Improving Productivity and Energy Efficiency in Copper Electrowinning Plants
This paper presents strategies to improve energy efficiency and productivity in copper electrowinning (EW) plants. Plant modeling is based on updated technical data and specific measurements obtained in a tankhouse during a complete production cycle (four to five continuous days). The industrial EW plant site examined produces 180 000 ton/year with an operating current density of 300 A/m2 and a current dispersion of 8.5%. Proposals are based on the use of Optibar intercell bars and the reduction of distance between electrodes. Due to these changes, an improvement of +4.3% in energy efficiency combined with an increase of +3.4% in production can be accomplished. The productivity improvement projected for the plant is U.S.$ 10 million/year.
Optimization of copper electrowinning from synthetic copper sulfate solution using a pulsed bed electrode
Abstract This paper concludes a series of investigations concerning the use of pulsed bed electrodes (PBEs) for copper electrowinning. In previous papers, the main operational parameters affecting the current efficiency (CE), space–time yield (Y), and energy consumption (EC) were identified and their effects on the performance of the process were analyzed. In light of the results, the fluidized bed time was set at 2 s and it was found that the electrode thickness should be reduced in order to achieve values of CE and EC lower than those obtained in conventional industrial processes using flat plate electrodes. In this work, the electrode thickness was reduced from 3.4 to 2.4 cm and the process was optimized using factorial experimental design and the Derringer desirability method to obtain current density (i), acid concentration (Cac), and pulsed bed time (tp) values that maximized CE and Y and minimized EC. The best Cac value was 100 mg L− 1 (a low level), while the optimum i and tp values were 2600 A m− 2 and 60 s, respectively (high levels). Use of these values avoided short circuit and minimized copper dissolution during fluidization. The overpotential distribution within the porous cathode was improved using the 2.4 cm electrode, and values of 100% (CE), 102 kg m− 3 h− 1 (Y), and 1.7 kWh kg− 1 (EC) were achieved under the optimized conditions. These values are better than those found for flat plate electrodes.
Large current rectifiers: State of the art and future trends
This paper presents the different technologies used in the generation of large controlled currents, in the kiloamperes range. After a brief review of processes requiring large currents, the paper discusses the working principles of thyristor phase-controlled rectifiers commonly used in these applications. Chopper-rectifiers using high-current insulated gate bipolar transistors are introduced as an alternative being considered in recent projects. The pulsewidth-modulated current-source rectifier, currently used in medium-voltage motor drives, is also analyzed as a future alternative for rectification in industrial processes. In addition, this paper presents the most important requirements and specifications to be considered in the applications of these high-power units. A system comparison is developed between thyristor and chopper-rectifiers in terms of quality of control, harmonics, power factor, losses, and efficiency.