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    Copper Sulfate Production Plant (CuSO4.XH2O)

    Copper sulphate

    GENERAL DESCRIPTION OF COPPER SULFATE PROCESSING TECHNOLOGY OF MENTIS

    This process relates  to the oxidation of metallic copper immersed in a dilute solution of sulphuric acid, the reaction taking place in a low pressure reactor (Leaching Reactor / Pos1 ) into which is introduced heated oxygen and distillated water, preferably in a finely divided condition, thereby converting the metallic copper to copper sulphate in solution. This process will rapidly convert any kind of metallic copper such as copper sheets, strips or wire etc. into copper sulphate to any desired degree of solutions.

    Leaching reactor (Pos 1) suitable for the operation of the process is shown in the accompanying drawing (flow sheet). This low pressure reactor is so constructed as to resist corrosion and to withstand whatever pressure is to be used in the operation or  the process. For this purpose, Reactor formed from PP, suitably supported, mounted and reinforced to withstand the required pressure.  Reactor is built as a steel construction lined with (Epoxy) resistant material.

    Oxidizing Reactor  is provided with a manhole or removable cover  at its top to permit charging the vessel with metallic copper, and with an outlet or discharge pipe  provided with valve  for discharging the contents after oxidation is complete. Means are provided for supplying heated gas oxygen.  The gas oxygen supplied is regulated and controlled by a valve and regulator.

    A perforated PP nozzle plate suitably supported and positioned at the bottom of the reactor, through this nozzle plate the current of heated gas oxygen  pass in a finely divided state to circulate through the solution part of which escapes through SO2 Recovery Unit ( Pos 2)  at the top of the reactor.

    The process may be carried out in the described apparatus as follows:

    Reactor is charged with metallic copper and a suitable amount of dilute sulphuric acid and distilled water. By the way un-crystallized solution and water-recovered SO2 gas from recovery unit (Pos.2)  as H2SO3  are turned back to the reactor for further concentration.

    The needed gas oxygen for the process is produced by an PSA oxygen generating system (Pos 8) from Compressed Air. (Pos 7) The produced oxygen is heated by waste heat recovery unit of air compressor and/or  oil/water heater. (pos 10)  if necessary during the cold weather conditions.

    The heated gas oxygen flow and pressure is controlled and regulated by a regulator and valve to control the requested reaction temperature. The gas oxygen is also used in the process to speed up oxidation of copper.

     A rotating mixer located at the top of leaching reactor  is mixing the solution till reaching the desired solution density. Meanwhile there is a constant monitoring system to measure Ph level and solution temperature.

    When desired solution density is obtained, solution is transferred to crystallization tank    (Pos 3)   by way of vacuum pressure (Pos 12)  and wait for the cooling and crystallization of the CuSO4  At the end of the crystallization period, while crystallized particles are transferred to the drying unit (Pos 5) , un-crystallized solution turn back to the waste solution recovery tank (Pos 4)

    Crystallized particles are collected in a storage tank (Pos 14) after passing through drying unit and send to the packing line either through anti-caking agent adding  unit or directly to the packing system depending on the requirement.

    Copper Sulphate (Sulfate)  Manufacturing Line CuSO4 .5H2O


    Production capacity of Plant :5 / 10 / 15 ton/day as a standard

    Final Product will be packed with 25 kgs PP bag's or 1.000 kgs big bag's


    Raw Materials ;

    • Waste Copper (Cu >98%) Scraped
    • H2SO4 (Sulphuric Asit)
    • RAW Water

    * Plant Consumptions  to Producing 1.000 Kgs CUSO4.5H2O (CopperSulfate Penta Hydrade) 

    * PLANT CONSUMPTIONS Amount
    1 Waste Copper (Cu 99%) 255 Kgs
    2 H2SO4 400 Kgs
    3 Water  750 Kgs
    4 Electricity ~100 KWh

    • Specification (Compound)
    • Copper (Cu) : 25 %
    • Cupric sulphate, pentahydrate : 98 %
    • Appearance : Free Fluent Granule/Powder. NonHygroscopic.
    • Partikel Size : 0,1 mm –0,85 mm > 90%
    • Loss on drying : 2 %
    • Compliance with EU Directive :  2002/32/EC
    • Cas No: 7758-99-8

     


    • Operating Condition

    • Control & Instrumentation: PLC based Programmable Controller (Siemens)
    • Service Life: At least 20 Years
    • Average life to Overhaul: 8 Years
    • Certification and Approvals: ISO 9001:2008 - ISO 13485:2010 – 93/42 EEC(EU) – 98/37EC(EU)
    • Manufacturer: Mentis Engineering Mechanical & Chemical Co. Ltd.
    • Country Of Origin: Turkey
    • Terms of Delivery : Ex-Works / Turkey / 3  month (Avarage)

    Agriculture 
    A. Major uses 
    01- Preparation of Bordeaux and Burgundy mixtures for use as fungicides
    02- Manufacture of other copper fungicides such as copper-lime dust, tribasic
    03- copper sulphate, copper carbonate and cuprous oxide
    04- Manufacture of insecticides such as copper arsenite and Paris green
    05- Control of fungus diseases
    06- Correction of copper deficiency in soils
    07- Correction of copper deficiency in animals
    08- Growth stimulant for fattening pigs and broiler chickens
    09- Molluscicide for the destruction of slugs and snails, particularly the snail host of the liver fluke


    B. Other uses 
    01- Seed dressing
    02- Soil steriliser, e.g. Cheshunt compound (a mixture of copper sulphate and ammonium carbonate) to prevent ""damping-off"" disease of tomato, etc.
    03- Control and prevention of foot rot in sheep and cattle
    04- Bacteriastat for addition to sheep dips
    05- Disinfectant in prevention of the spread of swine erysepelas and white scours in calves
    06- Control of scum in farm ponds
    07- Plant nutrient in rice fields
    08- Preservative for wooden posts, wooden buildings, etc.
    09- Preservative for wooden fruit boxes, planting baskets and other containers
    10- Ingredient of vermin repellents, e.g. for application to bark of trees against rabbits
    11- Stimulant of latex yield on rubber plantations
    12- Protection against algal growths on flower pots
    • Public Health and Medicine 
    01- Destruction of algal blooms in reservoirs and swimming pools
    02- Prevention of the spread of athletes foot in warm climates, by incorporation in the flooring mixture of swimming baths
    03- Control of bilharzia in tropical countries, as a molluscicide
    04- Prevention of malaria, in the preparation of Paris green for use against mosquito larvae
    05- Antiseptic and germicide against fungus infections
    06- Catalyst or raw material for the preparation of copper catalysts used in the manufacture of pharmaceutical products

    • Industry 
    A. Adhesives 
    01- Preservative in casein and other glues
    02- Additive to book binding pastes and glues, for insecticidal purposes
    03- Additive to animal and silicate glues to give water resistance

    B. Building
    01- Timber preservative and in the preparation of other wood preservatives, e.g. oil based copper naphthenates and water based copper/chrome/arsenic for the prevention of woodworms and wood rots
    02- Ingredient of plaster to prevent fungus infection, e.g. to prevent the spread of dry rot
    03- Ingredient of concrete, both as a colouring matter and as an antiseptic, e.g. for use in and around swimming pools
    04- Modification of the setting of concrete
    05- Protection against lichens, moulds and similar growths on asbestos cement roofing and other building materials
    06- Control of the growth of tree roots in sewers

    C. Chemical
    01- Preparation of catalysts for use in many industries
    02- Purification of gases, e.g. removal of hydrogen chloride and hydrogen sulphide
    03- Precipitation promoter in purifying zinc sulphate solutions
    04- Precipitation of alkaloids as double salts from crude extracts
    05- Source of other copper compounds such as copper carbonate silicate/arsenite/aceto-arsenite/resinate/stearate/tartrate/oleate naphthenate/chromate/chlorate /alginate/fluoride/hydroxide, cuprous oxide/chloride/cyanide and cuprammonium compounds
    D. Decorative trades
    01- Colouring glass
    02- Colouring cement and plaster
    03- Colouring ceramic wares
    04- Alteration of metal colours, e.g. darkening of zinc, colouring aluminium

    E. Dyestuffs 
    01- Reagent in the preparation of dyestuffs intermediates Catalyst or raw material for the preparation of copper catalysts, e.g. preparation of phenols from diazo compounds, preparation of phthalocyanine dyes

    F. Leather
    01- Mordant in dyeing
    02- Reagent in tanning processes
    G. Metal
    01- Electrolyte in copper refining

    H. Electrical
    01- Electrolyte in copper plating and electro forming
    02- Electrolytic manufacture of cuprous compounds, e.g. cuprous oxide
    03- Constituent of the electrodes and electrolytes in batteries
    04- Electrolyte in the manufacture of copper powder
    05- Electrolyte in aluminium plating and anodising
    06- Copper coating steel wire, prior to wire drawing
    07- Pickling copper wire, etc., prior to enamelling
    08- Providing a suitable surface for marking out iron and steel

    I. Mining 
    01- Flotation reagent in the concentration of ores, e.g. zinc blende

    J. Paint 
    01- Raw material for the manufacture of copper naphthenate and other copper compounds for use in anti-fouling paints
    02- Preparation of certain varnish or paint dryers, e.g. copper oleate, copper stearate
    03- Preparation of certain pigments, e.g. copper chromate, copper ferrocyanide, copper phthalocyanine"

    K. Printing
    01- Etching agent for process engraving
    02- Electrolyte in the preparation of electrotype
    03- Ingredient of printing inks

    L. Synthetic rubber
    01- Preparation of catalysts used in cracking certain gaseous and liquid petroleum

    M. petroleum
    01- Fractions
    02- Preparation of cuprous chloride, used in the purification of butadiene and in the separation of acetylene derivatives
    03- Preparation of catalysts used in chlorinating rubber latex
    04- Purification of petroleum oils

    N. Textiles 
    01- Preparation of copper compounds for rot-proofing canvas and other fabrics
    02- Rot-proofing sandbags
    03- Mordant, especially in calico printing
    04- Cuprammonium process for the production of rayon
    05- Production of aniline black and diazo colours for dyeing
    06- After coppering to increase the fastness of dyes
    07- Catalyst in the manufacture of cellulose ethers and in cellulose acetylation

    O. Miscellaneous 
    01- Improving the burning qualities of coke
    02- Laboratory analytical work
    03- Ingredient of laundry marking ink
    04- Dyeing of hair and horn
    05- Ingredient of hair dyes of the phenylene diamine or pyrogallol type
    06- Preparation of chlorophyll as a colouring material for food stuffs
    07- Imparting a green colour in fireworks
    08- Activator in the preparation of active carbons
    09- Preservative for wood pulp
    10- Preservation of fishing nets and hides on trawls
    11- Obtaining a blue-black finish on steel
    12- Treatment of carbon brushes
    13- Ingredient of the solution used for preserving plant specimens in their natural colours
    14- Impregnation in fruit wrapping papers to prevent storage rots