Exercise 6 Electrowinning

Copper is produced electrolytically using either electrolytic refining (ER) or electrowinning (EW). In ER, impure copper dissolves at the anode and pure copper deposits on the cathode. In EW, the insoluble anode evolves gas while pure copper deposits on the cathodes from the pregnant solution. Energy consumption in both methods depends on cell voltage and current efficiency. Cell voltage consists of anode/cathode equilibrium potentials, polarization losses, solution resistance, and connection losses. The document then provides examples calculating copper deposition, cathode mass, cell dimensions, and energy consumption for copper electrowinning based on various operating parameters and conditions.

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Exercise 6 Electrowinning

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CHEM-E6180 - Fundamentals of Hydrometallurgy (5 cr)

Exercise 6, 18.10.2016, Electrowinning

NOTE: This exercise has also instructions to homework that is evaluated with maximum
10 p.

Topics: Electrowinning, Dimensioning an electrochemical reactor, calculation of energy

consumption

Copper is produced electrolytically using either electrolytic refining (ER) or electrowinning

(EW). In electrolytic refining, the impure copper anode (98-99% Cu) is dissolved and pure
copper is deposited on the cathode (99.996% Cu) due to the inserted electricity. Whereas,
in electrowinning, the anode is insoluble and the anode reaction gas evolution. The
cathodes are again pure copper, which are deposited by copper from pregnant solution.
Energy consumption in both methods depends on the cell voltage and current efficiency.
The electrolysis cell voltage is composed of the difference between anode and cathode
equilibrium potentials, anodic and cathodic polarization, solution resistance and voltage
losses in the bus bars and connections.

First some refresher work on electrochemical systems, consult Free’s book Chapter 7
and PP slides of exercise lecture:

1. Copper electrowinning energy consumption

a) A copper electrowinning tankhouse operates at current density 300 A/m 2 and the
average cell voltage between the anode and the cathode is 2.2 V. Calculate copper
deposition current efficiency when the copper electrowinning energy consumption is 1.89
kWh/kg. Answer: about 98%.

b) A copper electrowinning tankhouse operates at current density 300 A/m2. First,

calculate the average cell voltage between the anode and the cathode (Tip: determine
the theoretical voltage of reactions and define then cell voltage according to average
shares of affecting factors). Then, calculate the copper electrowinning energy
consumption in kWh/kg when copper deposition current efficiency is 96%. Answer: about
1.5 kWh/kg.

2. Mass of copper cathode

a) In copper electrowinning tankhouse, the cathode plates are made of stainless steel,
and copper is deposited on them and removed mechanically after the plate has sufficient
thickness. Using the conditions of example 1, what is the cathode weight when it is
stripped after 7-day deposit period? Cathode surface area is 1 m2. Answer: about 60 kg.

b) With the same set-up introduced in 2. a), how long does it take to deposit 85.2 kg on
cathode, which has the surface area of 2.5 m2? Answer: about 4 years.
3. Calculate the the range of lenght for electrowinning cell, when the current density can
be adjusted between 300-350 A/m2. Cell consists of ten cathodes that have the surface
area of 1 m2 each. Current efficiency is 95% and calculated mass of deposited copper is
60 kg for each cathode. The electrowinning cell is 1.2 m wide and 1.5 m deep, while the
solution flow is 85 L/h. Answer: Length of cell varies between 6.5-7.6 m.

Home exercise:
4. Fixed temperature of 45 °C and current density of 300 A/m2 were used in
electrowinning. The surface area of cathode is 1.0 m2. The copper concentration in feed
was 25 g/L and sulfuric acid concentration 130 g/L. The symmetry factor for copper
reduction (cathode reaction) is 0.5 and for oxygen evolution (anode reaction) 0.17. The
thickness of diffusion layer was 0.5 mm. Electrolyte included next inclusions: As = 0.1 g/L
and Ni = 0.1 g/L. Distance between electrodes is 10 cm. Deposition current efficiency is
95%. Use ilimm = 10,000 A/m2 and i0 = 0.023 A/m2 for oxygen evolution. First, calculate
the cell voltage (when you know occurring reactions, then cathodic and anodic
overpotentials as well as potential drop due to solution resistivity can be calculated).
Finally, calculate the energy consumption. Answer: Ecell about 2.3 V and energy
consumption about 2 kWh/kg