Contact System Design to Improve Energy Efficiency in Copper Electrowinning Processes

To improve energy efficiency in copper electrowinning, different technologies have been developed, including electrode positioning capping boards and 3-D grids, electrode spacers, and segmented intercell bars. This paper introduces a design concept based on a female tooth shape for the contacts on the intercell bar to avoid electrode open circuits and reduce contact resistances. The results indicate that this design enhances electrode alignment, reduces contact resistances, simplifies contact cleaning, and ensures better electrical contact for the electrodes. Consequently, it leads to lower operational temperatures for the electrodes, less housekeeping required in the plant, an increased lifespan for capping boards, and higher rates of grade A copper production. The improvements in production levels and energy efficiency are projected to reach 0.5% and 3% respectively. A 3-D finite-element analysis and industrial measurements validate these findings, providing a useful guideline for implementing this type of intercell bar in electrowinning processes.