POU Power Converters for Copper Electrorefining Concentration Control

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Solution Overview

Problem

Conventional copper electrowinning processes produce impure copper cathodes, leading to increased handling costs and energy inefficiency, with traditional liberator circuits operating at non-optimum current densities and requiring excessive liberator capacity, especially during tankhouse expansions, and posing challenges in acid mist control.

Innovation Solution

Incorporating point of use (POU) power converters to drive individual anode-cathode pairs in copper electrorefining cells for in situ copper liberation, allowing direct control of copper concentration and optimizing current density, thereby reducing the need for additional liberator cells and improving acid mist management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional liberator circuits are used to remove copper from electrolyte, then copper concentration is controlled, but impure copper cathodes are produced requiring return to smelter

Engineering Contradiction:

Improvecopper concentration controlVSAvoidcopper cathode purity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent changes the operating parameters of the liberator circuit by applying optimum current density through POU power converters, which transforms the process outcome from producing impure cathodes to producing high-quality saleable copper cathodes that meet LME Grade A standards

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The liberator circuit is configured to produce saleable copper cathodes that can be directly sold rather than returned to the smelter, making the system self-sufficient and eliminating the need for external smelting operations for this portion of copper recovery

Inventive Principle:

Principle #25Self-service

2Productivity

If liberator capacity is increased to handle expanded tankhouse production, then more copper can be processed, but device complexity and cost increase

Engineering Contradiction:

Improvecopper processing capacityVSAvoidliberator section expansion

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

By changing the current density parameter to optimum levels and using POU power converters for precise control, the existing liberator capacity processes more copper effectively without requiring physical expansion of the liberator section

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The liberator cells perform multiple functions: they control copper concentration in the electrolyte, produce saleable copper cathodes, and can be operated at flexible current densities to adapt to different production requirements without requiring separate systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If non-optimum current density is used in liberator circuits, then operation is simpler, but energy efficiency decreases

Engineering Contradiction:

Improvecurrent density controlVSAvoidenergy efficiency

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

POU power converters provide precise control and monitoring of current density at each anode-cathode pair, enabling operation at optimum current density levels that maximize energy efficiency while maintaining simple operation through automated control

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

By dividing the liberator circuit into individually controlled anode-cathode pairs with separate POU power converters, each segment can be optimized for energy efficiency while the overall system remains easy to operate through centralized control

Inventive Principle:

Principle #1Segmentation

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 enhances copper production efficiency, reduces the load on liberator cells, and allows for safer operation by controlling acid mist, leading to higher-quality copper cathodes and more efficient energy use without automatic expansion of liberator sections.

Implementation Method 1

electrowinning of copper from an electrolyte

Methodology Applied

Scientific EffectElectrowinning: Electrodeposition

Implementation Method 2

copper concentration in the electrolyte circulating in the electrorefining tankhouse, decreasing the requirement for the removal of copper

Methodology Applied

Scientific EffectElectrochemical reduction: Reduction

Implementation Method 3

point of use (POU) power converters to drive current through the anode-cathode gaps of electrolytic cells locally

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 4

apparatus for the control of the acid mist generated to ensure safe operation

Methodology Applied

Scientific EffectAcid mist generation: Aerosol

Data Source

PatentEP3452640B1Equipment for decopperising an electrorefining process and way of operating the process

Publication Date: 2020.03.25 BARKER

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AI summary

The invention relates to an electrorefining cell and its use in a method of electrorefining of copper. The cell comprises: one or more electrorefining anodes comprising impure copper; one or more cathodes; an electrolyte containing copper sulfate and sulfuric acid; one or more electrowinning anodes; and one or more point-of-use power converters configured to supply current to the or each electrowinning anode whereby to control the copper concentration of the electrolyte when said cell is in use.