Cold-Rolled Lead Anodes With Low Segregation for Electrowinning
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Solution Overview
Problem
Existing methods for manufacturing lead insoluble anodes using hot lamination result in segregation of alloy components, leading to uneven wear, increased energy costs, and reduced corrosion resistance, which affects the operational reliability and purity of high-purity metals obtained through electro-winning and electro-refining processes.
Innovation Solution
The method employs continuous casting to produce lead plates with a thickness of 10 to 30 mm and a width of 900 to 1,100 mm, followed by cold lamination, eliminating the need for hot lamination and reducing segregation, while ensuring excellent conductivity and corrosion resistance by maintaining a temperature below 60°C during the lamination process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot lamination is used to manufacture lead anode plates, then the manufacturing process is established and plates can be produced, but segregation of alloy components occurs leading to uneven wear and reduced corrosion resistance
Solution Approach 1:
The patent changes the temperature parameter from hot lamination (>450°C) to cold lamination (<60°C), which prevents alloy component segregation while maintaining manufacturing feasibility. This parameter change resolves the contradiction by eliminating the thermal conditions that cause segregation.
Solution Approach 2:
The patent replaces the thermal-mechanical hot lamination system with a cold-rolling mechanical system. Instead of using heat and pressure to laminate plates, the invention uses cold rolling with reduced thickness increments, substituting thermal energy with mechanical deformation at ambient or controlled low temperatures.
2Ease of manufacture
If hot lamination is used to manufacture lead anode plates, then plates can be produced, but energy costs increase due to high temperature requirements
Solution Approach 1:
The patent dramatically reduces the temperature parameter from >450°C in hot lamination to <60°C in cold lamination, eliminating the need for high-energy heating processes while maintaining plate production capability through cold rolling techniques.
3Ease of manufacture
If hot lamination is used to manufacture lead anode plates, then plates can be produced, but corrosion resistance decreases due to component segregation
Solution Approach 1:
The patent changes the temperature parameter from hot to cold conditions, preventing the thermal diffusion that causes alloy component segregation. This maintains uniform composition throughout the plate, ensuring consistent corrosion resistance across the entire anode surface.
4Reliability
If continuous casting with cold lamination is used, then segregation is reduced and corrosion resistance improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent performs preliminary action by continuous casting the lead plates with controlled thickness (10-30mm) before lamination, preparing the material in advance for cold rolling. This preliminary preparation simplifies the subsequent cold lamination process by providing uniformly sized blanks ready for assembly.
Solution Approach 2:
The patent merges the continuous casting process with the lamination process, where the continuously cast plates are directly fed into the cold lamination line. This integration reduces the number of separate manufacturing steps and simplifies the overall process flow despite the added precision requirements.
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
This approach results in anodes with improved mechanical properties, reduced segregation, lower production costs, and enhanced corrosion resistance, leading to better conductivity, longer anode durability, and simplified manufacturing.
Implementation Method 1
Through the tube (2) the reservoir (1) feeds a cooled mold (3) where a continuous plate (4) is formed
Implementation Method 2
the pre-plates (6) obtained are transferred to a cold lamination station (7) in order to provide final thickness of the pre-plate (6), between 6 to 12 mm
Data Source
AI summary
A method for the manufacture of insoluble lead anodes, with low segregation of the constituent elements of the anodic alloy for the electrowinning of metals, free of buckling, used in electrolytic processes, which comprises: Obtaining a continuous plate (4) of lead or lead alloy 10 to 30 mm thick by 900 to 1,100 mm wide by means of a continuous casting process; Cut the continuous plate (4) according to a determined length obtaining a pre-plate (6) that will give the length of one or more plates of the anode (8); Roll the lead or lead alloy pre-plate (6) using a cold rolling mill (7) to a thickness of 6 to 12 mm, keeping the cold rolling temperature of the pre-plate under 60° C., obtaining the anode plate(s) (8); Remove the anode plate (8) from the rolling mill (7); Weld (12) a copper bar (10) to the upper end of the anode plate (11).