Synthesis of electrolytic copper and nickel powders from the copper bleed electrolyte of a copper smelter

The adaptation of certain processes for utilization of secondary resources to produce valuable products is currently given due attention in the metal extraction.
Copper bleed solution (CBS) obtained during electropurification of the impure copper anode to produce copper cathode for the purpose of controlling impurity, is one such secondary source which can be treated to produce valuable products. Copper bleed solution generated at Indian Copper Complex (ICC), Ghatsila contains 39.86 g/L Cu,
9.58 g/L Ni, 0.26 g/L Fe, 0.108 g/L Bi, 0.007 g/L As, 0.055 g/L Sb, 198.04 g/L H2S04. The recovery of copper and nickel as high value products such as metal powders from
the bleed stream of the copper smelter by pretreatment-solvent extraction (SX) separation-electrowinning (EW) has been attempted to provide an alternative to the
conventional process. The purity of the eletrolytic copper and nickel powders so produced was found to be 99.93% and 99.89%, respectively. The compact density of the annealed copper powder was 8.74 g/cc whereas it was 7.72 g/cc for nickel powder. The other properties of the copper and nickel powders such as flow-ability, particle size, etc.
were found to be suitable for the P/M applications.