Electrolytic cell

Details Electrolytic cell Electrolytic cell

2002-09-03

2004-05-04

Valentine, Donald R (Department: 1742)

Chemistry: electrical and wave energy

Apparatus

Electrolytic

C206S524500, C264S299000, C204S242000, C204S275100

Reexamination Certificate

active

06730195

ABSTRACT:

FIELD OF THE INVENTION
The invention relates to design improvements in the construction of electrolytic cell receptacles for electrowinning and electrorefining processes of nonferrous metals, with a novel mold and molding method and to new formulations for three-layered polymer composite materials for the monolithic formation of the structural core with surface sealing coatings in the receptacles or containers of such cells.
BACKGROUND OF THE INVENTION
There are currently several known designs for cell-type receptacles or containers intended for electrolytic refining and winning used in the purification and recovery of nonferrous metals. In order to obtain high purity cathodic copper, there are currently two well-established industrial electrolytic processes: electrorefining of melted copper anodes dissolved in sulfuric acid electrolytes, and electrowinning cathodic copper directly from copper sulfate electrolytes previously recovered by hydrometallurgic processes by extraction of ore heaps or piles using lixiviated copper solvents. The receptacles for electrolytic cells used in both processes are similar, having a parallelepipedic geometry, being self-supporting, with suitable dimensions to lodge electrodes in the form of vertically positioned parallel laminar plates supported at each end at the upper edges of the side walls of the receptacle, and provided with means for electrolyte infeed and overflow. The design of the electrolytic cell receptacle itself is functional in order to accommodate the specific requirements of the corresponding electrolytic process. Currently, electrorefining cells typically operate with moderate electrolyte flows, at temperatures between 55° C. and 75° C., and the length/width ratio of the receptacle, in terms of the number of electrodes required for each cell, is generally <4; electrowinning cells, on the other hand, operate with much higher electrolyte flows, at lower temperatures, between 45° C. and 55° C., and their length/width ratio is typically >4. Recent technological efforts to improve productivity of both electrolytic processes have shown tendencies toward greater current densities per electrode, higher electrolytic temperatures, and a higher number of electrodes per cell, i.e., with a length/width ratio that is typically 5 or 6.
One of the receptacles for electrolytic cells of the current state of the art is discussed in (Chilean) Patent No. 38,151, which characterizes a corrosive electrolyte receptacle or container used in electrolytic processes, where said receptacle consists of a polymer concrete box with side walls, a pair of opposite end walls, and a bottom, and each of said end walls has an inner and outer surface where a formation has been molded onto the outer surface of the end wall that extends from its upper and lower ends and that is intermediate between the sides of the wall; a depression has been formed on the upper end of the formation, which opens toward the inner surface of said end wall; and below the upper edge of the wall a generally vertical first discharge passage has been formed at a certain distance from the outer surface of the formation on the outer surface of the end wall; the discharge passage has a first opening on the end of the formation and a second opening adjacent to the lower end of the formation in order to drain off the electrolytes from the upper part of the receptacle, characterized in that it has a second passage formed in the end wall and running through the lower part of the wall to drain off the electrolytes from the lower part of the receptacle, wherein electrolytes may be removed from both the upper and lower part of the receptacle.
It also describes a formation with a second passage on the inner surface of the other end wall and forming part of the wall, said second passage running from the upper end of said wall downward to a position adjacent to the lower end, with a channel formed in the end wall and in the inner surface, with a covering over the channel that is open at its upper and lower ends, all for the purpose of distributing the electrolytes entering the cell.
In addition, a corrosion-resistant layer has been applied, which includes a surface layer of a material selected from a group that consists of vinyl ester resin and polyester resin, and a lining layer that consists of an inorganic fiber saturated with a material selected from a group that includes vinyl ester resin and polyester resin.
Said lining layer is made of about 20-30 wt % fiber and about 70-80 wt % resin. The inorganic fiber is fiberglass in the form of a sheet or layer, said sheet being made up of threads that are 12.7-50.8 mm long. The surface layer has a thickness of about 0.0254.0.0508 mm.
The polymer concrete consists of 10-19 wt % resin selected from a group that includes thermosetting vinyl ester and polyester resin. The modified resin includes 80-90% resin selected from a group consisting of vinyl ester and polyester resin, and the balance is a thinning agent, inhibitors, promoters, and a catalyst.
Finally, it describes a method that includes the steps of applying to the surface of a mold a surface layer made of a material selected from a group consisting of vinyl ester resins and polyester resins; applied to said surface layer is a lining layer consisting of a sheet of Inorganic fiber saturated with a material selected from a group consisting of vinyl ester resins and polyester resins a thermosetting resin selected from a group consisting of polyester resin and vinyl ester resin and an aggregate are mixed together, the mixture being continuously emptied into an inverted mold in which said surface layer and lining define the bottom, end, and side walls, thereby permitting said molded mixture to set, wherein the surfaces of the receptacle shall conic into contact with the surfaces of the mold, which casts the smooth inner surfaces. Said layer is formed of threads that are 12.7-50.8 mm long and 0.0254-0.0508 mm thick. Said lining layer has about 20-30 wt % of fiber and about 70-80 wt % of resin. The aggregate includes a mixture that is 80-90 wt % of particles that are 6.35-0.79 mm in size; 10-15 wt % of particles taken from a group that consists of fine silica sand and fine silica powder and 0.9-5 wt % of particles from the group that consists of mica flakes whose approximate size is {fraction (1/64)} mm and of cut fiberglass threads 6.35-3.175 mm in length. In addition, the modified resin includes 80-90% resin selected from the group that consists of vinyl ester resin and polyester resin, and the balance is a thinning agent, inhibitors, promoters, and a catalyst.
Another (Chilean) Patent No. 35,466, refers to a compound material for use in molding containers or structures exposed to corrosive chemicals, particularly to corrosive acids, characterized in that it contains a plastic synthetic resin with an inert particulate filler composed of no less than 70 wt % of round particles whose diameter is on the order of less than 0.5 mm, with a total weight ratio of the particulate resin to the surrounding resin of 8:1 (that is, 11.1% resin content).
In the subordinate claims, the particulate material filler is described, which includes & fraction of about 40 wt % of the total filler of particles whose size ranges from 0.5-1 mm, and a fraction of about 15 wt % of the total filler of particles whose size varies between 14.75 mm and 1.75-3 mm.
Another receptacle for electrowinning or electrorefining nonferrous metals uses the concept of an inner container made of a two-layered polymer composite material, with the body of said container being preformed on an inverted mold by several successive applications of a first polymer composite material consisting of a base of fiberglass layers saturated with high corrosion-resistant polyester/vinyl ester resin contents. As the layers of polymer composite material closest to the surface of the mold cure, the thickness of the walls and bottom of the inner container imparts sufficient structural strength so that it may itself form the core mold for the electrolytic receptacle,

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