Canadian Metallurgical Quarterly

The Canadian Journal of Metallurgy and Materials Science

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Copper Electrowinning using Segmented Intercell

Bars for Improved Current Distribution

E.P. Wiechmann, G.A. Vidal, A.J. Pagliero & J.A. Gonzalez

To cite this article: E.P. Wiechmann, G.A. Vidal, A.J. Pagliero & J.A. Gonzalez (2002) Copper
Electrowinning using Segmented Intercell Bars for Improved Current Distribution, Canadian
Metallurgical Quarterly, 41:4, 425-432, DOI: 10.1179/cmq.2002.41.4.425

To link to this article: https://doi.org/10.1179/cmq.2002.41.4.425

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 425

Canadian Metallurgical Quarterly, Vol 41, No 4 pp 425-432, 2002

© Canadian Institute of Mining, Metallurgy and Petroleum
Published by Canadian Institute of Mining, Metallurgy and Petroleum
Printed in Canada. All rights reserved

COPPER ELECTROWINNING USING SEGMENTED

INTERCELL BARS FOR IMPROVED
CURRENT DISTRIBUTION
E.P. WIECHMANN1, G.A. VIDAL1, A.J. PAGLIERO1 and J.A. GONZALEZ2
1
University of Concepcion, Faculty of Engineering, P.O. Box 160-C
Concepcion, 8 Region, Chile
2
Teck Cominco Research, Teck Cominco Metals Ltd. P.O. Box 2000
Trail, British Columbia, Canada V1R 4S4

(Editor’s Note: See also the Proceedings of the Metallurgical Society, Electrometallurgy 2001, ISBN: 1-8944475-16-X)

Abstract — The most widely used technology for obtaining pure copper (>99.999% Cu) from copper
oxide ores is LIX-SX-EW (Leaching – Solvent Extraction – Electrowinning). In the EW step, the maxi-
mum current that can be applied is partially limited by the possibility of the formation of short circuits.
The Walker configuration, despite its apparent robustness and simplicity, exhibits high dispersion of the
electrode currents. This paper reviews the current distribution phenomena and proposes a Whitehead
based configuration implemented with a multicircuit intercell bar to force the current balance. This
arrangement drives the current through more balanced resistance circuits despite intrinsic process para-
meter deviations. A more even current distribution produces cathodes capable of complying with tighter
standards improving chemical and physical cathode quality parameters. Also, the proposed configuration
can decrease the probability of short circuit formation allowing operation at higher current densities.
Finally, use of the proposed electrical arrangement makes possible the continuous measurement of the
flow of current in each electrode using current sensors. This allows for the early detection/correction of
short circuits and continuous monitoring of the current distribution in the whole cellhouse.

Résumé — La technique la plus utilisée dans l’obtention de cuivre pur (> 99.999% Cu) à partir de min-
erais d’oxyde de cuivre est LIX-SX-EW (Lessivage – Extraction par solvant – Extraction électrolytique).
À l’étape d’extraction électrolytique, le courant maximum qui peut être appliqué est partiellement limité
par la possibilité de formation de courts-circuits. La configuration de Walker, malgré sa robustesse
apparente et sa simplicité, exhibe une grande dispersion des courants de l’électrode. Ce document passe
en revue les phénomènes de distribution de courant et propose une configuration basée sur Whitehead,
mise en place avec une barre intercellulaire à circuits multiples pour forcer une balance du courant. Cet
arrangement conduit le courant à travers des circuits à résistance mieux balancée malgré les déviations
intrinsèques de paramètre du procédé. Une distribution de courant plus égale produit des cathodes
capables de satisfaire à des normes plus étroites, améliorant les paramètres chimiques et physiques de
qualité de la cathode. Également, la configuration proposée peut diminuer la probabilité de formation de
court-circuit, permettant ainsi l’opération à de plus grandes densités de courant. Finalement, l’utilisation
de l’arrangement électrique proposé rend possible la mesure continue du débit de courant à chaque
électrode en utilisant des détecteurs de courant. Ceci permet la détection/correction précoce des courts-
circuits et le contrôle continu de la distribution de courant dans l’ensemble des cellules.

INTRODUCTION duced from sulphide ores whereas, EW is usually required to

Electrodeposition processes are employed throughout the
world for obtaining several metals such as Cu and Zn.
Specifically, copper is recovered using either electrorefining
(ER) or electrowinning (EW) steps. Electrorefining (ER) is
required for producing high-grade copper from anodes pro-
recover copper from solutions produced from solvent extrac-
tion (SX) circuits. The SX-EW process has several advan-
tages over the pyrometallurgical ER routes: lower invest-
ment, lower operational costs and minimum environmental
impact. New technologies for obtaining high grade copper
from sulphide ores via lixiviation (solvent extraction) elec-

CANADIAN METALLURGICAL QUARTERLY

426 E.P. WIECHMANN, G.A. VIDAL, A.J. PAGLIERO and J.A. GONZALEZ
trowinning will further boost the use of electrowinning in
the coming decades [1].
Over the last 20 years copper EW plants have increased
in number and overall production. The original goal was to
boost copper production within low profile quality stan-
dards. However, cathode quality requirements are becom-
ing more restrictive and low conversion costs are more dif-
ficult to achieve. Companies capable of producing high
quality copper will benefit from the available premiums on
high purity cathodes. Thus, copper facilities will likely
invest to improve their cathode quality without compro-
mising production or conversion costs. This can be done by
increasing the overall efficiency of the EW process by
reducing the specific energy consumption and increasing
the anode and cathode lives.
Electrowinning processes have remained almost
unchanged over the years. Most copper EW plants employ
the Walker configuration for distributing current to the
electrodes. The main disadvantage of this arrangement is
that its use could produce a current imbalance between the
electrodes. To overcome this problem, this work aims to
identify electrical changes needed to force a reduction in
current dispersion. The challenge is to do this without sig-
nificantly changing the existing cellhouse infrastructure:
electrolyte conductivity, cathode alignment and cell
design.
The proposed multicircuit arrangement injects current
to each electrode instead of injecting the current to an
equipotential bar. This is accomplished by employing a
current source converter scheme [2] based on the
Whitehead configuration [3].
A better current distribution in EW leads to a more even
distribution of deposit weights in the cathodes, reducing
the frequency of short circuits and increasing current effi-
ciency. Also the cathode surfaces are more homogeneous
(improved physical quality) and entrap fewer impurities
(improved chemical quality). Additionally, reducing the
frequency of formation of short circuits can increase the
life of the anodes.
Many factors influence the quality and productivity of
the EW step [4]. Current density plays a very important
role in the process and must be as homogeneous as possi-
ble for all electrodes. Gonzalez [5] proved that a good cur-
rent distribution reduces the average energy consumption
in the zinc EW process. Up to 150 kWh per ton can be
saved in zinc EW. For the same process, Bestetti et al. [6]
represent the sum of fixed and variable costs as a function
of current density showing that there is an optimum current
density at which the overall costs are minimized. Thus,
operating close to the optimum current density and with an
even current distribution should further minimize capital
and operating costs associated with the EW step.
CANADIAN METALLURGICAL QUARTERLY
An acceptable current distribution alternative to distrib-
ute current must maintain a high current efficiency [7].
Current efficiency depends on the electrical conductivity
[8], on the Fe+2/Fe+3 concentrations in the electrolyte [9]
and more substantially, on the current distribution and fre-
quency of short-circuit formation. If the last two variables
can be controlled while improving cathode quality, then the
current density can be increased. This could translate into
considerable savings in the EW step [10-12].
In this work, an electrical configuration with intrinsic
current balance is studied. Thus, current efficiency, Cu pro-
duction and quality should improve. The scheme being
examined was computer simulated and laboratory tested.
Results showed a reduction in current imbalance. The
arrangement was reviewed for different plant operating
conditions and phenomena including short circuit genesis,
cathode harvesting and utilization of short circuit frames.
Therefore, the main contribution of this work is to identify
the advantages of using a Whitehead-based configuration
for the EW and ER processes.
The original Whitehead system used a segmented
equipotential bar. Anodes and cathodes were directly
connected (usually the cathode contact rested on the
anode). This made movement and positioning of the
electrodes extremely cumbersome. Thus, this system
was abandoned in preference to the Walker system. The
modified interelectrode configuration described in this
paper is similar to the Whitehead configuration, but,
dedicated intercell connecting blocks (labeled B in
Figure 3) are proposed for improved electrode move-
ment/positioning.
THE WALKER CONFIGURATION
With this arrangement, cells receive current from a high
current rectifier through a single bus-bar connecting the
positive and negative ends of the load. The anodes of the
first cell are connected to the positive end. The rectifier
current flows to the electrolyte and to the cathodes of the
cell. Next, a bar receives the current from the cathodes and
delivers it to the following cell anodes. The current flows
through the cells following the path bar-anodes-electrolyte-
cathodes-bar. The last cell’s cathodes deliver the current to
the negative end bar.
Figure 1 shows a schematic representation of an actual
EW cell electrode configuration. In this figure, anodes A of
the first cell receive the current from the rectifier through
the circuit C. The bar B distributes the incoming current to
the anodes. The cathode K receives the current from the
anodes through the electrolyte and delivers it to the bar B.
In this electrical configuration, the bar that holds the
anodes connects them electrically. Also, the bar that holds
the cathodes connects them electrically.
COPPER ELECTROWINNING USING SEGMENTED INTERCELL BARS FOR IMPROVED CURRENT DISTRIBUTION
Fig. 1. Walker configuration.
The use of a bar connecting all anodes and an opposite
bar for the cathodes imposes a unique cell voltage.
However, the resistance between each pair of electrodes is
not unique, varying with electrode positioning, electrolyte
composition and temperature and contact resistances.
Therefore, the application of a unique voltage to
unmatched parallel resistance results in uneven currents
flowing through the electrodes.
With the Walker arrangement, the current distribution is
highly sensitive to geometrical, chemical and electric para-
meters. The actual current dispersion of EW plants leads to
a variable cathode weight and impairs its quality parame-
ters. This is a vicious process. A cathode with an augment-
ed deposit (because of a higher current density) reduces the
distance to the anode, thus increasing the circulating cur-
rent and the thickness of the copper deposit. The reduction
of the distance between the cathode and the anode decreas-
es the electrolyte circulation in an area with elevated elec-
trolyte consumption reducing the Cu2+ concentration. This
reduces the physical and chemical quality of the deposit.
Eventually, the dendritic deposit on the cathode touches the
Fig. 2. Electrical circuit model for Walker (left) and multicircuit (right) configuration. Large resistances represent the electrolyte and smaller resistances
represent bar contacts.
427
anode producing short circuits. Short circuits reduce the
cathode quality enhancing the possibility of the formation
of uneven deposits and the contamination of the cathodes
with Pb. Finally, current and energy efficiencies are com-
promised.
WHITEHEAD BASED ELECTRICAL
CONFIGURATION: MULTICIRCUIT
In the Walker arrangement, a reduction of the resistance
between an anode and a cathode results in a higher current
flow through these electrodes. An identical resistance vari-
ation in the Whitehead based configuration results in a
smaller current deviation. Figure 2 shows both equivalent
circuit models. A simple inspection analysis may help to
explain the intrinsic capability of the multicircuit configu-
ration to withstand parameter deviations. Furthermore, the
arrangement generates preferred paths for the electrical
current, or current channels. These channels share similar
circuit equivalent resistances producing balanced currents
throughout the cell. Each equivalent circuit resistance is
comprised of a number of contact and electrolyte resis-
tances in series. This also means that resulting resistances
will be more balanced as the number of series cells increas-
es. However, the use of short circuit frames for cell main-
tenance reduces the effective number of series cells in the
multicircuit configuration.
The new arrangement maintains the main feeding bars
conducting the current from the rectifier to the Ø ends of the
load. The distinctive difference of this arrangement is the
segmented intercell bar. Each segment connects an anode
to a cathode forming the current channels. Figure 3 shows
the proposed arrangement. An added feature of the seg-
mented bar comes from its intrinsic measurement capabili-
ty. This is possible because individual cathode currents
flow through each bar segment. Thus, a current sensor
device installed inside the bar for each anode-cathode-con-
necting conductor can provide exact and continuous current
information. These data can be processed to determine var-
CANADIAN METALLURGICAL QUARTERLY
428 E.P. WIECHMANN, G.A. VIDAL, A.J. PAGLIERO and J.A. GONZALEZ

ious process parameters including the actual cathode cop-

per deposit, under and over current anomalies and harvest
ready conditions. The Walker configuration requires man-
made measurements and direct supervision of the 6,000
plant cathodes. Therefore, with the use of intercell seg-
mented bars, full process automation will be possible.

Fig. 3. Whitehead-based multicircuit configuration.

EXPERIMENTAL

The current balance of both approaches was measured in a

laboratory microplant formed by five electrowinning cells.
Each cell contained five cathodes designed to operate at an Fig. 4. Cells used to carry out the EW experiments. Electrodes, connec-
average current density of 250 A/m2. The immersed cath- tions and relays are shown.
ode size was 50 mm by 50 mm. The microplant was fed by
a controlled current source injecting 6.25 A. The electrolyte
temperature was 50 °C. Electrolyte was prepared using
reagent grade chemicals and distilled water. The synthetic
electrolyte contained 45 g/L Cu, 180 g/L H2SO4 and 200
mg/L Co. Twenty-four hour deposition cycles were carried
out. Stainless steel cathodes and Pb-Ca-Sn anodes were
used. Average current efficiency in the tests was near 94%.

The principal variables that affect the current imbalance

are contact resistance, electrolyte resistance and electro-
chemical potential. Thus, electrical switches were utilized
to swap Walker and multicircuit arrangements without
parameter changes. Photographs describing the experimen-
tal set up are shown in Figures 4 and 5. Cell 1 receives the
current from the anodes, while current leaves via the cath-
odes from cell 5.

Table I shows the current density measured in each

cathode for the Walker connection, while Table II shows
the current density measurements for the proposed arrange-
ment. The standard deviation of the current density
obtained with the Walker configuration is reduced from
54.0 to 27.4 A/m2 with the multicircuit configuration for
identical test parameters on a 250 A/m2 basis. Also, the
maximum and minimum currents are constrained. The
reduction accomplished by the multicircuit option is shown
Fig. 5. Copper deposits obtained during the EW tests. The five EW cells
are shown.
in Figure 6. This figure also suggests that the process cur-
rent can be boosted by at least 10% without increasing the
maximum permissible current density of the process to
350 A/m2.

CANADIAN METALLURGICAL QUARTERLY

COPPER ELECTROWINNING USING SEGMENTED INTERCELL BARS FOR IMPROVED CURRENT DISTRIBUTION 429

CATHODE HARVESTING

To remove the deposited copper from the starter sheet, a

stripping device is used. During this procedure, usually
one-third of the cell cathodes are removed and the process
current circulates through the remaining two-thirds. With
the Walker connection, the equipotential bars redistribute
the current between the electrodes. Adjacent cells are not
affected.

With the multicircuit arrangement, the absence of an

equipotential bar is compensated by the electrolyte conduc-
tion. In this case, current distribution in the upstream and
downstream cells is only minimally affected.

Table III shows the current measured in each cathode

Fig. 6. Current distribution results for Walker and multicircuit configu-
rations are shown in curves W and M, respectively
during the simulated cathode harvesting with the Walker
connection. In this case, two cathodes from the third cell
were removed. Table IV shows the current measured
employing the multicircuit connection during the simulated
cathode harvesting procedure. As shown in Table IV, cath-

Table I - Current density measured in a laboratory plant with Walker connection

Cathode current density [A/m2]

Cell 1 Cell 2 Cell 3 Cell 4 Cell 5

Cathode 1 306 204 309 234 225

Cathode 2 231 389 188 230 243
Cathode 3 267 196 275 244 325
Cathode 4 235 200 206 304 139
Cathode 5 211 262 271 238 317

Current density standard deviation [A/m2] 54.0

Maximum cathode current density [A/m2] 389
Minimum cathode current density [A/m2] 139

Table II – Current densities measured in a laboratory plant with multicircuit connection

Cathode current density [A/m2]

Cell 1 Cell 2 Cell 3 Cell 4 Cell 5

Cathode 1 262 269 288 260 233

Cathode 2 258 254 216 225 219
Cathode 3 238 220 241 221 319
Cathode 4 244 250 251 299 198
Cathode 5 246 257 255 245 282

Current density standard deviation [A/m2] 27.4

Maximum cathode current density [A/m2] 319
Minimum cathode current density [A/m2] 198

CANADIAN METALLURGICAL QUARTERLY

430 E.P. WIECHMANN, G.A. VIDAL, A.J. PAGLIERO and J.A. GONZALEZ

Table III – Current densities measured in a laboratory plant with the Walker connection
during simulated cathode harvesting

Cathode current density [A/m2]

Cell 1 Cell 2 Cell 3 Cell 4 Cell 5

Cathode 1 294 210 404 222 229

Cathode 2 240 377 0 232 239
Cathode 3 250 194 442 263 326
Cathode 4 240 204 0 303 146
Cathode 5 226 264 404 230 311

Table IV – Current densities measured in a laboratory plant with multicircuit connection

during simulated cathode harvesting

Cathode current density [A/m2]

Cell 1 Cell 2 Cell 3 Cell 4 Cell 5

Cathode 1 278 305 424 259 231

Cathode 2 259 250 0 221 227
Cathode 3 245 206 420 223 303
Cathode 4 233 242 0 255 190
Cathode 5 235 246 406 291 299

ode harvesting can be accomplished using the multicircuit
electrical configuration with a lower impact on the cells
next to the cell being harvested than that measured with the
cells using the Walker system.
SHORT CIRCUIT ANOMALY
The origin of short circuits was also researched. This phe-
nomenon occurs when copper is deposited in localized
regions creating a connecting bridge between the elec-
trodes. Specifically, local over current densities can induce
the progressive formation of dendrites. Moreover, this pro-
duces localized high temperature areas in the electrodes
that can damage them permanently. This over temperature
reduces the process efficiency, deteriorates the process
operation and produces partial melting of the anode
increasing electrolyte contamination. Both the dimensional
stability and integrity of the anode are compromised. Thus,
the short circuit phenomenon forces earlier anode replace-
ments, impairs copper quality and diminishes current effi-
ciency and productivity.
Experimental results obtained with the Walker configu-
ration and with the multicircuit connection are presented in
Table V and Table VI respectively. The purpose of this test
was to reproduce the genesis of a short circuit between the
cell electrodes, which was done by reducing the equivalent
resistance between the electrodes. Specifically, the affected
cathode in the Walker configuration exhibited a higher cur-
rent density deviation from the process mean value of 250
A/m2 to 478 A/m2. Such a high current density would easi-
ly induce the generation of a short circuit between the elec-
trodes. On the other hand the multicircuit configuration
showed just a mild current density increase to 360 A/m2,
thus effectively avoiding the possible generation of a short
circuit given that this maximum current density is within
the accepted standard deviation range.
CONCLUSIONS
Use of equipotential bars despite their apparent robustness
and simplicity, exhibits high dispersion of the cathode cur-
rent density. Alternatively, intercell segmented bars halves
the current dispersion. Thus, quality, efficiency, operation
and production are improved.
The current channeling effect grows with the number of
series cells. To obtain significant results over the equipo-
tential bar, a minimum of five cells in series using seg-
mented bars is required. As this number decreases, benefits
tend to decrease approaching those obtained with equipo-
tential bars.
The segmented bar provides a solid foundation for full
process automation. Its current measurement capability

CANADIAN METALLURGICAL QUARTERLY

COPPER ELECTROWINNING USING SEGMENTED INTERCELL BARS FOR IMPROVED CURRENT DISTRIBUTION 431

Table V – Cathode current densities measured in a laboratory plant with the Walker system simulating a
localized high current density that could lead to a short circuit (Cathode 3 in Cell 3)

Cathode current density [A/m2]

Cell 1 Cell 2 Cell 3 Cell 4 Cell 5

Cathode 1 300 209 226 229 227

Cathode 2 236 378 161 223 241
Cathode 3 260 197 478 269 323
Cathode 4 238 203 185 303 148
Cathode 5 216 263 200 227 310

Maximum cathode current density [A/m2] 478

Minimum cathode current density [A/m2] 148

Table VI – Cathode current densities measured in a laboratory plant with the Multicircuit system simulating a
localized high current density that could lead to a short circuit (Cathode 3 in Cell 3)

Cathode current density [A/m2]

Cell 1 Cell 2 Cell 3 Cell 4 Cell 5

Cathode 1 264 257 273 247 229

Cathode 2 254 211 177 261 221
Cathode 3 240 329 360 243 309
Cathode 4 242 241 207 273 205
Cathode 5 250 211 233 227 287

Maximum cathode current density [A/m2] 360

Minimum cathode current density [A/m2] 177

opens the door for various technological advances. Full REFERENCES

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