Filter Press Electrowinning Device with Ion-Exchange Membranes
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Solution Overview
Problem
Current electrowinning technologies face challenges such as high energy consumption, acid mist generation, and limited current density, which hinder the production of high-quality copper cathodes, and existing alternative cells have not transitioned beyond laboratory stages or are commercially impractical due to issues like corrosion and high costs.
Innovation Solution
A filter press electrowinning device using ion-exchange membranes with independently operating catholyte and anolyte chambers, allowing high current densities and flow rates, and eliminating the need for solvent extraction, enabling efficient metal deposition in a closed system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional electrowinning cells are used to deposit copper cathodes, then metal deposition occurs, but high energy consumption (3 kWh/kg Cu) and acid mist generation occur
Solution Approach 1:
The electrowinning cell is divided into multiple compartments separated by ion-exchange membranes, creating distinct anolyte and catholyte chambers. This segmentation allows independent control of electrolyte composition in each chamber, enabling optimization of deposition conditions while containing harmful byproducts in separate compartments.
Solution Approach 2:
Ion-exchange membranes act as intermediaries between the anolyte and catholyte chambers, selectively transporting ions while preventing direct mixing of electrolytes. This mediator enables controlled ion transfer necessary for electrochemical reactions while containing acid mist and harmful substances within the anolyte chamber.
2Productivity
If high current density is applied to increase productivity, then metal deposition rate increases, but deposit quality deteriorates (less dense, less shiny)
Solution Approach 1:
Different chambers are provided with different electrolyte compositions and conditions optimized for their specific function. The catholyte chamber maintains conditions optimal for high-quality deposit formation, while the anolyte chamber handles impurity removal, allowing each zone to operate at its optimal quality level.
Solution Approach 2:
The invention changes the chemical parameters of the electrolyte by separating anolyte and catholyte compartments. This allows independent optimization of pH, ion concentration, and other parameters in each chamber, enabling high current density operation while maintaining deposit quality through controlled catholyte composition.
3Loss of energy
If chloride technology is used to reduce energy consumption, then energy consumption decreases, but cathode quality problems occur (adherence and shininess issues)
Solution Approach 1:
The invention changes the electrolyte composition parameters by using sulfate-based catholyte instead of chloride technology. This parameter change enables achieving both low energy consumption and high cathode quality by optimizing the sulfate concentration and pH in the catholyte chamber independently from the anolyte chamber.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device achieves higher current densities, reduces energy consumption, prevents acid mist emissions, and produces high-quality metal deposits with improved operational safety and reduced chemical reactant usage, making it a viable industrial solution for metal extraction.
Implementation Method 1
The filter press device is made up of separating elements conformed by ion exchange membranes forming a plurality of anolyte and catholyte chambers
Implementation Method 2
the ion exchange membrane, which allows electrical conduction between both solutions
Implementation Method 3
the dissolved copper, by means of the application of electrical current, is deposited on a surface to form high-purity cathodes
Implementation Method 4
electrowinning (hereinafter also referred to as EW) if the copper comes from copper oxide or sulfate dissolved in a concentrated solution of sulfuric acid
Data Source
AI summary
A filter press device for electrolytic production of metal for electrodeposition of metal from solutions, constructed from a plurality of cells connected electrically and hydraulically in series. Each has alternating frames and ion-exchange membranes to form alternating anode and cathode compartments, allowing the free path of liquid. Anolyte or catholyte passes through each compartment. The electrolyzed product is discharged from the compartment in the form of metal or a metallic compound. The electrodes are designed with a vertical base plate acting as an anode with the respective anolyte in a cell unit and in the other, acting as a cathode with the respective catholyte in the adjacent cell unit. Completed the production cycle, the device is stopped, the cell is opened, allowing the metal deposition electrodes, cathodes, can be removed and replaced to start a new productive cycle or remain in place with automatic detachment of metal product.