Electrowinning Hanger Bar Sealing to Minimize Joint Corrosion
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Solution Overview
Problem
Conventional hanger bars in electrowinning processes suffer from corrosion, particularly at the joints and electrical contacts, leading to reduced efficiency and service life due to the corrosive tankhouse environment, where acid or electrolyte mist interacts with the materials.
Innovation Solution
A hanger bar design featuring a bar portion made from a corrosion-resistant material like stainless steel and contact portions made from a more conductive material like copper, with a welded seal using an aluminium bronze welding rod to minimize corrosion, ensuring a strong and corrosion-resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional hanger bars use copper or electroplated copper surfaces for electrical conductivity, then electrical conductivity is improved, but corrosion resistance deteriorates due to acid or electrolyte mist contact
Solution Approach 1:
The hanger bar employs a composite structure combining copper (or copper alloy) for electrical conductivity with stainless steel cladding for corrosion resistance. The stainless steel layer acts as a protective barrier against acid or electrolyte mist, while the copper core maintains electrical conductivity. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The hanger bar features different material properties at different locations: the outer surface is clad with stainless steel for corrosion resistance in the tankhouse environment, while the inner core remains copper for electrical conductivity. This local differentiation of material quality allows each region to optimize for its specific function.
2Use of energy by moving object
If stainless steel cathode plates are joined to solid copper hanger bars, then electrical conductivity is improved, but galvanic corrosion occurs at the joint between plate and hanger bar
Solution Approach 1:
An aluminium bronze welding rod serves as an intermediary material between the stainless steel cathode plate and the copper hanger bar. This intermediate layer prevents direct galvanic contact between dissimilar metals, eliminating galvanic corrosion while maintaining electrical conductivity through the joint.
Solution Approach 2:
The joint structure creates a composite connection sequence: stainless steel plate to aluminium bronze weld to copper hanger bar. This multi-material composite joint prevents galvanic corrosion by avoiding direct contact between stainless steel and copper, while the aluminium bronze provides adequate electrical conductivity.
3Use of energy by moving object
If copper is used for hanger bar electrical contacts, then electrical conductivity is improved, but service life is reduced due to corrosion at joints and electrical contacts
Solution Approach 1:
The hanger bar uses a composite construction with stainless steel cladding over copper core. The stainless steel outer layer protects the copper from corrosive environments, significantly extending service life while the copper core maintains electrical conductivity. This composite structure resolves the contradiction between conductivity and durability.
Solution Approach 2:
The hanger bar implements local quality differentiation where the outer surface is protected with corrosion-resistant stainless steel cladding, while the interior maintains copper for electrical conductivity. This localized material assignment optimizes both service life and electrical performance.
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 solution significantly reduces corrosion, enhances the structural integrity and electrical conductivity of the hanger bars, thereby increasing the service life and efficiency of the electrowinning process by preventing acid or electrolyte mist from entering the hanger bar and reducing galvanic corrosion.
Implementation Method 1
a welded seal is formed between the bar portion and the contact portions in order to minimise corrosion
Implementation Method 2
a welded seal is formed between the bar portion and the contact portions in order to minimise corrosion
Data Source
AI summary
A hanger bar for an electrowinning cell, wherein hanger bar includes a bar portion and one or more contact portions adapted, in use, to be brought into contact with an electrical conductor. The contact portions are fabricated from an electrically conductive material, and a welded seal is formed between the bar portion and the contact portions in order to minimize corrosion.