division of Facilities25
2.2 Flow Chart/Organizational Chart25
2.3 Experimental Research Activities28
2.4 Competence Areas29
2.5 Mineral Technology30
2.6 Hydrometallurgy36
2.7 Pyrometallurgy.38

Chapter 3
3.1 Environment42
3.2 Social Aspects44

Chapter 4
4.1 Activities45
4.2 Description of the Job48

Chapter 5
5.1 Conclusion52
5.2 Recommendations52
6.0 References53

Appendix A Average Statistics of Outokumpu Harjavalta

Metals Copper Refinery54

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,

would

also

like

to

thank

my

professors,

friends, family and especially God on making this training

possible and the writing of the report easier.

Chapter 1
1.1 Description of Facility
1.1.1 Outokumpu as a Group
Outokumpu
stainless

consist

steel,

of

companies

fabricated

that

copper

specialize

and

zinc

in

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

companys

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
companies

is

development
which

is

explains

structure
shown

in

of

the

figure

given

special

its

leadership

Outokumpu
1.1.1.

attention
in

the

Group

Research

by

the

world

of
and

company,
of

metal

development and fabrication. Outokumpu is globally present,

assuring
technology

the
for

future
the

of

human

metal
race.

consumption
Figure

1.1.1d

and

metal

shows

the

pictorial view of the company.

Figure 1.1.1. Operational Structure of the Outokumpu Group

5%
29%

10%
Others
15%

Building and Construction

Welded Tubes
Transportation
Catering and Households
Process Industry

25%

16%

Figure 1.1.1a. Pie Chart showing the Stainless Steel

Products at Outokumpu

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 worlds 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

Finland.

and

Table

ferrochrome
1.1.1a

shows

smelter
the

in
key

Tornio,

both

figures

for

in
the

stainless steel.
AvestaPolarits 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

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%

13%

43%

Others
Industrial Machinery and Equipment
Electrical
Electronics and Communication
Building and Construction
Heat Transfer

14%
15%

Figure 1.1.1b. Pie Chart showing the Copper Products at

Outokumpu

1.1.1b Copper Production

Outokumpu makes use of superior properties of copper:
heat

transfer,

transmission,

electrical

which

communications,

are

heat

conductivity

needed

and

signal

to

enhance

increasingly

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
and

architectural

industries,
products

sanitary
used

in

tubes
the

and

roofing

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%

23%
45%

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.
Outokumpus 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

which

have

production,

helped

develop

enhanced
and

the

increased

new

and

cost
the

innovative
efficiency

processes,
of

competitiveness

metals
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

Research

description

Center

has

of

the

the

facilities,

widest

range

of

Outokumpu
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

metallographic

compounds
specimens.

or

elemental

Computers

components,

run

almost

all

to
the

facilities and equipment in the Center so data acquisition

is versatile.
Outokumpu
facilities

Research

and

Center,

standards

can

with

develop

its

world

new

and

class
improve

technologies when it comes to mining, metallurgy and the

like, making it the backbone of the Outokumpu Company. It
is

here

Outokumpu

where

the

famous

Flash

Research

Center

can

Smelter
carry

was

out

developed.

research

and

analytical services in chemistry, fluid dynamics, materials

selection and modeling, and simulations. The state-of-theart

laboratories

developed

to

are

constantly

guarantee

outstanding

being

improved

research

quality

and
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,

platinum

group

production

mineral

metals

processing

(PGM)

and

process-HydroCopper

and
new

which

refining
copper

offers

of

metal
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,

hydrometallurgical

and

pyrometallurgical,

Table

the

research

1.1.2

shows

and

which
pilot

development

are
plants.
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

Development of existing and

Methods

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

recovering

high

transported

by

of

other

purity
train

refineries

copper.

from

when

Copper

Outokumpu

it

anodes

comes
are

Harjavalta

to

being

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 Researchs clients to

save on investments in research facilities. It has helped

18

develop
enhanced

new

and

the

innovative

performance

ideas

and

and

the

processes,

efficiency

of

which
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 inhouse because basically its facilities are
located in just only one roof. The Outokumpu group brings
about costefficiency 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

SFSEN

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

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

EUR 10.8 million

Sales inside Outokumpu Group

92 %

Stainless Steel

Copper

Zinc

Technology

1 %
24 %
9 %
35 %
1 %

Other Operations
Outokumpu Technology
22 % (Corporate)
Management

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

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

Outokumpu

two

ways

Plant in

of

means

Pori.

of

Airplane

transportation
is

also

an

for

the

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

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
global

company

to

operations.

metals

The

and

company

technology
started

in

group

with

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

1970s

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 1980s, 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

Bioleaching
organic

for
was

materials

the

also
in

cobalt

and

developed,
order

to

nickel

that

leached

use
ores

production.
bacteria
for

or

copper

production.
In the 1990s, 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

Harjavalta,

concentrates,
Finland.

which

Another

started

innovation

up
was

in

1995

also

in

being

developed during the 1990s 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,
situated

because

in

one

almost

all

roof.

The

of

its

main

laboratories

are

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
building.

are
The

situated
pilot

at

scale

the

second

plants

are

floor

of

the

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

Chart

Outokumpu

Research

of

2.2

shows

Center.

the

organizational

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

doctors 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

basically

pattern

Refining
in

the

of
above

Copper

at

flowsheet.

Outokumpu
The

is

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

hydrometallurgy

and

has

experimentations

pyrometallurgy

for

department.

the

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

materials

management.

developing

of

research

Method
and

of

test

Development

analytical

equipments
brings

methods

and

and

about
then

28

research
gives

equipment
support

investments.

for

characterization.

The

chemical

Figure

Analytical

analysis

2.3

shows

and

the

Services
material

experimental

activities of the Center.

2.4 Competence Areas

Figure 2.4. Competence Areas of the Group

From
special

the

diagram

competence

competence

areas

above,

areas

include

of

figure
the

Mineral

2.4,

Research

it

shows

Center.

Technology,

the
Core

Extractive

Metallurgy having the sub-headings of hydrometallurgy and

pyrometallurgy,
competence

ferrotechnology

areas.

Special

and

competence

other

special

areas

includes

29

mineralogy,

solvent

electrochemistry,
structure

reactor

analysis,

chemistry,
Research

extraction,

process

Center

analytical

the

science,

fluid

dynamics,

technique,

control

has

material

and

one

chemistry,

process

thermodynamics.

Outokumpu

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

group

cooperation,

to

make

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 clients demand or the companies demand.
Career

building

objectives,
environment.

in
As

or

enrichment

order
for

to
the

have

is

one

an

of

its

excellent

physical

main

working

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
different

the

duration

areas,

and

of

two

months,

facilities.

In

the

was

assign

first

week

to
of

training I was thought to the different working equipments

that

are

employees

available
have

interconnected

at

an
with

the

office.

access
a

to

network

in

Almost

all

computer
order

to

of

the

that

is

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,

determine

flow
good

rate,

amount

quality

of

of

shorts

cathode

and

copper.

how
For

to
the

remaining few weeks, office assignment was given in order

to make the report or research, to evaluate and correlate
the

data

obtained

electrolysis

plant.

in

the

Everyday

training

practice

activities

are

at

the

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

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
analyzed

and

in

the

order

correlation

to

measurements
to

the

have

parameters

of

data

report

that

needed

to

be

or

somewhat

have

obtained.

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

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 doctors 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
H2SO4, 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/m2
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