Use of Monolithic Cell Liners for Recovery and Performance Improvement of Damaged Cells, Codelco Chuquicamata Refinery

The narrow profit margins in the refinery business motivate us to extend the useful life of our assets without significant investments. One of the refinery's key assets is its electrolytic cells; the current refinery has 1,776 active cells, most of which were installed 20 to 30 years ago nearing the end of their design lifespan. To address declining cell performance, we sought to improve cell tightness, eliminate current leakage, enhance current efficiency, and prevent structural deterioration. The concept of using monolithic cell liners emerged as a solution to these challenges. These liners offer a practical method for replacing or repairing damaged cells while maintaining production capacity. They are designed to operate at high temperatures and withstand corrosive electrolytic acid solutions. Additional benefits include improved thermal insulation, potentially leading to energy savings. This paper details the design, manufacturing, installation, and performance of these monolithic cell liners at the Chuquicamata Refinery, focusing on initial production phases and progression from late 2024 to early 2025. This work was carried out in collaboration with the North American company Sunwest, which specializes in manufacturing this type of monolithic coating.