Projects
Innovation in Automated Anode Pressing: A Tailored Lug Press Solution
Dan Pozzobon, Designer at The EPCM Group
As one of the largest copper refineries in North America, a leader in diversified natural resource production. The refinery plays a pivotal role in the value chain, transforming copper anodes into high-purity cathodes used in energy, electronics, and infrastructure.
Challenge
The client required an upgraded anode preparation process to improve resolve a reliability issue within its hydrometallurgical operation. The specific need was to replace an aging lug press system in immanent failure that had become a downtime risk, high maintenance, and mechanical challenges.
A prior attempt to mitigate the failure but was a temporary stop-gap solution and had failed to meet the operational constraints and performance targets of the facility. The client needed more than just a replacement — they needed a custom-engineered solution that could be integrated with their existing brownfield infrastructure, without disrupting production timelines.
Solution
EPCM’s engineering and automation team in Oakville Canada, took on the challenge by developing a custom lug press as part of a broader Anode Preparation Machine (APM) system tailored to the client’s specific plant requirements.
This turnkey solution included:
- Complete 3D and 2D mechanical engineering
- Custom press design for high-precision lug forming
- Fully assembled industrial electrical installation
- Pre-installed hydraulics
- Factory Acceptance Testing (FAT) using simulated load conditions
- On-site Installation and Commissioning support and documentation package in accordance with Canadian and international standards
For this project, EPCM proposed a design that was a solid solution — highlighting our ability to think differently and deliver smarter, value-driven solutions for our clients.
This not only ensured a better return on investment but also demonstrated our flexibility in adapting designs to each client’s operational and budgetary constraints.
Outcome
The new APM Lug Press was delivered as a modular system at the client. Key improvements include:
- Improved uptime: Design optimization reduced potential failure points and simplified maintenance.
- Custom-fit integration: Built to seamlessly match existing layout constraints and interface requirements.
- Automation-ready: Fully compatible with Industry 4.0 standards including remote diagnostics and predictive maintenance.
- Standardized spare parts across multiple EPCM installations in the region, reducing operational overhead.
This solution not only meets current performance needs but is also scalable for future expansions of the client’s refinery operations.
Trusted Engineering for Global Impact
With over 45 years of experience across continents and industries, EPCM provides end-to-end solutions — from concept and design to manufacturing, delivery, and post-sale support. We work alongside our clients to solve complex challenges with smart, scalable systems tailored to their needs.
Ready to upgrade your process with customized automation and engineering? Contact us: info@epcm.com
