A method for compensating for a cell break
By designing a parallel structure of spare conductor bars in the copper electrolytic cell, and utilizing highly conductive copper alloy materials and insulating components, the problem of conductor bar open circuits or poor contact was solved, achieving automatic current compensation and cell voltage stability, thus improving production continuity and current efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- CHIFENG YUNTONG NON FERROUS METAL CO LTD
- Filing Date
- 2026-01-19
- Publication Date
- 2026-06-05
AI Technical Summary
Existing technologies cannot effectively predict and quickly resolve issues such as open circuits or poor contact in copper electrolysis production, leading to uneven current distribution, abnormal cell voltage, increased energy consumption, and production shutdowns. Furthermore, existing backup conductive structures suffer from electromagnetic interference and uneven current distribution.
The design uses a spare busbar connected in parallel with the original busbar, employing a highly conductive copper alloy material, combined with insulating components and a tight contact structure to form a dual-contact conductive structure. When the original busbar is broken, it automatically connects to the circuit for current compensation, ensuring uniform current distribution and stable tank voltage.
It achieves automatic current compensation and stable tank voltage, avoids the risk of open circuit, ensures production continuity, improves the uniformity of current distribution and current efficiency, and reduces tank voltage fluctuation.
Smart Images
Figure CN122147458A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of copper electrolysis production technology, specifically to a method for compensating for circuit breaks in an electrolytic cell. Background Technology
[0002] In the copper electrolytic refining process, to achieve efficient and stable electrolytic reactions, electrolytic cells generally employ a multi-connection method for circuit connection. This means that each cathode and anode plate within the cell is connected in parallel, while adjacent electrolytic cells are connected in series via conductive busbars, forming a complete electrolytic circuit system. Among these components, the inter-cell conductive plates, as the core key component for current transmission, directly play a crucial role in evenly distributing external power current to each electrolytic cell and conducting it orderly between cells. Their conductivity and contact stability directly determine the efficiency, product quality, and energy consumption level of copper electrolytic production.
[0003] When the original conductor busbar experiences an open circuit or poor contact, it can lead to poor conductivity in the electrolytic cell circuit, resulting in the following serious problems: First, uneven current distribution on the same pole, with excessively high current density in local areas, can cause overheating, passivation, or even ablation of the electrode plates, shortening the lifespan of the electrolytic cell; second, abnormally high or drastic fluctuations in cell voltage can not only significantly increase energy consumption but may also trigger the production system's protective shutdown, causing huge economic losses; third, there is a lack of rapid remedial measures when a fault occurs suddenly. Traditional handling methods require shutdown to replace the conductor busbar, and a single shutdown for maintenance typically lasts 4-8 hours, seriously affecting the continuity of production.
[0004] To address these issues, existing technologies primarily employ methods such as periodic maintenance and replacement of the conductor bars, increasing the cross-sectional size of the conductor bars, or using multiple conductor bars in parallel. However, these solutions have significant drawbacks: periodic maintenance cannot predict sudden failures and increases manual maintenance costs; increasing the cross-sectional size of the conductor bars leads to increased equipment costs and limited installation space, while failing to fundamentally eliminate the risk of open circuits; although parallel design of multiple conductor bars can improve redundancy, it lacks a dedicated insulation structure, making it prone to electromagnetic interference, uneven current distribution, and other problems, and unable to achieve automatic and rapid compensation in case of failure. Furthermore, existing backup conductor structures are mostly temporary overlapping designs, resulting in excessively high resistance, insufficient installation accuracy, and poor insulation performance, making it difficult to meet the stringent requirements of electrolysis production for current stability and cell voltage control accuracy. Summary of the Invention
[0005] To address the problems existing in the prior art, the present invention provides a method for compensating for circuit breaks in an electrolytic cell.
[0006] To achieve the above objectives, the technical solution of the present invention is as follows:
[0007] A method for compensating for circuit breaks in an electrolytic cell includes the following steps:
[0008] (1) Design of backup conductive path: Select a high conductivity copper alloy material and design a backup conductive bus that is compatible with the original conductive bus according to the size parameters of the conductive bus between the electrolytic cells. The cross-sectional area and length of the backup conductive bus meet the rated current load requirements of electrolytic production, and the resistance value does not exceed 30% of the resistance value of the original conductive bus.
[0009] (2) Insulation component setting: A bent and perforated composite insulation kit is set. The outer layer of the insulation kit is made of a flame-retardant oxygen index ≤26. The insulation kit is used to achieve insulation isolation between the spare conductive bus and the original conductive bus and the electrolytic cell shell.
[0010] (3) Installation and fixing: The spare conductive bus is installed above the original conductive bus between the two electrolytic cells through the insulating kit, so that the two ends of the anode and cathode in the electrolytic cell are in contact with the original conductive bus and the spare conductive bus respectively, forming a double contact point conductive structure. During the installation process, the spare conductive bus is kept parallel to the original conductive bus and in close contact, with a length direction deformation ≤1mm and a width direction offset ≤0.5mm.
[0011] (4) Current compensation operation: When the original conductive bar is open or has poor contact, the backup conductive path is automatically connected to the circuit. The current flows continuously through the backup conductive bar on the other side of the electrode plate to achieve current compensation, so that the current distribution of the same electrode in the electrolytic cell is uniform and the cell voltage is stable within the set range.
[0012] Furthermore, the cross-sectional dimensions of the spare conductive busbar mentioned in step (1) are 100mm×5mm, and the length is determined according to the actual spacing of the electrolytic cell, with a value range of 5400-5700mm.
[0013] Furthermore, the insulating kit in step (2) includes an insulating base and an insulating connector. The insulating base adopts an integral molding structure with a surface flatness error ≤0.2mm.
[0014] Furthermore, after the installation is completed in step (3), the vertical distance between the spare conductive bus and the original conductive bus is 25-50mm, and the error of the overlap of their axes is ≤1mm.
[0015] Furthermore, the stable range of the tank voltage in step (4) is a decrease of 0.01-0.015V.
[0016] Furthermore, the surface of the spare conductive bus is tin-plated, and the tin plating layer thickness is 5-10 μm.
[0017] Compared with the prior art, the beneficial effects of the present invention are as follows:
[0018] This invention provides a method for compensating for circuit breaks in electrolytic cells. By installing parallel backup conductive bars without altering the original structure, and utilizing the current-sharing principle of parallel circuits, when the resistance of the original path increases or the circuit breaks, the current automatically flows to the electrode through the backup path with lower impedance, achieving passive automatic compensation. This eliminates the risk of circuit breaks and ensures production continuity without requiring shutdown modifications. By limiting the vertical distance between the backup and original conductive bars to 25-50mm, and combining this with strict control of axis overlap and deformation, the geometric symmetry of the dual-contact conductive structure is optimized, avoiding uneven thermal distribution or electromagnetic interference caused by improper spatial distance, and reducing localized heating. Applying this invention significantly improves the uniformity of current distribution on the same electrode, and calculations show it can reduce cell voltage by 0.01-0.015V and improve current efficiency. Attached Figure Description
[0019] The embodiments of the present invention will be further described below with reference to the accompanying drawings, wherein:
[0020] Figure 1 A flowchart of the present invention is shown. Detailed Implementation
[0021] 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.
[0022] Reference Appendix Figure 1 An electrolytic cell circuit breaker compensation method includes the following steps:
[0023] (1) Design of backup conductive path: Select a high conductivity copper alloy material and design a backup conductive bus that is compatible with the original conductive bus according to the size parameters of the conductive bus between the electrolytic cells. The cross-sectional area and length of the backup conductive bus meet the rated current load requirements of electrolytic production, and the resistance value does not exceed 30% of the resistance value of the original conductive bus.
[0024] (2) Insulation component setting: Set up a bent and perforated composite insulation kit. The outer layer of the insulation kit is flame retardant with an oxygen index of ≤26. The insulation kit is used to achieve insulation isolation between the spare conductor and the original conductor and the electrolytic cell shell;
[0025] (3) Installation and fixing: Install the spare conductive bus above the original conductive bus between the two electrolytic cells using an insulating kit, so that the anode and cathode ends in the electrolytic cell are in contact with the original conductive bus and the spare conductive bus respectively, forming a double contact point conductive structure. During the installation process, ensure that the spare conductive bus is parallel to the original conductive bus and in close contact, with a length direction deformation ≤1mm and a width direction offset ≤0.5mm.
[0026] (4) Current compensation operation: When the original conductive bar is open or has poor contact, the backup conductive path is automatically connected to the circuit. The current flows continuously through the backup conductive bar on the other side of the electrode plate to achieve current compensation, so that the current distribution of the same electrode in the electrolytic cell is uniform and the cell voltage is stable within the set range.
[0027] In one embodiment of the present invention, the cross-sectional dimensions of the spare conductive bus in step (1) are 100mm×5mm, and the length is determined according to the actual spacing of the electrolytic cell, with a value range of 5400-5700mm.
[0028] In one embodiment of the present invention, the insulating kit in step (2) includes an insulating base and an insulating connector. The insulating base adopts an integral molding structure and the surface flatness error is ≤0.2mm.
[0029] In one embodiment of the present invention, after the installation is completed in step (3), the vertical distance between the spare conductive bus and the original conductive bus is 25-50mm, and the error of the overlap of their axes is ≤1mm.
[0030] In one embodiment of the present invention, the stable range of the tank voltage in step (4) is a decrease of 0.01-0.015V.
[0031] In one embodiment of the present invention, the surface of the spare busbar is tin-plated, and the tin plating layer has a thickness of 5-10 μm.
[0032] Example 1
[0033] 1. Preparation of backup conductive path
[0034] A high-conductivity copper alloy (grade Cu-Cr-Zr) was selected. A spare conductor was fabricated based on the original conductor dimensions (100mm × 8mm cross-section, 5400mm length) between the electrolytic cells. The cross-sectional dimensions were strictly controlled to 100mm × 5mm, and the length was selected to be 5400mm. Testing showed that the resistance of the spare conductor was 0.0012Ω, while the resistance of the original conductor was 0.004Ω, representing 30% of the original conductor's resistance. This meets the load requirement of a rated current of 3000A. Simultaneously, the surface of the spare conductor was tin-plated, with the tin plating thickness controlled to 5μm to ensure conductivity stability and corrosion resistance.
[0035] 2. Selection and fabrication of insulation components
[0036] The insulation kit employs a bent, perforated composite insulation design, with the outer layer made of flame-retardant epoxy resin, whose oxygen index is 26. This insulation kit includes an insulating base and insulating connectors. The insulating base is manufactured using a one-piece molding process, and its surface flatness error is measured to be 0.2mm, ensuring stable support after installation. The insulating connectors are made of polytetrafluoroethylene (PTFE) with a withstand voltage rating ≥10kV, meeting the insulation requirements of the electrolytic cell's working environment.
[0037] 3. Installation and fixing operation
[0038] The spare conductive busbar was installed above the original conductive busbar between the two electrolytic cells using the aforementioned insulating kit. During installation, a laser positioning device was used for calibration to ensure that the spare conductive busbar remained parallel to the original conductive busbar and that both ends were in close contact with the anode and cathode of the electrolytic cell, forming a double-contact conductive structure. Testing showed that after installation, the length deformation of the spare conductive busbar was 0.8 mm, and the width offset was 0.4 mm; the vertical distance between the spare and original conductive busbars was controlled at 25 mm, and the axial overlap error was 0.9 mm, fully meeting the installation accuracy requirements.
[0039] 4. Current compensation operation effect
[0040] This electrolytic cell is used in the chlor-alkali production process. Under normal operation, the original conductor bus carries a current of 3000A, and the cell voltage is stable at 3.2V. When a simulated open-circuit fault occurs in the original conductor bus, the backup conductor automatically connects to the circuit, and the current continues to flow through the backup conductor bus on the other side of the electrode, achieving rapid current compensation. After 72 hours of continuous operation and monitoring, the uniformity error of the current distribution on the same electrode in the electrolytic cell is ≤2%, the cell voltage is stable at 3.185V, which is 0.015V lower than the normal operating voltage, and the voltage fluctuation range is ≤±0.002V, meeting the requirements of the production process for cell voltage stability. No problems of decreased electrolysis efficiency or product quality fluctuations were observed.
[0041] Example 2
[0042] 1. Preparation of backup conductive path
[0043] A spare conductor was designed for a large electrolytic cell (original conductor cross-section 100mm × 10mm, length 5700mm) using a highly conductive copper alloy (grade Cu-Ag). Its cross-section is 100mm × 5mm, and its length is 5700mm. Test results show that the resistance of the spare conductor is 0.0015Ω, compared to 0.005Ω of the original conductor, representing 30% of the original resistance. It can handle a load with a rated current of 3500A. The spare conductor has a 10μm tin plating thickness, effectively improving its conductivity and oxidation resistance.
[0044] 2. Selection and fabrication of insulation components
[0045] The composite insulation kit uses a bent and perforated design. The outer flame-retardant material is phenolic resin, with an oxygen index of 24, meeting the flame-retardant requirements. The insulation base of the kit is a one-piece molded structure with a surface flatness error of 0.15mm. The insulation connectors are made of ceramic material, offering excellent insulation performance and making it suitable for high-temperature and high-humidity electrolytic environments.
[0046] 3. Installation and fixing operation
[0047] According to the installation specifications, the spare conductor was installed above the original conductor using an insulating kit, and real-time monitoring and adjustment were performed using a level and dial indicator. After installation, the deformation of the spare conductor in the length direction was 0.9 mm, and the offset in the width direction was 0.5 mm; the vertical distance between the spare conductor and the original conductor was 50 mm, and the axial overlap error was 1 mm. All installation parameters met the design requirements.
[0048] 4. Current compensation operation effect
[0049] This electrolytic cell is used in non-ferrous metal electrolytic refining processes, with a rated operating current of 3500A and a normal cell voltage of 3.5V. When the original conductor busbar experiences current attenuation due to poor contact, the backup conductor circuit quickly activates to compensate, ensuring stable current flow through the backup conductor busbar. Actual operation verification shows that the current distribution within the electrolytic cell is uniform, with no localized overcurrent. The cell voltage remains stable at 3.49V, a decrease of only 0.01V compared to the normal voltage. This voltage stability meets process requirements, ensuring that the purity and yield of the electrolytic products are not affected.
[0050] This invention provides a method for compensating for circuit breaks in electrolytic cells. By installing parallel backup conductive bars without altering the original structure, and utilizing the current-sharing principle of parallel circuits, when the resistance of the original path increases or the circuit breaks, the current automatically flows to the electrode through the backup path with lower impedance, achieving passive automatic compensation. This eliminates the risk of circuit breaks and ensures production continuity without requiring shutdown modifications. By limiting the vertical distance between the backup and original conductive bars to 25-50mm, and combining this with strict control of axis overlap and deformation, the geometric symmetry of the dual-contact conductive structure is optimized, avoiding uneven thermal distribution or electromagnetic interference caused by improper spatial distance, and reducing localized heating. Applying this invention significantly improves the uniformity of current distribution on the same electrode, and calculations show it can reduce cell voltage by 0.01-0.015V and improve current efficiency.
[0051] 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. A method for compensating for circuit breaks in an electrolytic cell, characterized in that, Includes the following steps: (1) Design of backup conductive path: Select a high conductivity copper alloy material and design a backup conductive bus that is compatible with the original conductive bus according to the size parameters of the conductive bus between the electrolytic cells. The cross-sectional area and length of the backup conductive bus meet the rated current load requirements of electrolytic production, and the resistance value does not exceed 30% of the resistance value of the original conductive bus. (2) Insulation component setting: A bent and perforated composite insulation kit is set. The outer layer of the insulation kit is made of a flame-retardant oxygen index ≤26. The insulation kit is used to achieve insulation isolation between the spare conductive bus and the original conductive bus and the electrolytic cell shell. (3) Installation and fixing: The spare conductive bus is installed above the original conductive bus between the two electrolytic cells through the insulating kit, so that the two ends of the anode and cathode in the electrolytic cell are in contact with the original conductive bus and the spare conductive bus respectively, forming a double contact point conductive structure. During the installation process, the spare conductive bus is kept parallel to the original conductive bus and in close contact, with a length direction deformation ≤1mm and a width direction offset ≤0.5mm. (4) Current compensation operation: When the original conductive bar is open or has poor contact, the backup conductive path is automatically connected to the circuit. The current flows continuously through the backup conductive bar on the other side of the electrode plate to achieve current compensation, so that the current distribution of the same electrode in the electrolytic cell is uniform and the cell voltage is stable within the set range.
2. The electrolytic cell circuit break compensation method according to claim 1, characterized in that, The cross-sectional dimensions of the spare conductive bus mentioned in step (1) are 100mm×5mm, and the length is determined according to the actual spacing of the electrolytic cell, with a range of 5400-5700mm.
3. The electrolytic cell circuit break compensation method according to claim 1, characterized in that, The insulating kit mentioned in step (2) includes an insulating base and an insulating connector. The insulating base adopts an integral molding structure with a surface flatness error of ≤0.2mm.
4. The electrolytic cell circuit break compensation method according to claim 1, characterized in that, After the installation is completed in step (3), the vertical distance between the spare conductive busbar and the original conductive busbar is 25-50mm, and the error of the overlap of their axes is ≤1mm.
5. The electrolytic cell circuit break compensation method according to claim 1, characterized in that, The stable range of the tank voltage in step (4) is a decrease of 0.01-0.015V.
6. The electrolytic cell circuit break compensation method according to claim 1, characterized in that, The surface of the spare conductive bus is tin-plated, and the tin plating layer thickness is 5-10μm.