A method of operating a system for controlling the quality of electrolyte in an electrolysis system

Abstract

The present application relates to a kind of control electrolytic system electrolyte quality system operation method.The control electrolytic system electrolyte quality system operation method is applied to the window period of PC electrolytic system power outage out tank operation to before re-power, including the following steps, after system power outage, first, carry out copper and electrolyte purification operation, the operation includes according to supernatant storage tank liquid level dynamic adjustment filter pump frequency to control suspended solids content;After tank filling is completed, the pretreatment operation including washing and at least one in-tank pickling is carried out to newly loaded anode plate;During the whole window period, the temperature of electrolyte is regulated by plate heat exchanger and heat preservation measure, so that it reaches preset target temperature range before power on;The control electrolytic system electrolyte quality system operation method can efficiently control electrolyte quality, and provide guarantee for cathode copper production quality.

Description

Technical Field

[0001] This invention belongs to the field of metal electrolysis technology, and specifically relates to a system operation method for controlling the quality of electrolyte in an electrolysis system. Background Technology

[0002] As technology continues to advance, high-purity copper plays an increasingly important role in industries such as manufacturing, construction, machinery, and national defense. At the same time, the quality requirements for metallic copper are becoming increasingly stringent, and national standards are constantly being improved and their quality requirements are being raised.

[0003] In the copper smelting PC electrolysis technology, an anode plate containing 99-99.5% copper is used as the anode, and a stainless steel cathode plate is used as the cathode. High-purity cathode copper is prepared by electrolysis. Due to the huge fluctuations in the raw materials used with the market, the copper and impurity content of the anode plates varies significantly. As the anode copper is continuously electrolyzed and a small amount of chemical dissolution occurs, impurities with negative potentials, such as arsenic, antimony, and bismuth, enter the electrolyte, causing impurities to accumulate in the electrolyte and affecting the quality of the electrolyte. This can lead to short circuits, particle generation, and even anode passivation due to the high content of some impurities during electrolysis.

[0004] Due to oxidation, copper oxide and cuprous oxide are present on the anode plate surface. Upon entering the system, these oxides easily cause electrolyte turbidity and readily migrate and adhere to the cathode copper surface. Insufficient pickling time after unloading can also lead to this situation. During normal operation of the electrolysis system, the ratio of supernatant to anode mud during unloading can be affected by production conditions, also causing electrolyte turbidity and increased suspended solids. Simultaneously, electrolyte temperature control plays a crucial role in ensuring the quality of cathode copper. Maintaining a higher electrolysis temperature is beneficial for improving cathode copper quality. On one hand, it accelerates ion movement, resulting in a more uniform electrolyte concentration and eliminating severe copper ion depletion near the cathode; on the other hand, it reduces electrolyte viscosity, facilitating the shedding, coagulation, and sedimentation of anode mud, accelerating the settling of suspended anode mud; and on the other hand, it accelerates the dissolution rate of oxides on the anode plate casting surface, preventing anode passivation. However, excessively high temperatures should also be considered, as they can accelerate the decomposition of thiourea, affecting the quality of cathode copper crystallization.

[0005] From the perspective of existing technology, the key to controlling electrolyte quality in electrolysis systems lies in controlling electrolyte temperature, impurity content, and suspended solids content. This ensures the electrolyte reaches the expected temperature before power is supplied, maintains the target temperature during electrolysis, and controls the levels of impurities and suspended solids entering the system. However, existing technologies primarily focus on steady-state control during continuous operation. For the special and critical operational window where power must be shut down for tank loading and unloading, a systematic and effective solution is lacking. This solution aims to coordinate and regulate electrolyte composition, impurities, suspended solids, and temperature to ensure the system quickly reaches and stabilizes at optimal electrolyte quality before power is restored, thereby guaranteeing high-quality and high-yield cathode copper. Summary of the Invention

[0006] To address the problems existing in the background technology, this invention aims to provide a system operation method for controlling the quality of electrolyte in an electrolysis system. This method is specifically applicable to the window period between power outage and tank unloading operations in a PC electrolysis system and power restoration after the operation is completed. By systematically sequencing and optimizing the parameters of steps such as anode plate pretreatment, electrolyte purification, and temperature control, multi-factor synergistic timing control is achieved. This efficiently and stably adjusts the electrolyte quality to the optimal preparatory state before power restoration, ensuring a high yield of high-quality cathode copper.

[0007] The present invention achieves the above objectives through the following technical solutions: A system operation method for controlling the quality of electrolyte in an electrolysis system, applied to the window period from power outage to re-energization of a PC electrolysis system, includes the following steps: After the system is powered off, the copper removal and electrolyte purification operation is performed first. This operation includes dynamically adjusting the frequency of the filter press pump according to the liquid level of the supernatant storage tank to control the suspended solids content. After the tank is filled, the newly loaded anode plates are subjected to pretreatment operations including washing and at least one in-tank acid washing. Throughout the entire window period, the electrolyte temperature is regulated by plate heat exchangers and insulation measures to ensure that it reaches the preset target temperature range before power transmission. The electrolyte purification, anode plate pretreatment, and temperature control operations are carried out in tandem during the window period to ensure that the electrolyte system reaches a preset quality state before power delivery.

[0008] Specifically, a system operation method for controlling the quality of electrolyte in an electrolysis system includes the following steps: Step S1: Electrolyte basic composition control: Based on daily test data, supplement copper, acid and chloride ions to maintain the Cu²⁺ concentration in the electrolyte at 44-46 g / L, the H₂SO₄ concentration at 182-185 g / L, and the Cl⁻ concentration at 0.42-0.46 g / L. Step S2: Control of impurities in anode plates: Before the anode plates are loaded onto the machine, their composition is analyzed, the furnace number matching and loading sequence are calculated and optimized, and the average copper content of the anode plates entering the tank is controlled to be ≥99.3%, the average oxygen content is controlled to be ≤0.06%, and the average content of impurity elements such as lead, nickel, and arsenic is controlled. Step S3: Control of suspended solids content: a) The anode plates are mechanically washed before being loaded onto the machine; b) After the anode plates are placed in the tank, they undergo an initial pickling process for no less than 4 hours; c) During copper tapping, adjust the pressure filtration ratio of the supernatant to reduce the suspended solids content in the electrolyte; Step S4 Electrolyte Temperature Control: After the system is powered off, adjust the set temperature of the plate heat exchanger; after the tank is filled, keep the electrolytic cell warm to ensure that the electrolyte temperature reaches the set target value before the planned power-on time.

[0009] As a further optimization of the present invention, the frequency of the pressure filter pump is dynamically adjusted according to the liquid level of the supernatant storage tank. Specifically, the frequency of the supernatant hydraulic filter pump is increased so that the liquid level of the supernatant storage tank is maintained in the low liquid level range of 1000-1300mm when copper is discharged, so as to suppress the turbidity caused by the reverse overflow of electrolyte.

[0010] As a further optimization of the present invention, the electrolyte purification operation also includes prioritizing the activation of the anode mud treatment system to treat the electrolyte when copper is discharged, and then activating the supernatant treatment system after its processing capacity is fully loaded.

[0011] As a further optimization of the present invention, the pretreatment operation of performing at least one in-tank acid washing on the newly installed anode plate specifically includes: powering on for 40±10 minutes after the initial acid washing, then powering off again and performing a second acid washing that lasts for more than 1 hour.

[0012] As a further optimization of the present invention, the electrolyte temperature is regulated, specifically by: after the system is powered off, raising the set temperature of the plate heat exchanger by 2-3°C, and maintaining the temperature of the electrolyte by circulating the system and keeping the tank warm, so that the fluctuation range of the electrolyte temperature before power is supplied is controlled within ±1°C, and the final temperature is stabilized at 66-68°C.

[0013] As a further optimization of the present invention, at the beginning of the window period, an anode plate proportioning step is also included: based on the anode plate composition analysis data, the order of their loading into the machine is arranged in conjunction with the furnace number to control the average copper content of the anode plates entering the tank to be no less than 99.3% and the average oxygen content to be no more than 0.06%.

[0014] As a further optimization of the present invention, the method further includes a dynamic feedback control step: acquiring the temperature or turbidity parameters of the electrolyte in real time through an online monitoring device, comparing the monitoring data with a preset target value, and automatically adjusting the power of the plate heat exchanger and / or the frequency of the supernatant hydraulic filter pump in real time according to the comparison result.

[0015] As a further optimization of the present invention, before the anode plate is put into the tank for pickling, an anode plate strengthening pretreatment step is also included: the anode plate is placed in an independent pretreatment station, and ultrasonic waves or pulsed currents are applied to perform surface activation treatment to assist in the peeling off of the surface oxide layer.

[0016] As a further optimization of the present invention, during the pickling stage in the tank or the system circulation stage, a composite additive is added to the electrolyte, the composite additive including a grain refiner and an impurity complexing agent.

[0017] The beneficial effects of this invention are as follows: This invention controls the electrolyte in the system from the time of tank unloading after a power outage until power is restored. This method controls the copper and impurity content of the anode plates entering the system within a certain range. It reduces the turbidity of the electrolyte and its suspended solids content by increasing the washing and acid-washing time of the anode plates and the pressure filtration ratio of the supernatant. Furthermore, it controls the electrolyte temperature within the standard range through a plate heat exchanger and effective insulation, thus efficiently controlling the electrolyte quality and ensuring the quality of the cathode copper. Attached Figure Description

[0018] Figure 1 This is a schematic flowchart of a system operation method for controlling the quality of electrolyte in an electrolysis system according to the present invention. Detailed Implementation

[0019] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0020] like Figure 1 As shown, this method discloses a system operation method for controlling the quality of electrolyte in an electrolysis system. This method is mainly applicable to the control of the electrolyte in a PC electrolysis system during the period from power outage to power restoration after the operation is completed. This method controls the impurities entering the system within a certain range. It alters the turbidity of the electrolyte by increasing the washing and acid-washing time of the anode plates and the pressure filtration ratio of the supernatant, thereby reducing its suspended solids content. Furthermore, it controls the electrolyte temperature within the standard range through a plate heat exchanger and effective insulation, thus efficiently controlling the electrolyte quality and ensuring the quality of cathode copper production.

[0021] This method includes: Electrolyte copper acid and chloride control: The content of key elements in the system is adjusted based on daily laboratory data; Electrolyte impurity content control: Before the anode plate is installed, the composition of the anode plate is analyzed and calculated, and the furnace number and installation sequence of the anode plate are reasonably arranged to control the impurity content entering the electrolysis system; Electrolyte suspended solids control: The anode plate is washed when it is loaded into the tank, and the acid washing time is increased after it enters the tank to reduce impurities and metal oxides on the surface of the anode plate to the greatest extent possible; when copper is discharged, the pressure filtration ratio of the supernatant is changed to reduce the suspended solids content in the electrolyte and reduce its turbidity. Electrolyte temperature control: After a power outage, adjust the plate heat exchanger temperature promptly, and after the tank is filled, effectively maintain the temperature to control the electrolyte temperature and ensure that it reaches the expected temperature before power is restored. Furthermore, after the copper outlet tank is powered off, the temperature of the plate heat exchanger is adjusted from 65℃ to 67℃, and the electrolyte temperature is controlled within ±1℃ after circulating through the system. Furthermore, after the copper outlet tank group is powered off, the frequency of the supernatant hydraulic filter pump is adjusted from 40Hz to 45Hz, so that the supernatant storage tank is kept in a low liquid level range of 1000-1300mm when copper is discharged, to prevent reverse overflow from causing electrolyte turbidity, and to control the electrolyte suspended solids content to be within 6.0mg / L. Furthermore, when copper is being tapped, the anode mud plug is removed first, and the electrolyte is processed through a pit, thickener, and anode mud filter press. When the load is full, the supernatant plug is removed, and the electrolyte is processed through a supernatant storage tank and a supernatant hydraulic filter press. Furthermore, the copper content of the anode plates was calculated, and the average copper content of the anode plates entering the tank was controlled to be above 99.3%; Furthermore, the impurity content of the anode plate was calculated, and the average O content of the anode plate entering the tank was controlled to be ≤0.06%, thereby reducing the anode passivation effect; Furthermore, the impurity composition of the anode plate was calculated, and the average impurity content of the anode plate entering the tank was controlled as follows: Pb≤0.6%, Ni≤0.25%, As≤0.20%; the impurity content of the electrolyte was controlled as follows: Pb≤0.025g / L, Ni≤15g / L, As≤6g / L. Furthermore, based on the test data, acid is added to the electrolysis system daily to control the content of Cu2+ to 44-46 g / L, H2SO4 to 182-185 g / L, and Cl- to 0.42-0.46 g / L. Furthermore, the anode forming unit is equipped with cleaning equipment. After the anode plate is milled on the upper and lower sides, the plate surface is rinsed. The copper powder washed off and the copper chips from the anode plate milling are returned to the silo. Furthermore, after the anode plates are placed in the tank for illumination, they are acid-washed for more than 4 hours to dissolve the oxides on the casting surface of the anode plates through a chemical reaction. Furthermore, after pickling is completed, the temperature is measured. Once the tank temperature reaches 60°C or above, power is supplied. Furthermore, after 40 minutes of power supply, the circuit is shut off and acid washing is carried out again for more than 1 hour; Furthermore, after the secondary power supply is completed, the tank temperature is controlled at 66-68℃.

[0022] Example 1 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 65℃. After circulating through the system, the electrolyte temperature drops by 1.4℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 45Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The system electrolyte suspended solids content is 5.8mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.6%, Ni≤0.25%, and As≤0.20%, and the impurity content of the electrolyte to be: Pb≤0.025g / L, Ni≤15g / L, and As≤6g / L; 4. Control the pickling time to 4 hours, and the second pickling time to 1.5 hours; 5. Control the electrolyte temperature at 58℃ before powering on, and then control the electrolyte temperature at 65℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper was 97.93%.

[0023] Example 2 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 65℃. After circulating through the system, the electrolyte temperature drops by 1.4℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 43Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The suspended solids content of the electrolyte in the system is 6.2mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.6%, Ni≤0.25%, and As≤0.20%, and the impurity content of the electrolyte to be: Pb≤0.025g / L, Ni≤15g / L, and As≤6g / L; 4. Control the pickling time to 4 hours, and the second pickling to 1 hour; 5. Control the electrolyte temperature at 60℃ before powering on, and then control the electrolyte temperature at 67℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper was 97.95%.

[0024] Example 3 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 66℃. After circulating through the system, the electrolyte temperature drops by 0.8℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 40Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The suspended solids content of the electrolyte in the system is 6.7mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.6%, Ni≤0.25%, and As≤0.20%, and the impurity content of the electrolyte to be: Pb≤0.025g / L, Ni≤15g / L, and As≤6g / L; 4. Control the pickling time to 4 hours, and the second pickling time to 1.5 hours; 5. Control the electrolyte temperature at 58℃ before powering on, and then control the electrolyte temperature at 65℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper was 97.87%.

[0025] Example 4 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 66℃. After circulating through the system, the electrolyte temperature drops by 0.8℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 43Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The suspended solids content of the electrolyte in the system is 6.2mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.6%, Ni≤0.25%, and As≤0.20%, and the impurity content of the electrolyte to be: Pb≤0.025g / L, Ni≤15g / L, and As≤6g / L; 4. Control the pickling time to 3 hours, and the second pickling time to 1.5 hours; 5. Control the electrolyte temperature at 60℃ before powering on, and then control the electrolyte temperature at 67℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper was 98.43%.

[0026] Example 5 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 66℃. After circulating through the system, the electrolyte temperature drops by 0.8℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 45Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The system electrolyte suspended solids content is 5.8mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.6%, Ni≤0.25%, and As≤0.20%, and the impurity content of the electrolyte to be: Pb≤0.025g / L, Ni≤15g / L, and As≤6g / L; 4. Control the pickling time to 4 hours, and the second pickling to 1 hour; 5. Control the electrolyte temperature at 60℃ before powering on, and then control the electrolyte temperature at 69℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper was 98.79%.

[0027] Example 6 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 67℃. After circulating through the system, the electrolyte temperature drops by 0.3℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 43Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The suspended solids content of the electrolyte in the system is 6.2mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.8%, Ni≤0.35%, and As≤0.25%, and the impurity content of the electrolyte to be: Pb≤0.029g / L, Ni≤16.2g / L, and As≤6.5g / L; 4. Control the pickling time to 4 hours, and the second pickling time to 1.5 hours; 5. Control the electrolyte temperature at 58℃ before powering on, and then control the electrolyte temperature at 66℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper was 99.11%.

[0028] Example 7 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 67℃. After circulating through the system, the electrolyte temperature drops by 0.3℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 45Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The system electrolyte suspended solids content is 5.8mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.8%, Ni≤0.35%, and As≤0.25%, and the impurity content of the electrolyte to be: Pb≤0.029g / L, Ni≤16.2g / L, and As≤6.5g / L; 4. Control the pickling time to 4 hours, and the second pickling to 1 hour; 5. Control the electrolyte temperature at 60℃ before powering on, and then control the electrolyte temperature at 68℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper was 99.39%.

[0029] Example 8 1. After the copper tank group is powered off, the plate heat exchanger temperature is controlled at 67℃. After circulating through the system, the electrolyte temperature drops by 0.3℃. 2. After the copper outlet tank is powered off, the frequency of the supernatant hydraulic filter pump is controlled at 45Hz, so that the supernatant storage tank is kept in the low liquid level range of 1000-1300mm when copper is discharged. The system electrolyte suspended solids content is 5.8mg / L, and the suspended solids content increases. 3. For the composition ratio of the anode plates, control the average impurity content of the anode plates to be Pb≤0.6%, Ni≤0.25%, and As≤0.20%, and the impurity content of the electrolyte to be: Pb≤0.025g / L, Ni≤15g / L, and As≤6g / L; 4. Control the pickling time to 4 hours, and the second pickling time to 1.5 hours; 5. Control the electrolyte temperature at 60℃ before powering on, and then control the electrolyte temperature at 67℃ after powering on. 6. With a controlled current of 34800A, after a 10-day electrolysis cycle, the high-quality rate of the cathode copper in this batch was 99.27%.

[0030] Based on the above embodiments, it can be found that: In all embodiments (6, 7, 8) where the yield of high-quality products exceeded 99%, the plate heat exchanger temperature was set to 67°C, and the system temperature drop was only 0.3°C. In embodiments (1-5) where the set temperature was 65°C or 66°C, the system temperature drop was greater (0.8-1.4°C), and the highest yield of high-quality products was 98.79%. This indicates that raising the heat exchanger temperature to 67°C can more effectively maintain the thermal stability of the system and create better initial thermodynamic conditions for electrolysis.

[0031] The top three examples in terms of high-quality yield—Examples 7 (99.39%), 8 (99.27%), and 6 (99.11%)—had post-energization control temperatures of 68°C, 67°C, and 66°C, respectively, all within the high-end range of 66-68°C. In contrast, Examples 1, 3, and 5, with post-energization temperatures of only 65°C, had high-quality yields not exceeding 98.8%. This indicates that maintaining a stable electrolyte temperature above 66°C after energization has a positive effect on obtaining high-quality cathode copper.

[0032] Examples 6 and 7 employed more lenient impurity standards for the anode plates (Pb≤0.8%, Ni≤0.35%, As≤0.25%), and the upper limit for electrolyte impurities was also relaxed accordingly, yet their yield of high-quality products still reached 99.11% and 99.39%, respectively. This contrasts with Examples 1-3, which used stricter impurity standards (Pb≤0.6%, Ni≤0.25%, As≤0.20%) but had lower yields of high-quality products. This indicates that when core conditions such as temperature control (heat exchanger 67°C, temperature control above 66°C after power-on) are optimal, the entire system becomes less sensitive to fluctuations in the impurity content of upstream raw materials, and the production process becomes more robust.

[0033] Although all embodiments maintained the supernatant tank level at 1000-1300 mm by controlling the pump frequency, the suspended solids content (5.8-6.7 mg / L) did not show a simple negative correlation with the yield of high-quality products. For example, Examples 1 and 5, with a suspended solids content of 5.8 mg / L, had yields of 97.93% and 98.79%, respectively; Examples 2, 4, and 6, with a suspended solids content of 6.2 mg / L, had yields ranging from 97.95% to 99.11%. This suggests that under the low-level operation, the suspended solids content is generally suppressed within a relatively low range, where its impact on quality may give way to stronger dominant factors such as temperature.

[0034] Example 3 (4 + 1.5 hours), with the longest total pickling time, only achieved a high-quality yield of 97.87%. In contrast, Examples 7 (4 + 1 hour) and 8 (4 + 1.5 hours, but with better temperature control), with shorter total times, achieved the highest high-quality yields. Example 4 (3 + 1.5 hours) had the shortest total time, but its high-quality yield (98.43%) was still superior to several examples with longer pickling times. This indicates that, while maintaining a basic pickling time (e.g., an initial 4 hours), precise temperature control is more effective than simply extending the pickling time.

[0035] Example 8 achieved an excellent performance index of 99.27%, and its parameter combination is representative: the highest plate heat exchanger temperature (67°C) and the smallest system temperature drop (0.3°C), a medium-high filter press pump frequency (45Hz), strict anode plate impurity control standards, sufficient acid washing time (4 + 1.5 hours), and precise post-power-on temperature control (67°C). This combination balances source control, process purification, and state conditioning, verifying the upper limit of the performance of the system operation method under optimal parameters.

[0036] There are synergies and trade-offs among the various control methods. Raising the plate heat exchanger temperature to 67°C and stabilizing the electrolyte temperature above 66°C after power supply are the core levers driving the high-quality product rate to exceed 99%. Under these conditions, the system exhibits greater tolerance to fluctuations in raw material impurities and pickling time. The value of this method lies in providing an adjustable parameter system that, by prioritizing key parameters (such as temperature), enables stable high-quality output amidst actual production fluctuations.

[0037] Example 9 In this embodiment, a high-precision online temperature sensor (model: PT100, accuracy ±0.1℃) is installed on the electrolyte outlet manifold after the plate heat exchanger, and an online turbidity meter (range: 0-20 NTU) is installed on the outlet pipe from the supernatant storage tank to the filter press. These sensors are communicatively connected to the existing distributed control system (DCS) in the workshop. Dynamic control targets for the electrolyte quality before power-on are set in the DCS: target temperature 67℃, allowable fluctuation range 66-68℃; target turbidity ≤5.5 NTU, alarm threshold 6.0 NTU.

[0038] When the system loses power, the dynamic control mode is activated: Temperature control loop: The DCS continuously reads the online temperature value. If the measured temperature is below 66.5℃, the system automatically fine-tunes the opening of the steam regulating valve of the plate heat exchanger according to the PID algorithm, increasing it by 1-2% each time, until the temperature rises back to the target range. In this embodiment, due to the low ambient temperature, the initial circulation temperature drops rapidly, and the system automatically increases the steam valve opening from 45% to 52%, allowing the electrolyte temperature to steadily rise from 64.8℃ and maintain at 67.2±0.3℃ within 90 minutes.

[0039] Turbidity control loop: During copper tapping and pressure filtration, the DCS monitors turbidity in real time. When copper tapping causes a momentary increase in turbidity to 5.8 NTU (approaching the alarm threshold), the system automatically increases the frequency of the supernatant hydraulic filter pump from the preset 45Hz to 47Hz to accelerate the separation of the clarified liquid. After approximately 30 minutes, the system turbidity drops back to 5.2 NTU and remains stable, at which point the system adjusts the pump frequency back to 46Hz to maintain operation.

[0040] This embodiment is compared with Embodiment 1 over the same period. In this embodiment, the electrolyte temperature is stable at 67.2±0.3℃ and the turbidity is stable at 5.2±0.3 NTU before power supply. In the comparative embodiment, the temperature range before power supply is 65.5-66.8℃ and the turbidity range is 5.6-6.4 NTU. The fluctuation range of key parameters in this embodiment is reduced by about 60%.

[0041] After the same 10-day electrolysis cycle, the high-quality rate of this batch of cathode copper reached 99.05%. In contrast, the high-quality rate of the comparison batch, which used only fixed parameter control under similar raw material conditions, was 98.20%.

[0042] With the introduction of dynamic feedback control, the system's adaptability to raw material fluctuations and production disturbances (such as copper tapping agitation) is significantly enhanced, enabling it to maintain electrolyte quality parameters more precisely within the preset optimal range. This stable "prepared state" is directly transmitted to the electrolysis process, resulting in an increased yield of high-quality cathode copper and better quality consistency.

[0043] Example 10: This embodiment targets anode plates with severe surface oxidation and a large amount of impurities. Before the anode plates are immersed in the pickling tank in Embodiment 1, a special physicochemical composite pretreatment process is added to enhance the source cleaning effect.

[0044] This embodiment targets anode plates with severe surface oxidation and a large amount of impurities. Before the anode plates in the core embodiment are immersed in the pickling tank, a special physicochemical composite pretreatment process is added to enhance the source cleaning effect.

[0045] A batch of anode plates with darkened surfaces due to prolonged storage (sample analysis showed an average surface oxygen content of 0.12%) were selected. After side and bottom milling and routine rinsing by the shaping unit, these anode plates were not directly placed into the main tank. Instead, the following steps were performed: each anode plate was hoisted into the pretreatment tank, ensuring that the plate surface was completely immersed in dilute sulfuric acid solution.

[0046] Turn on the ultrasonic generator, set the power density to 0.5 W / cm², and perform continuous ultrasonic treatment on the anode plate for 10 minutes. During this period, a large number of fine bubbles can be observed to precipitate on the plate surface, accompanied by the shedding of black flocculent matter.

[0047] After the treatment was completed, the anode plate was lifted and the liquid was drained. The metallic luster of the plate surface was restored, and a large area of ​​the attached dark, loose oxide layer was peeled off.

[0048] The anode plates that have undergone the above-mentioned enhanced pretreatment (experimental group) and another batch of anode plates with similar surface oxidation levels that were directly put into the tank after only routine rinsing (control group) were produced in parallel under the same process of Example 1 (4 hours for the first pickling, 1.5 hours for the second pickling, and the same temperature control).

[0049] In the experimental group, the electrolyte in the main tank became relatively clear one hour after the anode plates were acid-washed, and the period of intense oxide reaction on the plate surface was significantly shortened. In the control group, a large amount of suspended black slag was still visible in the tank two hours after acid washing.

[0050] After the initial pickling process lasted 4 hours and before power was supplied, samples of the electrolyte in the two corresponding electrolytic cells were taken and tested. Initial turbidity: The turbidity of the electrolyte in the experimental group was 4.8 NTU, while that in the control group was 7.1 NTU. The turbidity in the experimental group decreased by approximately 32%.

[0051] Suspended solids content: The suspended solids content in the experimental group was 4.5 mg / L, and that in the control group was 6.8 mg / L.

[0052] Final production results: The high-quality rate of cathode copper in the experimental group was 99.18%. After the same electrolysis cycle, the high-quality rate in the control group was 97.65%.

[0053] Conclusion: The added ultrasonic-assisted dilute acid pretreatment process can efficiently remove the dense oxide layer and embedded impurities on the anode plate surface through the synergistic effect of physical cavitation and chemical etching. This significantly reduces the suspended matter load entering the main electrolysis system from the source, making subsequent main tank pickling more efficient and thorough, and greatly improving the initial cleanliness of the electrolyte. For treating severely oxidized anode plates, this method has a particularly significant effect on improving the final cathode copper yield, reaching more than 1.5 percentage points.

[0054] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A system operation method for controlling the quality of electrolyte in an electrolysis system, characterized in that, Includes the following steps, After the system is powered off, the copper removal and electrolyte purification operation is performed first. This operation includes dynamically adjusting the frequency of the filter press pump according to the liquid level of the supernatant storage tank to control the suspended solids content. After the tank is filled, the newly loaded anode plates are subjected to pretreatment operations including washing and at least one in-tank acid washing. Throughout the entire window period, and up to the time of power supply, the electrolyte temperature is adjusted to a preset temperature range; The electrolyte purification, anode plate pretreatment, and electrolyte temperature control operations are all carried out in tandem within the specified window period to ensure that the electrolyte system reaches a preset quality state before power delivery.

2. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1, characterized in that: The frequency of the pressure filter pump is dynamically adjusted according to the liquid level of the supernatant storage tank. Specifically, the frequency of the supernatant hydraulic filter pump is increased so that the liquid level of the supernatant storage tank is maintained in the low liquid level range of 1000-1300mm when copper is discharged.

3. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1 or 2, characterized in that: The electrolyte purification operation also includes prioritizing the activation of the anode mud treatment system to treat the electrolyte when copper is being discharged, and then activating the supernatant treatment system after the supernatant treatment system has reached full capacity.

4. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1, characterized in that: The pretreatment operation of performing at least one in-tank acid pickling on the newly installed anode plates specifically includes: after the anode plates are positioned in the tank, performing an initial acid pickling for more than 4 hours; after the initial acid pickling, powering on the plates for 40±10 minutes, then powering off the plates again and performing a second acid pickling for more than 1 hour.

5. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1, characterized in that: The electrolyte temperature is regulated by: raising the set temperature of the plate heat exchanger by 2-3°C after the system is powered off, and maintaining the temperature of the electrolyte by circulating the system and keeping the tank warm, so that the fluctuation range of the electrolyte temperature before power is supplied is controlled within ±1°C, and the final temperature is stabilized at 66-68°C.

6. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1, characterized in that: At the beginning of the window period, an anode plate proportioning step is also included: based on the anode plate composition analysis data, the order of their loading into the machine is arranged in conjunction with the furnace number to control the average copper content of the anode plates entering the tank to be no less than 99.3% and the average oxygen content to be no more than 0.06%.

7. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1, characterized in that: The method also includes a basic component maintenance step: based on electrolyte analysis data, copper, acid, and chloride ions are replenished to maintain the Cu content in the electrolyte. 2+ The concentrations are 44-46 g / L, H2SO4 concentrations are 182-185 g / L, and Cl⁻ concentrations are 0.42-0.46 g / L.

8. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1, characterized in that: The method further includes a dynamic feedback control step: acquiring the temperature or turbidity parameters of the electrolyte in real time through an online monitoring device, comparing the monitoring data with a preset target value, and automatically adjusting the power of the plate heat exchanger and / or the frequency of the supernatant hydraulic filter pump in real time based on the comparison result.

9. The system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1, characterized in that: Before the anode plate is placed in the pickling tank, an anode plate strengthening pretreatment step is also included: the anode plate is placed in a separate pretreatment station and ultrasonic or pulsed current is applied for surface activation treatment to assist in the peeling of the surface oxide layer.

10. A system operation method for controlling the quality of electrolyte in an electrolysis system according to claim 1 or 4, characterized in that: During the pickling stage or system circulation stage in the tank, a composite additive is added to the electrolyte, the composite additive including a grain refiner and an impurity complexing agent.

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