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Novel Electrowinning Technologies:
The Treatment and Recovery of Metals
                from Liquid Effluents



                           Neelu sheoran
                            Bhagyashree
                     Pranitha Geedigunta
ELECTROWINNING

Electrowinning, also called electroextraction,
  is the electro-deposition of metals from
  their ores that have been put in solution or
  liquefied.
History of Electrowinning…
 It is the oldest industrial electrolytic process.
 In 1807, for the first time an English chemist Humphry
  Davy obtained sodium metal in elemental form by
  the electrolysis of molten sodium hydroxide .
 James Elkington patented the commercial process in
  1865 and opened the first successful plant in Pembrey,
  Wales in 1870.
 In 1883, the first commercial plant in the US was
  the Balbach and Sons Refining and Smelting
  Company in Newark, New Jersey.
Electrowinning Process

  In Electrowinning, direct current is passed from
  an inert anode through a liquid leach solution
  containing the metal so that the metal is
  extracted as it is deposited in an electroplating
  process onto the cathode.

The resulting metals are said to be electrowon.
Types of Electrolytic Cells used :-

                                Electrolytic
                                    cell




                Cylindrical               Rectangular tank/
               electrode cell               Rectangular
                                           electrode cell



Two- dimensional         Three- dimensional
(2-D) arrangement        (3-D) arrangement
Two-dimensional (2D) arrangements
 of cylindrical electrode cells : Cells
 where electrode is essentially in sheet
 form.
 Three- dimensional (3-D)
 arrangements of cylindrical electrode
 cells : Cells where the electrode is
 constructed to provide opportunities for
 electrochemical reaction from three
 axial source
Two novel solution treatment and electrowinning
 technologies are :-

• EMEW Technology
• RenoCell technology
EMEW Technology
EMEW Technology was developed by Electrometals Technologies
Ltd. of Australia to overcome a number of significant limitations
inherent in conventional rectangular electrowinning technology,
particularly the restricted window process characteristic of
conventional hardware.

This technology has been shown to achieve high performance
under chemical conditions well outside the limits required for
efficient operation of conventional cells.

 At the core of the technology is a specially designed cell that
improves electrowinning performance by providing a physical
mechanism by which the metal ions are delivered to the cathode
surface efficiently and continuously.
RenoCell Technology
RenoCell is a patented electrochemical cell technology
developed by EA technology. The RenoCell is currently being
commercialized by Renovare International, Inc. The
technology takes advantage of the extremely high surface area
provided by a special 3-D position.
Electrometallurgy for Selected Metals
Aluminum Electrowinning

Most of the aluminum metal, alumina derived from bauxite. Both low and high
silica bauxite are refined using the Bayer Process and the product is alumina
powder which is then electrolytically reduced to aluminum metal by the Hall-
Heroult process.

There have been many advances made in the Hall-Heroult production process
which have resulted in significant improvements in productivity, energy
efficiency and its impact on the environment. However, the process used today
that is based on a consuming carbon anode, a cathode metal pool and fluoride
based electrolyte is fundamentally the same as the process, originally developed
by Charles Hall and Paul Héroult 125 years ago.
Hall-heroult process
There are two types of electrochemical cells or
pots in use today :-
1. The Soderberg Cell, based on a continuous
anode that is made from carbon paste that is fed
to the cell and baked in-situ. This cell
technology accounts for around 10% of the
world Al production.
2. The Pre-bake (PB) Cell, based on multiple
anodes that are made from coke and pitch which
are formed and baked in furnaces outside of the
cell accounts for the rest of the metal production.
HORIZONTAL STUD SODERBERG (HSS)
Pre-bake electrolytic cells
Copper Electrorefining and Electrowinning
The main industrial use for copper is for electrical conductivity purposes and this
requires very pure copper product that can only be produced on a large scale through
electrolysis. Historically large scale refined copper production occurred almost
exclusively via electrorefining after the smelting of sulfide ores. Over the past four
decades, there has been growth in the large scale hydrometallurgical recovery of
copper by low cost heap leach, solvent extraction and electrowinning.
 Electrowon copper capacity growth has been in those regions where there is
leachable copper at mine sites in the Southwest USA, Chile and central Africa.
Electrorefining, now accounts for 70-80% of the worlds refined copper with
electrowinning producing the rest. Electrorefining is the older and still dominate
method to produce copper cathode. Technology development in ER has focused on
productivity, automation and quality.
 Electrowinning due to its inherent higher electrical energy consumption has
focused on electrical energy reduction as well as improvements in productivity
automation and quality. Often improvements can be utilized for both ER and EW
operations.
Lead Electrowinning

The process involves ferric leaching of galena concentrate in a
fluoboric based solution, electrowinning, and treating of
residues for possible by-product recovery. The electrowinning
portion of the process uses divided cells.

Lead is deposited on permanent stainless steel cathodes. The
electrolyte passes through a porous diagram to the anode where
ferric ion is regenerated for return to leaching. The anode is
reported to be graphite.
Magnesium Electrometallurgy
 Magnesium has two major raw materials –
• Dolomite from the lithosphere, and
• contained Magnesium in saline waters of the hydrosphere.
The lithospheric dolomite is calcined to calcium-magnesium oxide, and reduced with
   ferrosilicon at above 1250oC. One of the methods of the reduction is by an electro-
   thermal approach developed during the 1960’s in France, which is called
   Magnetherm Process. Here an electroslag melting approach is used where a pool
   of partly molten slag containing 50% Ca2SiO4, 18%Al2O3, 14% MgO, and 18%
   CaO is formed from the continuous feed of calcined dolomite and low grade
   ferrosilicon.
 The Electro-winning process is used to extract magnesium from the hydrosphere
   raw material magnesium chloride in the saline waters of lakes or oceans, as well as
   marine evaporites found in the lithosphere such as carnalite [KCl.MgCl2.6H2O],
   or kainite [MgSO4.KCl. 3H2O] . It should be noted that the earliest known
   isolation of magnesium was done by Humphrey Davy in 1808; incidentally Davy
   used an electrolytic approach to isolate most of the metals from their compounds.
Electrowinning from Chloride Electrolyte

The electrowinning of nickel from chloride electrolyte is used in a
process to treat ground matte. Chlorine gas is generated at the
anode and is used in matte leaching. Plants that perform
electrowinning from chloride electrolyte are located in France,
Japan and Norway.
 Nickel electrowinning from chloride electrolytes use divided cells
with the anode typically placed in a frame wrapped in a polyester
diaphragm. The frame and diaphragm allows for chlorine capture.
 Nickel is commonly plated on starter sheets which had been
grown previously on titanium blanks for 1 to 2 days. Nickel can
also be plated on masked titanium cathodes to produce nickel
crowns. Chlorine evolves from coated titanium mesh anodes.
Electrowinning from Sulfate Electrolyte

 Nickel electrowinning from sulfate electrolyte is
 used in a process to treat ground matte and has been
 demonstrated for laterite processing.
 The acid generated during oxygen evolution at the
 anode is used during atmospheric and pressure
 leaching. Plants that use this technology are located
 in Canada, Finland and South Africa.
Titanium electrometallurgy

Ti not produced commercially by electrowinning.
   It was thought that the history of Ti production would follow
   that of aluminum – beginning with as primitive
   thermochemical process with expensive limited production
   for a few decades, and then evolving to a large-scale
   industrial modern electrowinning process.
Ti electrowinning technology is related to conceptual
   confusion.
Ti electrowinning cell in molten fluorides.
Zinc Electrowinning

As the zinc deposition process is carried out from acidic solutions, the
process is sensitive to trace impurities necessitating an efficient
purification process. The purification process is based on cementing the
impurities onto zinc dust.
As the kinetics of cementation were not favourable, high quantities of
zinc dust were required to remove the impurities. In addition, the zinc
electrolysis was initially labour intensive necessitating high labour for
harvesting the zinc from the aluminum cathodes.
Alternative anodes for metal electrowinning
  The main disadvantages of lead anodes are elevated power
  consumption, corrosion products fouling the cathode deposit, and
  generation of a hazardous by-product. If lead-alloy anodes are to be
  replaced, the alternative anodes must be economically justifiable.
   Currently, DSA (dimensionally stable anodes) are used in
  electrowinning in chloride-based solutions and recovery of metals
  from dilute solutions.
   Recently, implementation of the titanium coated anodes has been
  made in the copper electrowinning..
   The advantages of using DSA anodes in zinc electrowinning are:
• the ability to operate at higher current densities,
• the elimination of sludge, and
• the ability to operate at a reduced anode voltage (300 mV less than
  Pb-alloy anodes).
Advantages of EMEW Technology
•   Continous and easy control of copper concentration below 3000 ppm
•   Recycling of acid
•   Reduction of effluent
•   Lower operating cost
•   Production of high purity (> 99.99%) copper cathode.
•   Reduction in acid consumption, handling and transportation
•   Improved safety
•   No lead contamination
•   No requirement for regular replacement of cathodes
•   Small and compact footprint
THANK
YOU 

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Novel electrowinning technologies.ppt copy

  • 1. Novel Electrowinning Technologies: The Treatment and Recovery of Metals from Liquid Effluents Neelu sheoran Bhagyashree Pranitha Geedigunta
  • 2. ELECTROWINNING Electrowinning, also called electroextraction, is the electro-deposition of metals from their ores that have been put in solution or liquefied.
  • 3. History of Electrowinning…  It is the oldest industrial electrolytic process.  In 1807, for the first time an English chemist Humphry Davy obtained sodium metal in elemental form by the electrolysis of molten sodium hydroxide .  James Elkington patented the commercial process in 1865 and opened the first successful plant in Pembrey, Wales in 1870.  In 1883, the first commercial plant in the US was the Balbach and Sons Refining and Smelting Company in Newark, New Jersey.
  • 4. Electrowinning Process In Electrowinning, direct current is passed from an inert anode through a liquid leach solution containing the metal so that the metal is extracted as it is deposited in an electroplating process onto the cathode. The resulting metals are said to be electrowon.
  • 5. Types of Electrolytic Cells used :- Electrolytic cell Cylindrical Rectangular tank/ electrode cell Rectangular electrode cell Two- dimensional Three- dimensional (2-D) arrangement (3-D) arrangement
  • 6. Two-dimensional (2D) arrangements of cylindrical electrode cells : Cells where electrode is essentially in sheet form.  Three- dimensional (3-D) arrangements of cylindrical electrode cells : Cells where the electrode is constructed to provide opportunities for electrochemical reaction from three axial source
  • 7. Two novel solution treatment and electrowinning technologies are :- • EMEW Technology • RenoCell technology
  • 8. EMEW Technology EMEW Technology was developed by Electrometals Technologies Ltd. of Australia to overcome a number of significant limitations inherent in conventional rectangular electrowinning technology, particularly the restricted window process characteristic of conventional hardware. This technology has been shown to achieve high performance under chemical conditions well outside the limits required for efficient operation of conventional cells. At the core of the technology is a specially designed cell that improves electrowinning performance by providing a physical mechanism by which the metal ions are delivered to the cathode surface efficiently and continuously.
  • 9. RenoCell Technology RenoCell is a patented electrochemical cell technology developed by EA technology. The RenoCell is currently being commercialized by Renovare International, Inc. The technology takes advantage of the extremely high surface area provided by a special 3-D position.
  • 10. Electrometallurgy for Selected Metals Aluminum Electrowinning Most of the aluminum metal, alumina derived from bauxite. Both low and high silica bauxite are refined using the Bayer Process and the product is alumina powder which is then electrolytically reduced to aluminum metal by the Hall- Heroult process. There have been many advances made in the Hall-Heroult production process which have resulted in significant improvements in productivity, energy efficiency and its impact on the environment. However, the process used today that is based on a consuming carbon anode, a cathode metal pool and fluoride based electrolyte is fundamentally the same as the process, originally developed by Charles Hall and Paul Héroult 125 years ago.
  • 12. There are two types of electrochemical cells or pots in use today :- 1. The Soderberg Cell, based on a continuous anode that is made from carbon paste that is fed to the cell and baked in-situ. This cell technology accounts for around 10% of the world Al production. 2. The Pre-bake (PB) Cell, based on multiple anodes that are made from coke and pitch which are formed and baked in furnaces outside of the cell accounts for the rest of the metal production.
  • 15. Copper Electrorefining and Electrowinning The main industrial use for copper is for electrical conductivity purposes and this requires very pure copper product that can only be produced on a large scale through electrolysis. Historically large scale refined copper production occurred almost exclusively via electrorefining after the smelting of sulfide ores. Over the past four decades, there has been growth in the large scale hydrometallurgical recovery of copper by low cost heap leach, solvent extraction and electrowinning. Electrowon copper capacity growth has been in those regions where there is leachable copper at mine sites in the Southwest USA, Chile and central Africa. Electrorefining, now accounts for 70-80% of the worlds refined copper with electrowinning producing the rest. Electrorefining is the older and still dominate method to produce copper cathode. Technology development in ER has focused on productivity, automation and quality. Electrowinning due to its inherent higher electrical energy consumption has focused on electrical energy reduction as well as improvements in productivity automation and quality. Often improvements can be utilized for both ER and EW operations.
  • 16. Lead Electrowinning The process involves ferric leaching of galena concentrate in a fluoboric based solution, electrowinning, and treating of residues for possible by-product recovery. The electrowinning portion of the process uses divided cells. Lead is deposited on permanent stainless steel cathodes. The electrolyte passes through a porous diagram to the anode where ferric ion is regenerated for return to leaching. The anode is reported to be graphite.
  • 17. Magnesium Electrometallurgy Magnesium has two major raw materials – • Dolomite from the lithosphere, and • contained Magnesium in saline waters of the hydrosphere. The lithospheric dolomite is calcined to calcium-magnesium oxide, and reduced with ferrosilicon at above 1250oC. One of the methods of the reduction is by an electro- thermal approach developed during the 1960’s in France, which is called Magnetherm Process. Here an electroslag melting approach is used where a pool of partly molten slag containing 50% Ca2SiO4, 18%Al2O3, 14% MgO, and 18% CaO is formed from the continuous feed of calcined dolomite and low grade ferrosilicon. The Electro-winning process is used to extract magnesium from the hydrosphere raw material magnesium chloride in the saline waters of lakes or oceans, as well as marine evaporites found in the lithosphere such as carnalite [KCl.MgCl2.6H2O], or kainite [MgSO4.KCl. 3H2O] . It should be noted that the earliest known isolation of magnesium was done by Humphrey Davy in 1808; incidentally Davy used an electrolytic approach to isolate most of the metals from their compounds.
  • 18. Electrowinning from Chloride Electrolyte The electrowinning of nickel from chloride electrolyte is used in a process to treat ground matte. Chlorine gas is generated at the anode and is used in matte leaching. Plants that perform electrowinning from chloride electrolyte are located in France, Japan and Norway. Nickel electrowinning from chloride electrolytes use divided cells with the anode typically placed in a frame wrapped in a polyester diaphragm. The frame and diaphragm allows for chlorine capture. Nickel is commonly plated on starter sheets which had been grown previously on titanium blanks for 1 to 2 days. Nickel can also be plated on masked titanium cathodes to produce nickel crowns. Chlorine evolves from coated titanium mesh anodes.
  • 19. Electrowinning from Sulfate Electrolyte Nickel electrowinning from sulfate electrolyte is used in a process to treat ground matte and has been demonstrated for laterite processing. The acid generated during oxygen evolution at the anode is used during atmospheric and pressure leaching. Plants that use this technology are located in Canada, Finland and South Africa.
  • 20. Titanium electrometallurgy Ti not produced commercially by electrowinning. It was thought that the history of Ti production would follow that of aluminum – beginning with as primitive thermochemical process with expensive limited production for a few decades, and then evolving to a large-scale industrial modern electrowinning process. Ti electrowinning technology is related to conceptual confusion.
  • 21. Ti electrowinning cell in molten fluorides.
  • 22. Zinc Electrowinning As the zinc deposition process is carried out from acidic solutions, the process is sensitive to trace impurities necessitating an efficient purification process. The purification process is based on cementing the impurities onto zinc dust. As the kinetics of cementation were not favourable, high quantities of zinc dust were required to remove the impurities. In addition, the zinc electrolysis was initially labour intensive necessitating high labour for harvesting the zinc from the aluminum cathodes.
  • 23. Alternative anodes for metal electrowinning The main disadvantages of lead anodes are elevated power consumption, corrosion products fouling the cathode deposit, and generation of a hazardous by-product. If lead-alloy anodes are to be replaced, the alternative anodes must be economically justifiable. Currently, DSA (dimensionally stable anodes) are used in electrowinning in chloride-based solutions and recovery of metals from dilute solutions. Recently, implementation of the titanium coated anodes has been made in the copper electrowinning.. The advantages of using DSA anodes in zinc electrowinning are: • the ability to operate at higher current densities, • the elimination of sludge, and • the ability to operate at a reduced anode voltage (300 mV less than Pb-alloy anodes).
  • 24. Advantages of EMEW Technology • Continous and easy control of copper concentration below 3000 ppm • Recycling of acid • Reduction of effluent • Lower operating cost • Production of high purity (> 99.99%) copper cathode. • Reduction in acid consumption, handling and transportation • Improved safety • No lead contamination • No requirement for regular replacement of cathodes • Small and compact footprint