Integrated Metal Recovery and Electrochemical Refining Systems

​

Metal recovery systems are integrated engineering solutions that enable the economic, sustainable, and high-purity recovery of valuable metals from ore or process solutions.

Physical beneficiation, hydrometallurgy, and electrochemical refining units operate within a single, unified system to ensure maximum efficiency and quality.

​

How the Process Works

​

1. Ore Preparation and Beneficiation

The process begins with the acceptance of run-of-mine (ROM) ore at the facility.

• Crushing

• Grinding

• Screening and classification

The objective is to achieve the appropriate particle size to ensure mineral liberation.

The beneficiation stage then follows:

• Gravity separation

• Flotation

• Magnetic separation

These processes remove gangue minerals and produce a higher-grade concentrate.

​

2. Leaching Systems (Hydrometallurgy)

During the leaching stage, valuable metals are transferred from the solid phase into the liquid phase.

Main methods used:

• Tank leaching

• Heap leaching

• Cyanide leaching (particularly for gold)

The output of this stage is a metal-bearing solution known as PLS (Pregnant Leach Solution).

​

3. Purification and Separation

​

CIL / CIP Systems (Gold)

• Adsorption of gold onto activated carbon

• Elution

• Recovery by electrolysis

• Production of doré bullion

• ​

Solvent Extraction (SX)

• Selective separation of metals from the loaded solution

• Production of high-purity electrolyte

• Purification prior to electrowinning

Widely used for copper, nickel, and certain precious metals.

​

Electrochemical Metal Production

The final and most critical stage of metal production involves electrochemical processes.

​

Electrowinning (EW)

Metal ions are deposited in metallic form onto the cathode through the application of electrical current.

Advantages:

• Direct metal production from leach solutions

• High-purity cathode production

• Continuous and controlled operation

• Low operating cost

• Economic processing of low-grade ores

EW represents the final metal production stage in hydrometallurgical circuits.

​

Electrorefining (ER)

The metal is already in metallic form but contains impurities (e.g., cast anodes). Through electrolysis, purity levels of 99.99%+ are achieved.

Advantages:

• Ultra-high purity

• Energy efficiency

• Recovery of valuable metals such as Au, Ag, and Se from anode sludge

• Additional economic recovery potential

• ​

Integrated Operating Philosophy

These two processes are not alternatives but complementary stages.

Typical Flow Scheme

Ore → Beneficiation → Leaching → SX → Electrowinning → Cathode Metal
If required → Electrorefining → Ultra-Pure Metal

​

Example Application Scenarios

​

Copper Production

• Ore → Leaching → SX

• SX output → Electrowinning → Cathode Copper

• If higher quality is required → Electrorefining

• ​

Gold Production

• Doré production via electrolysis following CIL/CIP

• Further refining at refinery level

• ​

Final Products

• Gold (Au)

• Silver (Ag)

• Copper (Cu)

• Zinc

• Lead

Customized solutions can be developed for different metal types depending on plant design.

​

Sustainability and Environmental Safety

Modern metal recovery plants are focused not only on production but also on environmental responsibility and sustainability.

• Tailings thickening

• Environmentally compliant storage

• Process water recovery

• Energy efficiency optimization

The objective is to maximize metal recovery while minimizing environmental impact.

​

Conclusion

Integrated metal recovery systems:

• Provide a holistic engineering approach

• Deliver high-purity production

• Offer economic and sustainable solutions

• Create maximum value by optimizing both electrowinning and electrorefining processes

 

With tailor-made, turnkey, or modular solutions designed specifically for your operation, we make your metal production processes more efficient and more profitable.