Multicircuit Approach for Electrolytic Cells, a Novel Method to Force

Current Balance in Electrowinning Plants.

Eduardo P. Wiechmann
Senior Member, IEEE
University of Concepci6n
Dept. of Electrical Engineering
Concepcion, Chile
ep.wiechmann@ieee.org
Antonio J. Pagliero
University of Concepcibn
Dept. of Metallurgical Engineering
Concepci6n, Chile
apaglier@udec.cl
Guillermo A. Vidal
Student Member, IEEE
University of Concepcih
Dept. of Electrical Engineering
Concepcion, Chile
gvidalaieee. org

Abstract - The most used technology for obtaining pure
copper in oxide ore copper mining is LIX-SX-EW (Leaching -
Solvent Extraction - Electrowinning). In this process, the
maximum allowable current which does not lead to electrode
short-circuit sets the production limit. This is a major drawback
if equipotential bars to connect the electrodes are used. This
common practice exhibits a high dispersion value for the
current distribution. This paper presents a connection
arrangement of the electrowinning cells to balance cathode
currents. The new connection drives the current through more
balanced resistivity channels. Moreover, the uniform level of
current achieved produces a more standardized product. Both,
chemical and physical quality of cathodes is improved. Finally,
the approach limits anode-cathode overcurrent preventing
short circuit formation. Thus, current efficiency and plant
operation are also improved.
I. SUMMARY
In electrowinning processes (EW) metallic copper is
obtained fi-om diluted copper. Typically an electrowinning
process uses a high current rectifier delivering 30000 [A] to
100 cells connected in series. Each cell containing 61 anodes
and 60 cathodes designed to operate with a current density of
250 [A/m2].
Electrode current unbalances are responsible for a number
of process anomalies. Some of the more important
consequences are; lower production volume, higher product
rejection, lower copper price, lower energy efficiency and
lower electrode life. On top, process operation is also
compromised because of the tendency to short circuit
formation. This proposal is focused in forcing a current
balance instead of trying to reduce a number of factors,
which causes unbalance in the actual configuration.
The proposed multicircuital connection allows a
significant reduction of current unbalance. Therefore all the
above mentioned problems are mitigated. It has been
estimated that at least a gain of five percent in productivity
should be attainable. Moreover, process operation is greatly
simplified.
This work was supported by FONDECYT, Chilean Research
Council, Projects 198-0463 and 798-0005.
11. INTRODUCTION
Some of the reasons accepted to anticipate that EW
processes will fh-ther increase its market share are;
0 Lower investment
Lower operational costs
0 Higher product quality
0 Minimum environment impact
The most important operation cost of EW processes is
electrical energy. Thus, current efficiency [l] is a key factor
and must be maintained as high as possible. This greatly
depends on the electric conductivity [2] and on the effect of
iron concentration of the electrolyte [3]. Also, process losses
should be as low as possible.
A major problem for EW plants is the inherent current
unbalance that decreases product quality and limit
productivity. In [4] a cell was modified to obtain quality
copper at 400 [A/m2]. This current density depends on mass
transfer rates in the cell and energy aspects [SI. The proposed
approach forces current balance in EW plants allowing
increasing productivity without reducing current efficiency
and without changing the rectifier system. The approach is
based on the principle of current source converters [6].
111. ACTUAL
ELECTRICAL
CONNECTION:
VOLTAGE
SOURCE
Electrowinning cells receive the current from a high current
rectifier through a single bus-bar package connecting the
positive and negative ends of the load. The anodes of the first
cell are connected to the positive end. Now, 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 following cell anodes. The current flows through
the cells following the path bar-anodes-electrolyte-cathodes-
bar. The last cell cathodes deliver the current to the negative
end bar.
Figure 1 shows a scheme of actual EW cells electrodes
connection. In this figure anodes A of the first cell receive the
current from the rectifier through the circuit C. The bar B
distribute the incoming current to the anodes. The cathodes K
receive the current from the anodes through the electrolyte
and deliver it to the bar B that delivers it to the following cell.
In this electric configuration the bar that hold the anodes
connects them electrically. Also the bar that hold the cathodes

0-7803-6606-9/00/$10.00 02000 IEEE - 501 - ISIE’2000, Cholula, Puebla, Mexico

 ;LI‘ ‘uv”’
Fig. 1. Actual electrowinning plant electrodes connection.
connects them electrically. This parallel connection of
anodes and cathodes is like having many different resistances
parallel connected to a voltage source. In fact, the cell
voltage is unique and is the voltage applied to all electrodes
in the cell.
IV. MULTICIRCUITAL
ELECTRIC
CONNECTION:
CURRENT
SOURCE
The improvement in current balance is accomplished using
the principle of current source operation. Connecting the load
in a multicircuital configuration creates path channels for the
current that become naturally balanced among them. This
series-connected electrode arrangement offers an average
load resistance, which is by far less sensitive to parameter
variations. Some of these variations are produce by;
electrical contacts, electrode geometry, position and shape,
and electrolyte temperature and composition.
The new arrangement can be implemented maintaining the
load current distribution circuit, flowing the current from the
rectifier to the first cell using the circuit C . The main
difference of this arrangement is the segmented intercell bar.
Instead of connecting one-cell cathodes with next cell anodes
through one bar, the connection is done with multiple B bars.
Then each cathode delivers its current to one anode creating
current channels. Figure 2 shows the proposed load
arrangement.
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Fig. 2. Multicircuital electrowinning plant electrodes connection.
v. CELL MODELING
A model suitable for simulating geometrical, chemical and
electrical variations is shown in figure 3. A number of
measurements obtained in two electrowinning facilities were
used to extensively crosscheck its validity. In this model, the
electrochemical process is modeled as a constant DC voltage
and a resistance between anode and cathode. Contact
resistances for cathodes and anodes are included. The
complete electric circuit of an EW plant was obtained using
this model. The resulting circuit requires more than 50k
elements.
It should be noted that the model uses lumped elements to
represent anodes A and cathodes K. This also means that is
not intended to predict the current density across the
electrodes surface. The Rc resistances represent the contact
resistances, and the Rak resistance represents the resistance
between an anode and the adjacent cathode. The voltage V
represents the electrochemical potential.
Simulated results were obtained assigning random values
(within a range suggested by real plant measurements) to
contact resistances, anode-cathode resistances and anode-
cathode potentials.
ISIE’2OO0, Cholula, Puebla, Mexico
 540

520

500

480

460
m
440

Fig. 3. Electrowinning cell model. Rc are contact resistances, Rak are anode- Cell position Cathode position
cathode resistances and V are anode-cathode potentials.
Fig. 4. Plant current distribution pattern with the actual voltage
source connection.
VI. CURRENT
DISTRIBUTION

In actual plants the voltage applied to each pair of

electrodes in a cell is unique. However, the current
distribution shows a large dispersion. This happens because
this voltage is applied to unmatched resistances and process 540

potentials. Higher current densities flow through lower 520

resistances paths and vice-versa. This produces a high
current unbalance in cathodes. 500

A 33-cell electrowinning plant containing 21 anodes and 480

20 cathodes per cell was simulated. Random variations were
considered for the model parameters as mentioned. First, 20
460

using the voltage source connection with 10,000 [A] resulted 440
in a 500 [A] mean value with a 26.13 [A] standard deviation.
Cell posnioo Calhode p o s i l m
These results are shown in Figures 4 and 6.
Next, the proposed arrangement was tested. The rectifier
provides 10000 [A] for obtaining the 250 [A/m2] current Fig. 5. Plant current distribution pattern with the current source
density per plate face. The cathode current exhibits a normal connection.
distribution with 500 [A] mean value and a reduced 13.26
[A] standard deviation. These results are shown in Figures 5
and 6.
Comparing both connection arrangements with the aid of
Figure 6 (actual voltage source vls proposed current source)
becomes clear that the newer connection greatly reduces
current dispersion.
Figure 6 also suggests that the process current can be
boosted at least five percent without increasing the maximum
permissible current of the process (565 [A]).

VII. SHORT CIRCUIT ANOMALY

Short circuit formation tendency was also researched. This
phenomenon occurs when an excessive of copper is
deposited producing a connecting bridge between electrodes.
Specifically, local overcurrent densities induce this
progressive formation. Moreover, this phenomenon produces
high temperature points in electrodes. This overtemperatures
reduce process efficiency and may affect process operation.
Finally, anodes are subjected to deformations or melting
increasing electrolyte contamination. Thus, short circuit
formation affects electrodes, copper quality, productivity and
current efficiency.
I
Fig. 6. Current distribution results. Trace SI was obtained with the
voltage source approach, while trace S2 was obtained with the
current source approach.
The origin of the short circuit anomaly was simulated by
reducing a Rak resistance of a pair of electrodes to 50% of its
nominal value. The voltage source connection failed in
preventing the short circuit. Figure 7 shows this result where
the overcurrent in the affected cathode is 5 1.60%.

- 503 - ISIE’2000, Cholula, Puebla, Mexico

 VIII. CONCLUSIONS

The proposed connection reduces current unbalance. In the

case studied, the standard deviation of current distribution
was reduced from 26.13[A] to 13.26[A]. Therefore, a 5%
increase on production should be achieved with the new cell
connection arrangement. Finally, short circuit formation
tendency is cancelled. This improves process operation and
reduces losses.
Future work should be done to establish the percentage
increase in copper Grade A accomplished with the
connection. It is expected a figure around 4%. This means
from 90 to 94% of the production.
Cell posilinn Cathode o w t i o n

Fig. 7. Short circuit formation in EW plants with voltage source REFERENCES

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