Cathodic Protection System of the Spiral Classifier at the KGHM Polska Miedź S.A. Ore Concentration Plant—Case Study of Commissioning and Control of Operating Parameters

Abstract

The project involved designing, constructing and commissioning a cathodic protection system for a selected spiral classifier operating at the KGHM Polska Miedź S.A. Ore Concentration Plant (O/ZWR). The authors developed a concept and assumptions regarding the corrosion protection of a large industrial device using a cathodic protection system with an external power source. Pre-project studies included conducting a trial polarization of one of the 28 classifiers operating at O/ZWR. The obtained results enabled the determination of the protective current demand required and the selection of a target polarization device, ensuring the flow of current with an intensity that guarantees that the required corrosion protection level will be achieved. The ultimately installed cathodic protection system consisted of an external cathodic protection current source with maximum output parameters of 50V/20A, a power supply system and a polarization anode system. Elements for monitoring corrosion occurring during system operation were installed, which employed reference electrodes of zinc (Zn) and silver chloride (Ag/AgCl) to measure the potential of the structure under cathodic protection. Furthermore, resistive corrosion sensors were installed to measure the steel corrosion rate under polarization conditions, making it possible to assess the effectiveness of the protection. The system will also be equipped with a prototype system for remote monitoring of the operation of the protection system, enabling online observation and analysis of settings and temporary indicators influencing the ongoing corrosion processes.