Copper mining operations rely on Sulfuric Acid Tank Houses to extract and refine copper. In these facilities, cathodes are submerged in a sulfuric acid solution to facilitate electrowinning, where copper ions adhere to the cathodes, forming pure copper sheets. However, the highly corrosive sulfuric acid environment poses a major challenge to electrical infrastructure, particularly power and control cables. Over time, standard commodity cables deteriorate due to acid exposure, leading to frequent cable failures, unplanned downtime, and increased maintenance costs.
A leading U.S. copper mining operation was experiencing persistent cable failures in its tank house due to the use of low-grade commodity cables that could not withstand prolonged sulfuric acid exposure. The mine collaborated with an Amphenol TPC Wire & Cable sales representative and field engineer to identify a more reliable solution.
The recommended solution was Super-Trex® Multi-Conductor P&R Cable, specifically engineered for harsh mining environments where chemical resistance and durability are critical. This cable is ideal for powering sensors and control systems in sulfuric acid tank houses due to its:
CUSTOMER’S RESULT:
Reduced Downtime & Lower Maintenance Costs
By replacing failing commodity cables with Amphenol’s Super-Trex® Multi-Conductor P&R Cable, the mining operation achieved:
✅ Extended cable lifespan – Reducing the need for frequent replacements and unscheduled maintenance.
✅ Significant downtime reduction – Ensuring continuous and more consistent copper production.
✅ Lower total cost of ownership – The durable, acid-resistant design eliminated recurring failures, reducing long-term expenses.
✅ Enhanced operational efficiency & safety – Reliable sensor operation in highly corrosive sulfuric acid environments, preventing costly disruptions.
With each stack of copper sheets valued at $37,000 and seven stacks processed per hour, downtime could cost approximately $259,000 per hour! By preventing cable failures, Super-Trex® P&R Cable helped the mine minimize financial losses, maintain peak production levels, and reduce maintenance costs. Its robust construction provided long-term reliability, ensuring safer, more efficient mining operations and giving the customer peace of mind.
Amphenol TPC Wire & Cable delivers mining-grade cable solutions engineered to withstand the extreme demands of copper mining, mineral processing, and electrowinning operations. Our innovative solutions help mines maintain safe, efficient, and cost-effective production while mitigating the risks of equipment failure in corrosive environments.
