Copper electrolytic refining heat preservation-cooling-heat energy recovery integrated energy-saving system

Abstract

The present application relates to non-ferrous metallurgy and energy-saving and environment-protecting technical field, specifically relates to a copper electrolytic refining heat preservation-cooling-heat energy recycling integrated energy-saving system, central control unit is respectively connected with electrolytic cell composite heat preservation module, electrolyte intelligent cooling module, heat energy recycling module electricity, tank body heat preservation assembly is arranged on the outer wall of electrolytic cell, the tank surface sealing heat preservation assembly covers on the electrolytic cell liquid surface, circulating tank cooling assembly is communicated with electrolyte circulating pipeline of electrolytic cell, temperature monitoring unit is arranged in electrolyte circulating pipeline and circulating tank, heat energy recycling module includes heat energy capture assembly, heat energy transmission assembly and heat energy reuse assembly, heat energy transmission assembly is connected with heat energy capture assembly and heat energy reuse assembly respectively, the present application realizes the automation dynamic balance control of heat preservation-cooling-heating, controls electrolyte temperature fluctuation in a small range, effectively guarantees the crystallization quality of cathode copper.

Description

Technical Field

[0001] This invention relates to the fields of non-ferrous metal metallurgy and energy conservation and environmental protection technology, specifically to an integrated energy-saving system for copper electrolytic refining involving heat preservation, cooling, and heat recovery. Background Technology

[0002] Copper electrolytic refining is a key process in copper smelting. It uses direct current to dissolve copper at the anode and deposit copper at the cathode, ultimately yielding high-purity cathode copper. This process has strict requirements on the electrolyte temperature, which must be maintained within a stable range of 65-69℃ to ensure electrolytic reaction efficiency and cathode copper quality. Current technologies typically use steam heating to maintain the electrolyte temperature, but this method still presents many problems that need to be solved in practical applications.

[0003] First, the insulation effect is poor and the energy consumption is high. Traditional electrolytic cells are mostly made of concrete or vinyl ester resin quartz sand, which have poor insulation performance. Especially in areas with large seasonal temperature differences, the cell loses heat quickly in winter, resulting in high steam consumption; in summer, due to insufficient insulation and the combined effect of ambient temperature, the electrolyte temperature is prone to exceed the standard. To improve this situation, relevant technical fields have carried out targeted research. For example, patent CN208501123U discloses an energy-saving electrolytic copper refining device. By setting up a double-layer cell structure with an inner and outer tank and using an acid-resistant pump to achieve electrolyte circulation, it reduces energy consumption and improves the quality of refined copper to a certain extent. However, the core improvement of this patent focuses on the optimization of electrode structure and the design of cell circulation, without specifically strengthening the insulation structure of the electrolytic cell, nor solving the core problems of rapid heat loss and excessive steam consumption in winter. Its insulation performance still relies on the traditional cell structure itself, which is difficult to meet the needs of low-energy production.

[0004] Secondly, the problem of temperature control imbalance is prominent. Relying solely on steam heating cannot achieve precise control of electrolyte temperature. Heating energy consumption is high in winter, and there is a lack of effective cooling measures in summer, which can easily lead to quality problems such as increased silver content in cathode copper. In existing technologies, some cooling solutions only use simple ventilation and heat dissipation structures without coordinated control with the insulation system, resulting in low temperature control accuracy and difficulty in adapting to the temperature requirements of different seasons and operating conditions.

[0005] Furthermore, there is a serious problem of heat energy waste. During the electrolysis process, the power supply system resistance generates a large amount of heat energy, which accounts for a certain proportion of the total energy consumption of electrolysis. Existing technologies, including the device disclosed in patent CN208501123U, do not effectively recover this heat energy, resulting in the direct loss of heat energy into the environment and causing energy waste. At the same time, there is also heat loss during the steam heating process, which further increases the overall energy consumption. Summary of the Invention

[0006] To address the problems existing in the prior art, the present invention provides an integrated energy-saving system for copper electrolytic refining, including heat preservation, cooling, and heat recovery.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows:

[0008] An integrated energy-saving system for copper electrolytic refining, comprising an electrolytic cell composite insulation module, an electrolyte intelligent cooling module, a heat recovery module, and a central control unit, wherein the central control unit is electrically connected to the electrolytic cell composite insulation module, the electrolyte intelligent cooling module, and the heat recovery module respectively; the electrolytic cell composite insulation module includes a cell body insulation component and a cell surface sealing insulation component, wherein the cell body insulation component is disposed on the outer wall of the electrolytic cell, and the cell surface sealing insulation component covers the electrolyte surface of the electrolytic cell; the electrolyte intelligent cooling module includes a circulating tank cooling component and a temperature monitoring unit, wherein the circulating tank cooling component is in contact with the electrolyte in the electrolytic cell. The circulation pipeline is connected, and the temperature monitoring unit is installed in the electrolyte circulation pipeline and circulation tank. The heat energy recovery and utilization module includes a heat energy capture component, a heat energy transfer component, and a heat energy reuse component. The heat energy capture component is installed at the power supply system of the electrolytic cell. The heat energy transfer component is connected to the heat energy capture component and the heat energy reuse component respectively. The heat energy reuse component includes a heat exchange coil and a temperature regulating valve. The heat exchange coil is wound around the outside of the electrolyte circulation pipeline or embedded in the inner wall of the electrolyte storage tank. The inlet of the heat exchange coil is connected to the heat-insulated conveying pipe. The temperature regulating valve is installed at the outlet end of the heat exchange coil and is electrically connected to the central control unit.

[0009] Furthermore, the tank insulation component includes, in sequence, a base bonding layer, a needle-punched felt filling layer, a thin insulation board filling layer, a thick insulation board covering layer, a fiberglass cloth reinforcement layer, and a resin protective layer; the needle-punched felt filling layer is used to fill gaps between electrolytic cells with a width ≤ 5cm, the thin insulation board filling layer is used to fill gaps between electrolytic cells with a width 5-15cm, and the thick insulation board covering layer has a thickness of 5-10cm and is made of ceramic fiber felt.

[0010] Furthermore, the tank surface sealing and insulation component includes a PVC polypropylene acid-resistant tank cover, a sealing frame, and elastic clamping components. The edge of the PVC polypropylene acid-resistant tank cover is attached to the opening of the electrolytic tank through the sealing frame. The elastic clamping components are evenly distributed on the outside of the sealing frame. The tank surface sealing and insulation component is also equipped with a temperature sensor, which is electrically connected to the central control unit.

[0011] Furthermore, the circulating tank cooling assembly includes fiberglass pipes, an axial flow fan, an acid mist settling tower, and an airflow regulating valve. The fiberglass pipes have a diameter of 350-450mm, one end of which is connected to the circulating tank, and the other end is connected to the axial flow fan. The airflow of the axial flow fan is 15000-20000m³. 3 / h, the acid mist settling tower is connected to the top of the circulation tank, and the air volume regulating valve is installed on the fiberglass pipe and electrically connected to the central control unit.

[0012] Furthermore, the heat capture component includes a high-temperature resistant heat-conducting plate, a heat insulation cover, and a heat collection cavity. The high-temperature resistant heat-conducting plate is disposed on the surface of the resistive heating component of the power supply system, the heat insulation cover is disposed on the outside of the resistive heating component, and the heat collection cavity is filled with a heat-conducting medium.

[0013] Furthermore, the heat transfer component includes a heat-conducting pipe, a circulating pump, and an insulated delivery pipe. One end of the heat-conducting pipe is embedded in the heat-conducting medium of the heat collection cavity, and the other end is connected to the insulated delivery pipe through the circulating pump. The insulated delivery pipe is connected to the heat reuse component.

[0014] Furthermore, the temperature monitoring unit includes a first temperature sensor installed in the electrolyte inlet pipe, a second temperature sensor in the circulation tank, and a third temperature sensor in the electrolyte outlet pipe. The measurement accuracy of the first temperature sensor, the second temperature sensor, and the third temperature sensor is ±0.5℃, and the measurement range is 40-80℃.

[0015] Furthermore, the central control unit includes a data processing module, a PID adjustment module, and an execution control module. The data processing module receives monitoring data from the temperature monitoring unit and the heat capture component. The PID adjustment module generates control signals based on preset temperature thresholds. The execution control module controls the axial flow fan speed, the air volume regulating valve opening, the temperature regulating valve opening, and the circulating pump power, respectively.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0017] 1. This invention constructs a heat energy recovery loop from the power supply system to the electrolyte, recovering the waste heat generated by the resistive heating components of the power supply system and using it to heat the electrolyte, which significantly reduces the external energy consumption required to maintain the electrolyte temperature during electrolysis production.

[0018] 2. Through data processing and PID regulation by the central control unit, automated dynamic balance control of "heat preservation-cooling-heating" is realized, which keeps the electrolyte temperature fluctuation within a small range and effectively ensures the crystallization quality of cathode copper.

[0019] 3. The graded filling insulation structure for different gap widths eliminates the thermal bridging effect and significantly reduces heat loss; combined with the tank surface sealing component and acid mist settling tower, it effectively suppresses and treats acid mist emission while preventing heat loss, thus improving the workshop working environment.

[0020] 4. The heat capture component actively removes the accumulated heat from the power supply system, reducing the risk of electrical components failing due to overheating while recovering heat energy and extending the service life of the equipment. Attached Figure Description

[0021] The embodiments of the present invention will be further described below with reference to the accompanying drawings, wherein:

[0022] Figure 1 A schematic diagram showing the connection relationship between the modules of this invention is provided. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0024] Reference Appendix Figure 1 An integrated energy-saving system for copper electrolytic refining, comprising an electrolytic cell composite insulation module, an electrolyte intelligent cooling module, a heat recovery and utilization module, and a central control unit, wherein the central control unit is electrically connected to the electrolytic cell composite insulation module, the electrolyte intelligent cooling module, and the heat recovery and utilization module respectively; the electrolytic cell composite insulation module includes a cell body insulation component and a cell surface sealing insulation component, the cell body insulation component being disposed on the outer wall of the electrolytic cell, and the cell surface sealing insulation component covering the electrolyte surface; the electrolyte intelligent cooling module includes a circulating tank cooling component and a temperature monitoring unit, wherein the circulating tank cooling component is connected to the electrolytic cell... The electrolyte circulation pipeline of the tank is connected, and the temperature monitoring unit is set in the electrolyte circulation pipeline and the circulation tank. The heat energy recovery and utilization module includes a heat energy capture component, a heat energy transfer component and a heat energy reuse component. The heat energy capture component is set at the power supply system of the electrolytic cell. The heat energy transfer component is connected to the heat energy capture component and the heat energy reuse component respectively. The heat energy reuse component includes a heat exchange coil and a temperature regulating valve. The heat exchange coil is wound around the outside of the electrolyte circulation pipeline or embedded in the inner wall of the electrolyte storage tank. The inlet of the heat exchange coil is connected to the heat insulation conveying pipe. The temperature regulating valve is set at the outlet end of the heat exchange coil and is electrically connected to the central control unit.

[0025] In one embodiment of the present invention, the tank insulation component includes a base bonding layer, a needle-punched felt filling layer, a thin insulation board filling layer, a thick insulation board covering layer, a fiberglass cloth reinforcement layer, and a resin protective layer arranged sequentially; the needle-punched felt filling layer is used to fill gaps between electrolytic cells with a width ≤ 5cm, the thin insulation board filling layer is used to fill gaps between electrolytic cells with a width 5-15cm, and the thick insulation board covering layer has a thickness of 5-10cm and is made of ceramic fiber felt.

[0026] In one embodiment of the present invention, the tank surface sealing and heat preservation component includes a PVC polypropylene acid-resistant tank cover, a sealing frame and an elastic clamping component. The edge of the PVC polypropylene acid-resistant tank cover is attached to the opening of the electrolytic tank through the sealing frame. The elastic clamping component is evenly distributed on the outside of the sealing frame. The tank surface sealing and heat preservation component is also provided with a temperature sensor, which is electrically connected to the central control unit.

[0027] In one embodiment of the present invention, the circulating tank cooling assembly includes a fiberglass pipe, an axial flow fan, an acid mist settling tower, and an airflow regulating valve. The fiberglass pipe has a diameter of 350-450 mm, one end of which is connected to the circulating tank, and the other end is connected to the axial flow fan. The airflow of the axial flow fan is 15,000-20,000 m³ / h. 3 / h, the acid mist settling tower is connected to the top of the circulation tank, and the air volume regulating valve is installed on the fiberglass pipe and electrically connected to the central control unit.

[0028] In one embodiment of the present invention, the heat capture component includes a high-temperature heat-conducting plate, a heat insulation cover, and a heat collection cavity. The high-temperature heat-conducting plate is disposed on the surface of the resistance heating component of the power supply system, the heat insulation cover is disposed on the outside of the resistance heating component, and the heat collection cavity is filled with a heat-conducting medium.

[0029] In one embodiment of the present invention, the heat transfer component includes a heat-conducting pipe, a circulating pump, and an insulated delivery pipe. One end of the heat-conducting pipe is embedded in the heat-conducting medium of the heat collection chamber, and the other end is connected to the insulated delivery pipe through the circulating pump. The insulated delivery pipe is connected to the heat energy reuse component.

[0030] In one embodiment of the present invention, the temperature monitoring unit includes a first temperature sensor disposed in the electrolyte inlet pipe, a second temperature sensor disposed in the circulation tank, and a third temperature sensor disposed in the electrolyte outlet pipe. The measurement accuracy of the first temperature sensor, the second temperature sensor, and the third temperature sensor is ±0.5℃, and the measurement range is 40-80℃.

[0031] In one embodiment of the present invention, the central control unit includes a data processing module, a PID adjustment module and an execution control module. The data processing module receives monitoring data from the temperature monitoring unit and the heat capture component. The PID adjustment module generates a control signal according to a preset temperature threshold. The execution control module controls the axial flow fan speed, the air volume regulating valve opening, the temperature regulating valve opening and the circulating pump power, respectively.

[0032] Structurally, the electrolytic cell composite insulation module of this invention includes a cell body insulation component disposed on the outer wall of the electrolytic cell, and a cell surface sealing insulation component covering the liquid surface of the electrolytic cell. The cell body insulation component adopts a multi-layer composite structure, consisting of, from the inside out, a base bonding layer, a needle-punched felt filling layer, a thin insulation board filling layer, a thick insulation board covering layer, a fiberglass cloth reinforcement layer, and a resin protective layer. To address gaps of varying widths generated during electrolytic cell installation, this system employs a graded filling strategy: the needle-punched felt filling layer is specifically used to fill minute gaps ≤5cm wide between electrolytic cells; the thin insulation board filling layer is used to fill medium-sized gaps 5-15cm wide; and the thick insulation board covering layer serves as an overall outer covering, with a thickness of 5-10cm, preferably made of ceramic fiber felt material with excellent thermal insulation properties. The tank surface sealing and insulation component consists of a PVC polypropylene acid-resistant tank cover, a sealing frame, and elastic clamping components. The edge of the cover is tightly fitted to the opening of the electrolytic tank through the sealing frame, and the elastic clamping components are evenly distributed on the outside of the frame to ensure sealing. The component also integrates a temperature sensor to monitor the liquid surface temperature in real time and feed it back to the central control unit.

[0033] The intelligent electrolyte cooling module actively manages the electrolyte's thermal properties through a circulating tank cooling assembly, working in conjunction with a temperature monitoring unit. The circulating tank cooling assembly includes fiberglass pipes with a diameter of 350-450mm and an airflow of 15,000-20,000 m³ / h. 3 The system includes an axial flow fan ( / h), an acid mist settling tower, and airflow regulating valves. One end of a fiberglass duct connects to the circulation tank, and the other end connects to the axial flow fan. The acid mist settling tower is located at the top of the circulation tank. The airflow regulating valves are installed on the duct to control and adjust the cold air flow. The temperature monitoring unit includes first, second, and third temperature sensors respectively installed in the electrolyte inlet pipe, inside the circulation tank, and in the outlet pipe. All sensors have a measurement accuracy of ±0.5℃, covering a process range of 40-80℃.

[0034] The heat recovery and utilization module constructs a heat energy circulation path from the power supply system to the electrolyte. Its heat capture component (including a high-temperature heat-conducting plate, a heat insulation cover, and a heat collection cavity filled with a heat-conducting medium) is directly installed on the surface of the resistance heating component of the power supply system; the heat transfer component transports the collected heat to the heat reuse component through heat pipes, a circulation pump, and an insulated delivery pipe; the heat reuse component uses heat exchange coils (wound around the electrolyte pipeline or embedded in the storage tank) and temperature regulating valves to use the recovered waste heat to heat the electrolyte.

[0035] The central control unit includes a data processing module, a PID regulation module, and an execution control module. By receiving temperature data and heat capture status from various locations, it uses a PID algorithm to generate control commands and dynamically adjusts the axial fan speed, air volume valve opening, heat reuse valve opening, and circulating pump power to maintain the thermal balance of the electrolysis system.

[0036] The present invention has the following beneficial technical effects:

[0037] 1. This invention constructs a heat energy recovery loop from the power supply system to the electrolyte, recovering the waste heat generated by the resistive heating components of the power supply system and using it to heat the electrolyte, which significantly reduces the external energy consumption required to maintain the electrolyte temperature during electrolysis production.

[0038] 2. Through data processing and PID regulation by the central control unit, automated dynamic balance control of "heat preservation-cooling-heating" is realized, which keeps the electrolyte temperature fluctuation within a small range and effectively ensures the crystallization quality of cathode copper.

[0039] 3. The graded filling insulation structure for different gap widths eliminates the thermal bridging effect and significantly reduces heat loss; combined with the tank surface sealing component and acid mist settling tower, it effectively suppresses and treats acid mist emission while preventing heat loss, thus improving the workshop working environment.

[0040] 4. The heat capture component actively removes the accumulated heat from the power supply system, reducing the risk of electrical components failing due to overheating while recovering heat energy and extending the service life of the equipment.

[0041] The foregoing descriptions have outlined some exemplary embodiments of the present invention. It is understood that these embodiments are merely illustrative and do not constitute a limitation on the scope of protection of the present invention. Features in these embodiments can be rearranged in suitable ways, and the resulting solutions remain within the scope of protection claimed by the present invention. All other embodiments obtained by those skilled in the art based on the foregoing embodiments without inventive effort, i.e., all modifications, equivalent substitutions, and improvements made within the spirit and principles of this application, fall within the scope of protection claimed by the present invention.

Claims

1. An integrated energy-saving system for copper electrolytic refining, characterized in that: The system includes an electrolytic cell composite insulation module, an electrolyte intelligent cooling module, a heat energy recovery and utilization module, and a central control unit. The central control unit is electrically connected to the electrolytic cell composite insulation module, the electrolyte intelligent cooling module, and the heat energy recovery and utilization module, respectively. The electrolytic cell composite insulation module includes a cell body insulation component and a cell surface sealing insulation component. The cell body insulation component is disposed on the outer wall of the electrolytic cell, and the cell surface sealing insulation component covers the electrolyte surface. The electrolyte intelligent cooling module includes a circulation tank cooling component and a temperature monitoring unit. The circulation tank cooling component is connected to the electrolyte circulation pipeline of the electrolytic cell, and the temperature monitoring unit... The measuring unit is installed in the electrolyte circulation pipeline and circulation tank; the heat energy recovery and utilization module includes a heat energy capture component, a heat energy transfer component, and a heat energy reuse component. The heat energy capture component is installed at the power supply system of the electrolytic cell. The heat energy transfer component is connected to the heat energy capture component and the heat energy reuse component respectively. The heat energy reuse component includes a heat exchange coil and a temperature regulating valve. The heat exchange coil is wound around the outside of the electrolyte circulation pipeline or embedded in the inner wall of the electrolyte storage tank. The inlet of the heat exchange coil is connected to the heat-insulated conveying pipe. The temperature regulating valve is installed at the outlet end of the heat exchange coil and is electrically connected to the central control unit.

2. The integrated energy-saving system for copper electrolytic refining with heat preservation, cooling, and heat recovery as described in claim 1, characterized in that, The tank insulation component includes, in sequence, a base bonding layer, a needle-punched felt filling layer, a thin insulation board filling layer, a thick insulation board covering layer, a fiberglass cloth reinforcement layer, and a resin protective layer; the needle-punched felt filling layer is used to fill gaps between electrolytic cells with a width ≤ 5cm, the thin insulation board filling layer is used to fill gaps between electrolytic cells with a width 5-15cm, and the thick insulation board covering layer has a thickness of 5-10cm and is made of ceramic fiber felt.

3. The integrated energy-saving system for copper electrolytic refining with heat preservation, cooling, and heat recovery as described in claim 1, characterized in that, The tank surface sealing and insulation component includes a PVC polypropylene acid-resistant tank cover, a sealing frame, and elastic clamping components. The edge of the PVC polypropylene acid-resistant tank cover is attached to the opening of the electrolytic tank through the sealing frame. The elastic clamping components are evenly distributed on the outside of the sealing frame. The tank surface sealing and insulation component is also equipped with a temperature sensor, which is electrically connected to the central control unit.

4. The integrated energy-saving system for copper electrolytic refining with heat preservation, cooling, and heat recovery as described in claim 1, characterized in that, The circulating tank cooling assembly includes fiberglass pipes, an axial flow fan, an acid mist settling tower, and airflow regulating valves. The fiberglass pipes have a diameter of 350-450mm, one end of which is connected to the circulating tank, and the other end is connected to the axial flow fan. The airflow of the axial flow fan is 15,000-20,000 m³ / h. 3 / h, the acid mist settling tower is connected to the top of the circulation tank, and the air volume regulating valve is installed on the fiberglass pipe and electrically connected to the central control unit.

5. The integrated energy-saving system for copper electrolytic refining with heat preservation, cooling, and heat recovery as described in claim 4, characterized in that, The heat capture assembly includes a high-temperature resistant heat-conducting plate, a heat insulation cover, and a heat collection cavity. The high-temperature resistant heat-conducting plate is disposed on the surface of the resistance heating component of the power supply system, the heat insulation cover is disposed on the outside of the resistance heating component, and the heat collection cavity is filled with a heat-conducting medium.

6. The integrated energy-saving system for copper electrolytic refining with heat preservation, cooling, and heat recovery as described in claim 5, is characterized in that, The heat transfer component includes a heat-conducting pipe, a circulating pump, and an insulated delivery pipe. One end of the heat-conducting pipe is embedded in the heat-conducting medium of the heat collection cavity, and the other end is connected to the insulated delivery pipe through the circulating pump. The insulated delivery pipe is connected to the heat reuse component.

7. The integrated energy-saving system for copper electrolytic refining with heat preservation, cooling, and heat recovery as described in claim 6, characterized in that, The temperature monitoring unit includes a first temperature sensor installed in the electrolyte inlet pipe, a second temperature sensor in the circulation tank, and a third temperature sensor in the electrolyte outlet pipe. The measurement accuracy of the first temperature sensor, the second temperature sensor, and the third temperature sensor is ±0.5℃, and the measurement range is 40-80℃.

8. The integrated energy-saving system for copper electrolytic refining with heat preservation, cooling, and heat recovery as described in claim 7, characterized in that, The central control unit includes a data processing module, a PID adjustment module, and an execution control module. The data processing module receives monitoring data from the temperature monitoring unit and the heat capture component. The PID adjustment module generates control signals based on a preset temperature threshold. The execution control module controls the axial flow fan speed, the air volume regulating valve opening, the temperature regulating valve opening, and the circulating pump power, respectively.

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