Segmented AC Sources for Copper Electrolysis
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Solution Overview
Problem
Current methods for overlaying alternating current over direct current in industrial electrolytic cells for copper electrowinning and electrorefining are limited by the need for a single large alternating current source, which is economically and geometrically impractical, and often require modifications to existing infrastructure, leading to inefficiencies and quality issues in copper deposition.
Innovation Solution
Implementing multiple small alternating current sources connected between the end electrodes of each electrolytic cell, with each source having a capacity equivalent to one face of an electrode, allowing high-frequency alternating current to circulate between cells while direct current flows in parallel, using passive components like capacitors and inductors to manage tension and protect against overcurrent and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single large alternating current source is used to overlay AC on DC in electrolytic cells, then the copper deposition quality is improved, but the device complexity and implementation cost increase significantly
Solution Approach 1:
The patent divides the single large alternating current source into multiple small alternating current sources, with each source connected to a specific electrolytic cell. This segmentation reduces the complexity of implementing and maintaining a single large system while achieving the same copper deposition quality improvement across multiple cells through distributed AC overlay.
2Manufacturing precision
If a single large alternating current source is used, then the copper deposition quality is improved, but the implementation cost and infrastructure modification requirements increase
Solution Approach 1:
By segmenting the AC source into multiple small units, each can be independently installed and configured on existing electrolytic cells without requiring comprehensive infrastructure modifications. This modular approach reduces implementation costs and simplifies the manufacturing/deployment process compared to installing a single large AC source system.
Solution Approach 2:
Each small alternating current source is designed to be self-contained and independently operable, allowing for easier installation and maintenance without requiring complex centralized infrastructure. The distributed architecture enables each unit to serve its associated electrolytic cell autonomously.
3Manufacturing precision
If high alternating current intensity is applied, then the copper deposition quality is improved, but the risk of overcurrent and short circuits increases
Solution Approach 1:
Dividing the high current application into multiple small current sources distributed across different cells reduces the risk concentration. If one source experiences overcurrent or short circuit conditions, the other sources continue to operate independently, maintaining overall system reliability while still achieving high deposition quality at each location.
Solution Approach 2:
The patent incorporates protective components such as fuses and circuit breakers in each small alternating current source configuration. These protective elements are pre-installed to prevent overcurrent and short circuit damage, cushioning the system against reliability issues before they can propagate and affect the entire copper deposition process.
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 enables efficient electrical agitation of the electrolyte, improving copper quality and reducing operational costs by allowing higher alternating current intensities without modifying existing equipment or infrastructure, thus enhancing the copper deposition process while maintaining low implementation complexity and cost.
Implementation Method 1
efficient electrical agitation of the electrolyte, improving copper quality
Implementation Method 2
using passive components like capacitors and inductors to manage tension
Implementation Method 3
using passive components like capacitors and inductors to manage tension and protect against overcurrent and short circuits
Implementation Method 4
Rectifiers generate direct electric current which allows settling of the copper dissolved in the electrolyte and bonds to the surface of the cathode
Implementation Method 5
bonds to the surface of the cathode, which according to Faraday's Law, is proportional to the current
Data Source
AI summary
The present invention relates to a system for superimposing alternating current on direct current flowing through one or more electrolytic cells, for electro-winning or electro-refining processes, in which the terminals of an alternating current source are connected to the first and last electrode of a cell or a group of cells.