Zero Safety Incidents
EW Cell Crud Removal at High-Altitude Copper Plant
Operation
Copper SX/EW Plant
Location
Atacama Region, +4,200 masl
Service
Comprehensive EW cell crud removal
Management System
SG-SSSC (Safety, Health, Sustainability)
The Challenge
EW cell cleaning under extreme high-altitude conditions
Operational Problem
The accumulation of metallic and organic crud at the bottom of cells during electrolytic operation creates multiple problems affecting EW process efficiency and safety.
Short Circuits
Metallic deposits cause electrical failures and safety risks
High Power Consumption
Accumulated crud increases resistance and energy costs
Cathode Quality
Contamination reduces copper purity
Extreme Conditions
Hypobaric conditions requiring special protocols and trained personnel
- • Electrical risk in energized cells
- • Exposure to acid mist
- • Mechanical entrapment risk
- • Confined space work
Strict compliance with MLCC's Safety, Health, Sustainability and Communities Management System
The Tec-Ionic Solution
Comprehensive crud removal methodology with the highest safety standards
Safety Analysis
JSA and electrical/structural parameter review for each cell
Electrode Removal
Controlled removal of 3 cathodes and 3 anodes to enable access
Vacuuming and Cleaning
Pneumatic crud suction and controlled-pressure hydraulic cleaning
Verification and Reinstallation
Leveling, electrode reinstallation and photographic record
Specialized Equipment
All equipment certified and designed for high-altitude operations
Safety Management
Certified PPE
- • P100 filter respirators
- • Waterproof suits
- • Dielectric footwear
Procedures
- • Lockout/Tagout (LOTO)
- • Gas verification and ventilation
- • Special permits (hot work, confined spaces)
Training
- • HYPOBARIA (geographic altitude work)
- • PREXOR (noise exposure)
- • PLANESI (silica exposure)
Verifiable Results
Measurable impact on safety, quality and operational continuity
Safety
- "Life-Saving Rules" compliance
- 100% deadlines met
- Law 20.393 adherence
Quality
- Electrical conductivity restored
- Cathodes within LME standard
- Georeferenced photographic record
Operations
- Reduced energy consumption
- Lower short-circuit risk
- Successful staged planning
Tec-Ionic's operating model proved to be an efficient, quick-to-implement, low-impact alternative for operations under extreme high-altitude conditions.
Environmental Management
Waste Control
Metallic waste and contaminated water stored in sealed containers
DS-43 Regulation
Disposal in accordance with current MINSAL regulations
PR-SUST Compliance
PR-SUST-009 and PR-SUST-010 compliance for hazardous substances
Need Crud Removal Services for Your EW Plant?
Our specialized team operates under extreme conditions with the highest safety standards. We guarantee measurable results and zero incidents.