Erection and Commissioning of 6,000 TPA Copper Cathode Plant

Client: Gujarat Victory Forging Pvt. Ltd. Location: Vadodara, Gujarat, India Execution: Turnkey Design, Erection, and Hot Commissioning Capacity: 6,000 TPA

Sector of Activity

Secondary Copper Refining & Smelting

Execution Model

Turnkey Design, Erection, and Hot Commissioning

Production Capacity

6,000 TPA

Primary Feedstock

Secondary Copper Scrap (Birch/Cliff)

Output Specification

LME Grade-A Copper Cathodes (99.99% Cu)

Project Status

Completed & Operational

Commercial Challenge & Objectives

The client required a highly reliable, scalable manufacturing facility to extract commercial-grade copper cathodes using secondary copper scrap as raw material. The primary objective was to deliver a low-Capex, high-recovery processing core capable of maintaining strict operational efficiency and consistent throughput under varying scrap qualities.

Core Process Engineering Scope

Proventus Valuetech isolated and engineered the high-value metallurgical core of this facility:

Advanced Pyrometallurgical Block

Comprehensive design, sizing, and thermal balance configurations for the scrap-melting and fire-refining furnace circuits.

High-Purity Electrorefining System

Custom design of the electrolytic cell house layout, optimized busbar structures to maximize current density, and an advanced electrolyte circulation system to prevent impurity occlusion.

Detailed Engineering Package

Delivery of 3D digital plant models, core process flow diagrams (PFDs), and piping and instrumentation diagrams (P&IDs) for the fluid circuits.

Project Delivery Mode Execution

Turnkey EPC & EPCM Delivery

Acting under a Turnkey Supply and EPCM framework, Proventus Valuetech managed the engineering design, fabrication coordination of specialized cell components, on-site supervision of core mechanical erection, and the execution of final hot chemical commissioning protocols to hand over an operating plant.

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