Note: Descriptions are shown in the official language in which they were submitted.
~113~90
This invention relates to a method of electrowinnlng metals and to
cells and anodes for use in connection with such a method.
The extraction and recovery of metals from aqueous acidic solutions
by electrowinning involves the use of an insoluble anode in an electrolytic
cell. The aqueous solution forms the electrolyte, and a suitable cathode,
usually in the form of a plate or sheet on which the metal is deposited,
forms the remaining part of the cell. Under suitable conditions, metal of
very high purity can be deposited, and the process is used for winning metal
from solutions derived from metal ores, scrap metal and from metal refining
processes. In particular, copper, nickel, cobalt, manganese and zinc are
common metals which may be extracted from acid solutions by such a process
and such solutions are completely or partly stripped of their metal content
without significant replenishment from the anode material. Electrowinning
is to be distinguished from electrorefining in which the anode is a soluble
anode principally composed of the metal which is to be deposited on the
cathode.
Ideally, the anode used in electrowinning should be completely resistant
to the electrolytic conditions, should suffer no weight loss, should not
form a passive film or give rise to any reaction which would interfere with
the cathodic deposition of metal at an economic current density. In
practice, these conditions cannot be fulfilled by any economically realistic
anode and all of the anodes presently being used have a small amount of
dissolution which may affect the purity of the metal deposit. Thus, lead
and lead-based alloy anodes, which are widely used in electrowinning, are
not completely resistant to anodic loss and some lead becomes co-deposited
with the copper, thereby reducing the purity and hence the commercial value
of the copper deposit. Whilst the wear rate of lead and lead-based alloys
may be acceptably low for low current density electrolytic cells, some lead
is picked up in the cathode and the wear rate increases in certain commonly
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found conditions. These are increasing current density, increasing acidity,
increasing electrode temperature, and increasing chloride concentration.
With the increase in current density, lead tends to oxidise and flake away
from the anode and this increases the removal rate to an unacceptable degree.
Lead in copper has a deleterious effect on the conductivity of the copper
and it also adversely affects the ability to draw the copper to fine wire.
Another form of non-consumable anode is titanium, either commercially
pure or alloyed, which is coated with fiome form of noble metal or noble metal
compound. Titanium on its own is unsatiæfactory because it rapidly polarises
when made anodic. By polarisation i8 meant the rapid formation of an
insulating film, usually an oxide, on the e~terior surface of the anode
material such that it is unable to pass a current at a voltage which is
economically viable in a commercial electrowinning cell. Whilst noble
metal coated anodes are technically attractive for electrowinning operations,
there is a very small loss of noble metal, which although not significantly
affecting the purity of the deposited metal, does adversely affect the
economics of the process because of the very high cost of the noble metal
wastage and the high capital costs of the electrode.
In the electrorefining of copper, insoluble anodes have been proposed
which consist of alloys of copper and silicon with additions of iron, tin,
lead and manganese. These alloys, available commercially under the trade
name "Chilex", have been used in Chile and are cast into suitable shapes for
use in the electrolytic bath. These alloys have been in use for 40-50 years
but tests have shown that they have a passivating tendency, principally due
to the continual formation of silicon-rich layer on the surface. The wear
rate of these alloys is about 10-25mm/year depending on electrolyte con-
ditlons and the current density. The wear is principally due to copper
passing into solution, which copper is then eventually deposited on the
cathode. This dissolution is not in itself objectionable since it does not
V
contaminate the cathode deposit, but is does mean that the anode has to be
replaced periodicallyO Also, the tendency to passivation with increasing
wear means that the anode materials have to be removed from the electrolyte
and washed to remove the silicon-rich layer on the surface.
In the electrowinning of cobalt, insoluble anodes of cobalt-silicon
have been proposed, these alloys being commercially available under the trade
name "Luilu". These "Luilu" alloys are again cast into suitable anode shapes
and wear gradually in use. Since they are used in cobalt electrolysis, the
cobalt is recovered from the anode and is not lost. Both copper-silicon
alloys and cobalt-silicon alloys are relatively brittle and can become damaged
during transit and handling which again reduces their effective life and in-
creases their costs.
By the present invention there is provided a method of electrowin-
ning metal comprising electrolysing an aqueous solution of metal using as'ff~
anode an alloy comprising one or more high melting point passive film-forming
metals selected from the group consisting of titanium, zirconium, niobium and
tantalum and one or more of the elements of atomic numbers 23-29 in the
Periodic System of Elements the percentage by weight of elements 23-29 being
greater than that at which passivation of the alloy occurs in said aqueous
solution and less than that percentage at which dissolution of the alloy
occurs at half the faradaic dissolution rate in said aqueous solution and
being greater than the percentage by weight of the film-forming metal, and,
optionally, one or more of the elements selected from the group consisting of
hydrogen up to 2000 parts per million; aluminium up to ~ wt%, tin up to 5%,
oxygen up to 1.5%; vanadium up to 2%; molybdenum up to 5%; silicon up to 1%;
palladium up to 0.5%; platinum up to 0.5%; ruthenium up to 0.5%; iridium up
to 0.5%; phosphorus up to 10%; carbon up to 15%; the additional elements, if
present, totalling no more than 40%.
~13Z~3V
The dissolution rate need not exceed 20mm/year at a current density
of 500 amps/m and preferably does not exceed lOmm/year.
The present invention further provides a method of recovering an
electrowinnable metal from an aqueous solution of the metal which comprises
0l,~
the steps of inserting ~anode and a cathode into the aqueous solution,
connecting the anode to a positive potential with respect to the cathode,
passing an electrical current through the anode and the cathode to electro-
deposit the metal onto the cathode and removing the cathodically deposited
metal from the solution, characterised in that the anode has as its electrical-
ly conducting surface an alloy comprising one or more high melting point
passive film-forming metals selected from the group consisting of titanium,
zirconium, niobium and tantalum and one or more of the elements of atomic
numbers 23-29 of the Periodic System of Elements, the percentage by weight of
elements 23-29 being greater than that at which passivation of the alloy
occurs in said aqueous solution and less than that amount at which dissolution
of the alloy occurs at half the faradaic dissolution rate in said aqueous
solution and being greater than the percentage by weight of the film-forming
metal, and, optionally one or more of the elements selected from the group
consisting of hydrogen up to 2000 parts per million; aluminium up to ~ wt%;
tin up to 5%; oxygen up to 1.5%; vanadium up to 2%; molybdenum up to 5%;
silicon up to 1%; palladium up to 0.5%; platinum up to 0.5%; ruthenium up to
0.5%; iridium up to 0.5%; phosphorus up to 10%; carbon up to 15%; the addition-
al elements, if present, totalling no more than 40%.
The anode may be a solid integral item of the alloy; alternatively,
the anode may include a basket and a current lead to the basket, which may be
of foraminate high melting point passive film-forming metal and which contains
the alloy in particulate form. The particulate material may be periodically
added to the basket.
.
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1~3Z6~90
The anode mate~ial may be ~ coppe~titanium alloy~ cQ~per being present
in an amount in the range 50~80 wt %, preferably~50~60 wt %~ Alternatively, the
alloy may be an iron-~titanium alloy, iron being present in the range 50-80% by
weight. In a further alternative, the alloy may be a nickel-titanium alloy,
nickel being present in an amount in the range 50-80%, preferably 50-60% by
weight. In a further alternative, the alloy may be a titanium-cobalt alloy,
cobalt being present by an amount in the range 50-55% by weight.
In a still further embodiment of the invention, the alloy may be a
manganese-titanium alloy, the manganese being present in an amount of 50-85 wt %,
preferably 50-60 wt %.
As indicated, the alloy may contain one or more additional elements
chosen from the group hydrogen, aluminium, tin, oxygen, vanadium, molybdenum,
silicon, palladium, platinum, ruthenium, iridium, phosphorus or carbon, in an
amount so as not to excessively adversely affect the dissolution rate of the
anode material.
The upper limits of the additional elements may be: hydrogen up to 0.2
wt %, aluminium up to 10 wt %, tin up to 5 wt %, oxygen up to 1.5 wt %, vanadiumup to 2%, molybdenum up to 5 wt %, silicon up to 1 wt %, palladium up to 0.5 wt
%, platinum up to 0.5 wt %, ruthenium up to 0.5 wt %, iridium up to 0.5 wt %,
phosphorus up to 10 wt %, carbon up to 15 wt %, the additional elements total-
ling no more than 40%.
The invention still further provides an electrolytic cell comprising
an anode basket and a cathode, both located in an aqueous electrolyte including
ions of an electrowinnable metal, the anode being connectable electrically
positive with respect to the cathode, and an anode material in the basket, the
anode material being a particulate alloy of one or more high melting point
passive Eilm-forming metals-as defined above and one or more elements of atomic
; - 6 -
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2090
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nu~bers 23-29 of the Peri~odic Sys~e~ of Ele~ents~ the percent~ge b!y weight
of elements 23-29~ ~eing greater than that at whi~ch passiyation of the
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alloy occurs and less than the percentage at which dissolu-tion of the alloy
occurs at half the faradaic dissolution rate and being greater than the percen-
tage by weight of the film-forming metal.
The electrolytic cell may utilise an alloy of titanium with any one
of the metals chosen from the group copper, iron, cobalt and nickel. The dis-
solution rate would be less than 20mm/year, probably less than lOmm/year, when
the current density is 500 amps/m .
The present invention still further provides an anode material compris-
ing an alloy of one or more high melting points passive film-forming metals as
defined above and one or more of the elements of atomic numbers 23-29 of the
Periodic System of Elements, the percentage by weight of elements 23-29 being
greater than that at which passivation of the alloy occurs and less than that
percentage at which dissolution of the alloy occurs at half the ~aradaic dissolu-
tion rate when used in the method according to the present invention and being
greater than the percentage by weight of the film-forming metal.
The dissolution rate would not exceed 20mm/year, probably not lOmm/
year, when the current density is 500 amps/m .
As indicated above, the high melting poin-t passive film-forming metals
are titanium, zirconium, niobium and tantalum. Zirconi~m may contain hafnium
which occurs naturally with zirconium. These metals in the unalloyed state
form in
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~132~)~30
\
certain electrolytes a passive film which inhibits transfer of electrons
and all are corrosion-resistant.
Elements 23-29 are vanadium, chromium, manganese, iron, cobalt, nickel
and copper. By "faradaic dissolution rate' is meant the rate at which
material dissolves when all the current through the anode is used in dissolu-
tion of the metal.
The alloys used as anode material may contain as impurities derived
from the constitutentfi of the alloy several percent of other elements
normally associated with such materials.
By way of example, embodiments of the present invention will now be
described with reference to the accompanying drawings, of which:
Figure I is a plan view of one embodiment of the invention;
Figure 2 is a plan view of a second embodiment;
Figure 3 is a perspective view of a foraminate basket and
hanger bar assembly;
Figure 4 is a perspectivve view of a foraminate basket having
hooks and a hanger bar assembly; and
Figure 5 i8 a perspective view of a cast anode.
An electrowinning cell basically comprises a tank 1 having copper
busbars 2 and 3 running in parallel along either side of the tank. The
busbar 2 is connected to a positive source of electricity and the busbar 3
is connected to a negative source. Located in the tank 1 are a series of
anodes and cathodes which alternate along the length of the tank. In the
embodiment of Figure 1, the anodes 4 are in the form of hanger bars 5 from
which depend foraminate titanium baskets 6. The cathodes 7 are in the form
of copper-cored titanium hanger bars to which are welded sheets of titanium
to form the surface on which the electrowon material i8 deposited. The
-``` 1~3~090
electrical supply to the anodes 4 is via the busbar 2 and the electrical
supply to the cathodes 7 is via the busbar 3.
The form of the anode container is shown clearly in Figure 3. A multi-
compartment titanium mesh basket 8 is spot-welded to titanium strips 9 which
at their upper ends are spot-welded to a sheath 10 of a copper-cored hanger
bar 11. The copper core 12 provides a high conductivity throughout the length
of the hanger bar 11 protected by the exterior sheath 10. The exterior sheath
also enables good electrical contact to be made between the copper and the
basket. Into the compartments of basket 8 is placed the anode material of
the invention in a particulate form such as small blocks or small slabs.
During operation of the cell, the anode material is gradually consumed and
is simply replaced by adding further particles of the anode material into
the basket.
In an alternative form, the anode comprises a foraminate titanium basket
13 which is suspended by hooks 14 from a copper hanger bar 15.
In an alternative form of the invention, the anodes 16, which alternate
with the cathodes 17 in the electrolytic cell, are in the form of cast slabs
of the material as is shown clearly in Figure 5. The ears 18 at the upper
end of the slab 15 enable the slab to be positioned in and supported in the
electrolytic cell. Additionally, current can be led into the anode via the
ears 18.
The use of titani~ anode baskets has been previously disclosed in
connection with electroplating of various articles but has not previously
been considered possible for electrowinning applications. Clearly it would
be useless to use pure copper in the basket in an electrowinning cell since
the anode would simply dissolve completely, leaving only the titanium basket
which would rapidly passivate and the electrolysis would stop.
It has been discovered that, using the anode material of the invention
in a titanium anode basket, the current is able to pass through the oxide
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film on the titanium basket, into the anode material and this conductivity is
sufficient for an economic electrowinning cell.
The choice of anode material depends to some extent on the metal
being deposited. Where, for example, copper is that metal, an alloy of
titanium and copper is particularly advantageous since any copper which is
slowly dissolved from the anode material will not adversely affect the
quality of the copper deposit by altering the purity of the deposit or its
form of growth.
The invention is illustrated by the following examples, somc of
which are included for reference purposes only.
Example 1
Copper-titanium alloys were arc-melted under argon at a pressure of
400mm of mercury. The material was triple melted to reduce the risk of
segregation and the material was then made into solid anodes after the sur-
face had been abraded with 800 grit emery. The anodes were tested in
sulphuric acid and sulphuric acid-containing copper sulphate. The results
of the tests are given in Table I.
``` 1~32~
TABLE I
Wear Rate of Copper-Titanium Alloys Under Various Conditions
.
Current
Densit~ Wear Rate
Alloy Environment Amps/m (mm/year)
_
Ti2Cu 150g/l H2S04, 20C 500 11.4, 9.1
TiCu 150g/1 H2SO4, 20C 500 11.4, 8.1
Ti2Cu3 150g/1 H2SO4, 20C 500 19.2, 17.9
TiCu3 ~ l50g/1 H2S04, 20DC 500 106.4, 9202
Ti2Cu 150g/1 H2SO4 + 40g/1 Cu2+, 20 C 500 7 76' 7- 9
60C 14.0
Ti 50wt% Cu 150g/1 H2SO4 + 40g/1 Cu2+, 20C 500 10.4
Ti 52.5wt% Cu 150g/1 H2SO4 + 40g/1 Cu2+, 20C 500 9.5
Ti 55wt% Cu 150g/1 H2SO4 + 40g/1 Cu2+, 20C 500 9.3
TiCu l50g/1 H2SO4 + 40g/1 Cu2+, 20C 500 7.5, 8.2
40C 11.7
60C 31.0
Ti 60wt% Cu 150g/1 H2S04 + 40g/1 Cu2+, 20C 500 9.3
TiCu + 0.1% Pt 150g/1 H2SO4 +40g/1 Cu2+, 20C 500 7.9
TiCu + 0.5% Pt 150g/1 H2SO4 +40g/l Cu2+, 20C 500 7.3
TiCu + 1.0% Pt 150g/1 H2S04 +40g/1 Cu2+, 20C 500 7.0
TiCu 150g/1 H2S04 + 40g/1 Cu2+, 20C 500 9.1
TiCu 150g/1 H2S04 + 40g/1 Cu2+, 20C 2000 37. 6
TiCu 150g/l H2S04 + 40g/1 Cu2+, 20C - 5000 101.9
TiCu lOOg/l H2S04 + 40g/1 Cu2-~9 20C 500 7.2
TiCu 150g/l H2S04 + 40g/1 Cu2+, 20C 500 7.8
TiCu 200g/1 H2SO4 + 40g/1 Cu2+, 20C 500 8.0
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It can be seen that there is little cha~ge ln the wear rate as the
composition of the alloy i6 changed from 40wt% copper to 60wt% copper.
The cell voltage increases with decreasing copper content when less than
55wt% copper is present in the alloy. For titanium 50wt% copper at 20C,
150g/1 H2S04, 40g/l CU2+ at a current density of 500 amps/m2, the dissolution
rate i6 approximately 1.9% of the faradaic dissolution rate.
The wear rate of titanium-copper alloys changes almost linearly as the
current density is increased from 500 amps/m2 to 5boo amps/m2. It can be
seen, however, that the rate of dissolution of titanium-copper does not
depend upon acidity of the electrolyte over the range 100-200g/1 sulphuric
acid. It can be seen that the wear rate increases with increasing tempera-
ture in the range 20-60~C for both Ti2Cu and TiCu. Additions of platinum
to the TiCu alloy (where TiCu appears in Table I is meant the intermetallic
compound which contains equal atomic proportions of titanium and copper)
reduced the rate of dissolution only slightly and the cell voltage was
also reduced only slightly.
Example 2
Three titanium-manganese alloys were tested under conditions of 150g/l
sulphuric acid, 40g/l copper and a current density of 500 amps/m2 at ambient
temperature.
1. TiMn Ti 46.58wt% Mn 53.42wt% Corrosion rate 18.6mm/year
2. TiMn2 Ti 30.36wt% Mn 69.64wt% Corrosion rate 3.7mm/year
3. TiMn3 Ti 22.52wt% Mn 77.48wt% Corrosion rate 17mm/year
Test 1 was performed with the material in slab form; tests 2 and 3
utilised material in a basket. The results of tests 2 and 3 are cons~dered
less reliable than those of test 1. After 3 days at a current density of
500 amps/m2, the TiMn3 became agitated in the basket due to gas evolution
and the test wes terminated. In all cases the preferred anode reaction was
one of oxygen evolution.
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`` 113;~0
Example 3
Sillcon additions were made to a basic material of TiCu3 under the
same electrolysis condi~ions as for Example 2. Three alloys were tested
as follows, under the same electrolysis conditions a6 Example 2.
Ti wt% Cu wt% Si wt%
A 90% TiCu3 + 10% Si 18.1 73.8 9.1
B 80% TiCu3 + 20% Si 16.6 66.7 16.7
C 70% TiCu3 + 30% Si 15.3 61.6 22.1
The corrosion rates were for A 226.8mm/year, and C 118mm/year. Sample B
shattered and no test results were available. In view of the adverse
effect of silicon, copper-silicon alloys were tried (ie similar to "Chilex")
and these are given below as Example 19.
Example 4
Titanium-iron alloys were tested and the same conditions were used as
far as electrolyte, current density etc as for Example 2. Three alloys of
25%, 30% and 35% iron were tested and the cell voltage measured over a period
of up to 168 hours. The results obtained were as follows:
Time in hours _ 24 48 72 96 126 150 168_
Ti + 25X Fe 3.60 3.17 3.06 3.09 2.99 2.98 2.94 2.94
Ti + 30% Fe 3.18 2.89 2.83 2.82 2.77 2.78 2.75 2.74
Ti + 35% Fe 3.00 2.85 2.79 2.81 2.75 2.73 2.70 2.69
The corrosion rate for the 25wt% iron was 4.32mm/year which corresponds
to 1.0% of the faradaic dissolution rate, for the 30% iron was 7.7mm/year
and for the 35% iron was 10.7mm/year. These alloys, particularly the 25wt%
iron alloy, were deemed to be particularly useful.
Example 5
Titanium-chromium was manufactured having a 50wt% content of chromium
and under the same conditions as Example 2 was found to give a ~orrosion
13
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1~32~
rate of 128.7mm/year. This is equivalent to approximately 30.9% of the
faradaic dissolutlon rate.
Example 6
Titanium-vanadium, having a 5% vanadium content, was manufactured but
it was discovered that the cell voltage rose rapidly when material was used
in the basket.
- Example 7
Two titanium-cobalt alloys were manufactured, Ti2Co, having a titanium
content of 62wt%, and TiCo, having a titanium content of 44wt%. Under the
same conditions as Example 2, the corrosion rate was determined to be 4.7
mm/year for Ti2Co, which is equivalent to about lZ of the faradaic dissolu-
tion rate, and 27.4mm/year for TiCi, which is equivalent to about 5% of the
faradaic dissolution rate.
Example 8
Titanium-copper alloys of 50-50wt~ titanium and copper were manu-
factured with 1%, 2% and 5% of phosphorus added. Under the same conditions
as Example 2, the wear rate for 1% phosphorus was 10.6mm/year, for 2%
phosphorus it was 11.5mm/year and for 5% phosphorus, it was 10.6mm/year.
Example 9
A titanium-copper alloy of 50-50wt% had added to it lwt% niobium (which
is itself a passive film-forming metal) and under the same conditionas as
Example 2, it was determined that the corrosion rate was 5.2mm/year.
Example 10
` Two ternary titanium-copper-iron alloys were manufactured of:
! 25 (a) 50% titanium, 25% copper, 25% iron, and
(b) 47.5% titanium, 47.5% copper, and 5% iron.
The corrosion rate was 10.4mm/year for (a) and 10.4mm/year for (b). Sample
(a) was tested under the ~ame conditions as Example 2, alloy (b) was tested
.
14
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in the same electrolyte as Example 2 with the same current density, but the
temperature was 40C.
Example 11
A 50-50wt% copper-titanium alloy had 25% molybdenum added and a second
sample had 5% chromium added and tests under the same conditions as Example
2, except that the electrolyte temperature was 40C, showed a wear rate of
30mm/year for the molybdenum-containing alloy and 12.3mm/year for the
chromium-containing alloy.
Example 12
To assess the effect of a number of additives in the alloy, a base
titanium alloy was manufactured incorporating 3% aluminium, 1.3% tin,
1% vanadium, 1% zirconium, 1% molybdenum, 0.25% copper, .05% silicon.
Two copper/titanium alloy compositions were tested, the first one corres-
ponding to the (titanium alloy)2Cu and the second to (titanium alloy)Cu.
Under the same test conditions as Example 2, the corrosion rate for the
first composition was 11.2mm/year apd for the second was 6.9mm/year.
Example 13
Two nickel-titanium alloys with ompositions corresponding to TiNi and
TiNi3 were manufactured and tested under the conditions of Example 2. The
wear rate for TiNi was found to be 7.8mm/year and for TiNi3 was found to be
105mm/year, which corresponds to a dissolution rate of 19.7% of the faradaic
disolution rate.
Example 14
Since copper-titanium alloys show great promise, a particular further
example was tried in particulate form in an anode basket in a commercial
electrowinning cell. The alloy 49wt% copper, 0O5Wt% iron, 50.5wt% titanium
was melted, cast and broken into small pieces. The particles were inserted
into a basket of the type illustrated in Figure 3, the basket having an
external size of lm x lm x 5cm wide. The basket was made of titanium mesh
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and was inserted into an electrolytic cell contalning 40g/l copper,
200g/l sulphuric acid, 5g/l arsenic, 30g/1 nickel, lg/l iron, balance
water except for the normal impurities. The electrolyte was maintained
at 60C and a current density of 150 amps/m2 based on the bafiket surface
area was pas6ed through the anode. After 1640 hours, the weight loss of the
material in the basket was only 4.5%. This corresponds to 2.3% of the
- faradaic dissolution rate. In a second sample of material, after 2252 hours
the weight loss was only 4.3% . This corresponds to 1.6% of the faradaic
dissolution rate. The anode basket was placed in series ln the cell with
conventional lead anodes and the anode basket passed a fair proportion of
the current through the cell and did not shed current into the lead anodes.
This test shows that such a copper-titanium alloy produces wear rates
sufficiently low to enable the material to be used economically and viably
in an anode basket.
Example 15
A second copper-titanium alloy was prepared although the alloy was of
much lower purity than the alloy prepared and described in Example 14.
After melting, the analysis of the alloy was 56.75% copper, less than 1%
iron, .5% nickel, 1% aluminium, 1% zirconium, balance titanium. Under
exactly the same conditions of cell liquor, current density, temperature and
! particle sizes as set out in Example 14, it was found that after 1400 hours
exposure, there was a weight loss of 47.6%. This corresponds approximately
; to a wear rate of 20mm/year and to 26% of the faradaic dissolution rate.
Example 16
A particulate ferro-titanium alloy was prepared and found to have a
composition of 30% iron, 1% copper, .5% nickel, .5% chromium, balance titanium.
This material was used in the same liquor and under the same conditions in
baskets as set out in Example 14 and it was found that with two separate
samples, there was no weight loss at all after 2770 hours' use. This test
16
1~3~
also shows that particulate ferro-titanium of the correct compo6ition may
be used in anode baskets satisfactorily in commercial electrowinning liquors.
Example 17
A nickel 56wt% niobium alloy was cast into a single piece and tested
as an anode material. The electrolyte used was an aqueous solution contain-
ing 16.5g/l copper, 26.4g/l nickel, 8g/l arsenic, 229g/l sulphuric acid.
The electrolyte was maintained at 60C and a current density of 200 amps/m2
was used. A cell voltage of 4.9 volts was required to maintain the
current and the wear rate was determined to be 94mm/year.
Example 18
A copper 50% zirconium alloy was tested in the same electrolyte and
under the same conditions of temperature and current density as for Example
17. Again, the material was cast into a solid piece and it was found that
a cell voltage of 3 volts was required to maintain the current and the wear
rate was determined to be 50.5mm/year.
Comparison Example 19
In view of the prior use of copper-silicon alloys in slab form, attempts
were made to use the alloy in particulate form in a basket. The alloy 70wt%
copper, 20wt% silicon, 8wt~ iron, 2wt~ lead, was cast and broken up into
small pieces. The pieces were placed in an anode basket and were tested in
a liquor containing 16.5g/l copper, 26.4g/l nickel, 229g/l H2S04, 8g/l arsenic.
Using a current density of 200 amps/m2 and a temperature of 60C, it was
,, found that the cell voltage increased from 2.6 volts to 10.2 volts and that
the wear rate was approximately 24mm/year. This wear rate has to be
compared with approximately 10-15mm/year for large slabs of material. The
important feature to note, however, is that the cell voltage increases to an
unacceptably high level and it is believed that this is due to the continual
formation of a ~ilicon-rich layer on the alloy surface. This layer effectively
insulates the particles one from another, and more importantly, from the
.
17
1132~0
basket ~tself and would mean in practice that this material would not be
suitable in small baskets, ie 6 inch deep baskets.
One of the important features of the invention is that the anode
material can be chosen in most cases so that the metal which dissolves slowly
fro~ the anode is the same as the metal being deposited on the cathode.
Thus, no contamination of the cathode material occurs. If, for example,
copper is being electrowon, then by using a copper-titanium alloy, it has
been found that the amount of titanium incorporated in the copper is less
than 15 parts per million. This level of titanium is the detectable limit
for the technique used, hence it is probable that there is even less titanium
than 15ppm present. Of course, any copper which is incorporated in the cathode
from the anode is beneficial rather than deleterious. It is believed that
the titanium which is dissolved from the anode is hydrolysed to form titanium
oxide which forms part of the anode slime and can be extracted with it. The
small amount (if any) of titanium present in the cathodically deposited
copper would probably be slagged out if the cathode copper were to be melted.
Similarly, if cobalt was being electrowon by the use of titanium-cobalt
alloys, then no significant contamination of the cobalt electrodeposit on
the cathode would occur.
The alloys of the invention may be used in slab form if they are
sufficiently ductile but it is considered that it is preferable to use them
in particulate form because of the ease with which the anodes can be main-
tained and replaced. A further important feature of the invention is that
since the surface area of the anode material within the basket can be altered
by changing the particle size ~smaller particles giving a greater surface
area), the current density at the surface of the anode material can be kept
to a relatively low level when compared with slab anodes. Since the wear
rate of the material divided by the current density increases as the current
density increases~ this is extremely valuable since it means that the wear
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rate can be kept low at the anode by using small particles, although the
current density at the cathode and hence the effective cell utilisation can
be kept high. When compared with prior art anodes, this advantage can be
clearly seen since if it is attempted to use high current densities with
copper-silicon alloys, then a high wear rate is obtained. If it i5
attempted to use a high current density with lead anodes, then a high wear
rate and the deleterious incorporation of lead in the cathode deposit occurs.
It has also been discovered that the anode materials of the present
invention are relatively unaffected by sulphuric acid concentrations and by
chloride ion concentrations, which is not so in connection with lead anodes.
The combination of features of the anode materials of the present invention
enables them to be used in circumstances and conditions where they are
economically advantageous over the prior art anodes which have been used
for the past 40-50 years and more.
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